2009 Kawasaki MULE 4010 Trans4x4 Owners Manual

2009 Kawasaki MULE 4010 Trans4x4 Manual

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  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 1
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 2
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION HOW TO OPERATE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE j j j j j j A Table of Contents is included after the Foreword.
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 3
    of particular inMULE 4010 TRANS 4 × 4...KAF620R/S NOTE terest for more efficient and convenient operation. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. żThe KAF620S is identical to
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 4
    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1), exhaust emission (2) and evaporative emission (3) control systems in compliance with applicable regulations of the United States Environmental Protections Agency. 1.
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 5
    the owner of this vehicle, you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have provided
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 6
    its features, capabilities, and limitations. To ensure a long, trouble-free life for your Mule, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their Mule, a Service Manual is available for purchase from any authorized Kawasaki
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 7
    TABLE OF CONTENTS BASIC SAFE DRIVING ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Light Switch ...Coolant Temperature Warning Light...Oil Pressure Warning Light...
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 8
    119 119 119 119 121 122 123 124 124 125 Fuse ...Power Steering System...Breaker ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ...ENVIRONMENTAL PROTECTION ...MAINTENANCE RECORD ... 129 130 131 132 132 133 134 136 137 138 139
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 9
    your new Kawasaki vehicle, so drive carefully, safely, and exercise good judgement. Practice basic maneuvers so you can drive confidently and safely. Read the Owner's Manual Read and understand this Owner's Manual. This is especially important for inexperienced drivers. Refer to this Owner
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 10
    BASIC SAFE DRIVING 9 Protect Yourself, Use Proper Riding Gear As appropriate to your operating conditions, wear approved helmet, eye protection, and protective clothing. Operating in a recreational setting, like trail driving or any aggressive riding, could increase the risk of head injury, and thus
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 11
    10 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) Front Rear 3 305 mm (130.12 in.) 1 486 mm (58.50 in.) 1 925
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 12
    SPECIFICATIONS 11 Compression Ratio Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil 10.3 : 1 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5°/750 ∼ 22°/4 000 (BTDC
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 13
    12 SPECIFICATIONS Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Castor Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light 12 V 14
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 14
    SPECIFICATIONS 13 LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load 603 kg (1 330 lb) Short Bed Mode: 182 kg (400 lb) Long Bed Mode: 363 kg (800 lb) :California model only Specifications subject to change without notice.
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 15
    14 SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the vehicle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 16
    LOCATION OF PARTS 15 LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Battery 14. Latch 15. Air Cleaner (
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 17
    16 LOCATION OF PARTS (Two-person mode) 18. 19. 20. 21. Screen Latch Handle Tail Gate Dashboard 22. 23. 24. 25. Tail/Brake Lights Muffler (Spark Arrester) Trailer Hitch Bracket Fuel Tank 26. 27. 28. 29. Fuel Tank Cap Fuel Gauge Rear Seat (folded) Air Cleaner
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    LOCATION OF PARTS 17 30. 31. 32. 33. 34. 35. 36. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 37. Parking Brake Warning Light 38. Right Glove Compartment 39. FI Warning Light 40. Power Steering Warning Light 41.
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    18 LOCATION OF LABELS LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Caution (Shifting) Specification Warning (General) Warning (Pinching Fingers: both sides) Important Information (Tires/Max. Load
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    LOCATION OF LABELS 19
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    20 LOCATION OF LABELS
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    LOCATION OF LABELS 21 (1) (2) (3) (4) (KAF620R) (4) (KAF620S)
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    22 LOCATION OF LABELS (5)
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 24
    LOCATION OF LABELS 23 (6) (8) (7) (9)
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    24 LOCATION OF LABELS (10) (11) (13)
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    LOCATION OF LABELS 25 (12)
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    26 LOCATION OF LABELS (14) (15)
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    LOCATION OF LABELS 27 (16) (18) California model only (17)
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    the vehicle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has front body work and fenders are not designed to carry cargo or to support your weight. They may break. Because any vehicle is sensitive to
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 30
    LOADING INFORMATION 29 subtract trailer tongue weight from the • Always Maximum Load capacity. Refer to the "Trailer Hitch Bracket" section in the "General Information" chapter. Maximum Load Weight of operator, passengers, and cargo must not exceed 603 kg (1 330 lb). vehicle is not designed to carry
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 31
    30 GENERAL INFORMATION j GENERAL INFORMATION Lighting/Electrical Accessory Connector The lighting/electrical accessory 12 volt connector is located on the dashboard. An auxiliary light or an accessory may be connected to this connector. Light Switch Turn on the headlights and taillights by
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 32
    GENERAL INFORMATION 31 Coolant Temperature Warning Light The coolant temperature warning light (TEMP) comes on whenever the coolant temperature rises too high while the vehicle is in operation or when the ignition switch key is turned to ON. If it stays on, stop the engine and check the coolant
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 33
    32 GENERAL INFORMATION j Oil Pressure Warning Light The oil pressure warning light goes on whenever the oil pressure is dangerously low or the ignition switch key is in the ON position with the engine not running, and goes off when the engine oil pressure is high enough. CAUTION If the engine oil
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 34
    switch key is turned to "ON" and goes off soon after ensuring that its circuit functions properly. The warning light also goes on whenever the troubles occur in digital fuel injection system (DFI). If the warning light comes on, have the DFI system checked by an authorized Kawasaki dealer. Parking
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 35
    fittings of steering actuator, or the neutral position setting of the steering will be adversely affected and will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer. If the steering becomes more difficult than usual or you experience other steering
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 36
    GENERAL INFORMATION 35 j Brake Pedal The brake pedal is the left pedal on the foot board. Depress the pedal to slow or stop the vehicle. Cargo Bed For loading and unloading, the tail gate of the cargo bed can be opened. Raise the latch handles at each end of the tail gate and slide both latches
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 37
    operations. Extended Cargo Bed Raising the cargo bed The cargo bed can be raised for engine maintenance or servicing, release the latches on both sides and raise it with the handgrips. Support the bed in the tilted position with the rod. The raising & lowering procedures are different with the
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 38
    GENERAL INFORMATION 37 WARNING Overloading or improper use of the cargo bed can cause changes in handling which can lead to an accident. Follow guidelines provided in the "LOADING INFORMATION" chapter. Passengers riding in the cargo bed can be tossed about or even thrown out causing serious injury
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 39
    gasoline with a minimum Antiknock Index of 87. The Antiknock Index is posted on service station pumps in the U.S.A. The octane rating of a gasoline is a measure standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 40
    the fuel tank and carburetors. See the "STORAGE" chapter in this manual. j CAUTION Avoid using blends of unleaded gasoline and methanol (wood alcohol gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 41
    40 GENERAL INFORMATION j Fuel Gauge The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank. Raise the front seat and check the fuel amount left. When the red indicator needle comes near the empty mark (red line), refuel at the earliest opportunity. Glove Compartment A glove
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 42
    GENERAL INFORMATION 41 j Front Cargo Compartment The front cargo compartment is located under the front cargo hood. Store only light-weight items in it to avoid damage to the inside of the compartment. Do not put items which must not get wet or dirty inside. A. Right Glove Compartment A. Front
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 43
    42 GENERAL INFORMATION j A. Latch Release Knob A. Push here B. Latches żWhen the hood is hard to open, pull and lift up the front hood center portion with pulling the knob to open the hood. Hood Closing Close the hood until it locks. After the hood is closed, push the two edges of the hood to
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 44
    GENERAL INFORMATION 43 j Horn Button A car type horn button is provided on the center of the steering wheel. Push the horn button to sound the horn. Ignition Switch This is a three-position, key-operated switch. The key can be removed from the switch only when it is in the "OFF" position. A. Horn
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 45
    44 GENERAL INFORMATION OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is in "N" (neutral) position. Upon release, key will return to "ON" position. you need,
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 46
    GENERAL INFORMATION 45 j Hour Meter The hour meter shows the total hours that the vehicle has been operated. This meter cannot be reset. Shift Levers This vehicle is equipped with three different shift levers: the gear shift lever, the 2WD-4WD shift lever and the differential shift lever. Gear
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 47
    46 GENERAL INFORMATION climbing hills, pulling a trailer, or keeping constant low speeds. The high gearing raises the speed range for ordinary off-highway use. Stop the vehicle before moving the Hi-Lo shift lever. j CAUTION Use of the high range for heavy loads, climbing hills, and pulling a
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 48
    GENERAL INFORMATION 47 j A. B. C. D. 2WD-4WD Shift Lever Stopper "2WD" Position "4WD" Position A. Differential Shift Lever B. Stopper C. Differential (Unlocked-Axle) Mode Position (UN-LOCK) D. Locked-Axle Mode Position (LOCK) Differential Shift Lever This vehicle is equipped with a dual-mode
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 49
    48 GENERAL INFORMATION j Parking Brake Lever The parking brake lever is located at the left side of the seat. Pull the lever up and to the rear to apply the parking brake. To release, push in and hold the knob on the end of the lever and push the lever all the way down. Spring pressure helps return
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 50
    GENERAL INFORMATION 49 4-passenger mode j Seats There are front and rear seats on this vehicle. It can be transformed from 2-passenger to 4-passenger by unfolding the rear seat. 2-passenger mode żConverting the rear seat must be made in combi- NOTE nation with cargo bed conversion. See the
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 51
    50 GENERAL INFORMATION j Seat Belts The vehicle is equipped with retractable lap-style seat belts for all occupants - operator and passenger for the front seat and two passengers for the rear seat. Always wear the seat belts when operating and riding in the vehicle WARNING Seat belts reduce injury
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 52
    GENERAL INFORMATION 51 j Throttle Pedal The throttle pedal is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. In
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 53
    this vehicle. To avoid injury and property damage, observe the following precautions: WARNING Do not operate or install winch without reading and understanding the operators manual supplied with the winch. A. Trailer Hitch Bracket
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 54
    GENERAL INFORMATION 53 Installing procedure for a winch 1. Remove the front bumper cover screws, and front bumper cover. 2. Remove the front bumper to gain access by releasing four bolts. j A. Front Bumper Cover B. Screws A. Front Bumper B. Bolts C. Winch Bracket
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    54 GENERAL INFORMATION 3. You can see the bracket attached to a cross -member. j A. Winch Bracket B. Bolt Holes 4. 5. Follow a manual to be supplied by the winch maker for installing the winch and other accessory as necessary. After installing the winch, be sure to re-install
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 56
    . If any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating condition. j WARNING Failure to perform these checks every day before operation
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 57
    56 HOW TO OPERATE Throttle ...Throttle pedal free play 5 ∼ 10 mm (0.2 ∼ 0.4 in.). Throttle pedal operates smoothly and returns to rest position when released. Steering ...Steering wheel free play 0 ∼ 20 mm (0 ∼ 0.8 in.). Action smooth without excessive play, rough spots, or strange noises. Brakes
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 58
    HOW TO OPERATE 57 Starting the Engine żThe NOTE WARNING Never run the vehicle in a closed area, such as a garage. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. the seat belts (both
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 59
    58 HOW TO OPERATE Jump Starting If your vehicle's battery is "run down," it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. the cover under the left end of the front • Remove seat. j WARNING Battery acid
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    HOW TO OPERATE 59 WARNING Do not make this last connection at the carburetor or battery. Take care not to touch the positive and negative cables together, and do not lean over the battery when making this last connection. Do not connect to a frozen battery. It could explode. Do not reverse polarity
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 61
    60 HOW TO OPERATE Moving Off the brake pedal. • Depress Put the gear shift lever into the "H" (High) or "L" • (Low) position. the parking brake. • Release increase engine speed by pressing on • Gradually the throttle pedal. Braking j żPractice starting and stopping (using the brakes) until you
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 62
    HOW TO OPERATE 61 Stopping the Engine the throttle pedal completely. • Release Put the gear shift lever into the "N" (Neutral) posi• tion. the parking brake to help prevent the vehicle • Apply from rolling. • Turn the ignition switch key to the "OFF" position. Parking the Mule • Stop the vehicle
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 63
    62 HOW TO OPERATE the ignition switch key to prevent unau• Remove thorized use. parking inside a garage or other structure, • When be sure the structure is well ventilated and the vehicle is not close to any source of flame or sparks. This includes any appliance with a pilot light. Hi-Lo Shifting
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 64
    HOW TO OPERATE 63 Shifting to High Range the vehicle completely. • Stop Put the gear shift lever in neutral. • Move the shift lever to the "H" (High) position. • Reversing Gears the throttle pedal, and stop the vehicle. • Release When you want to operate the vehicle in reverse, • stop the vehicle
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 65
    64 HOW TO OPERATE 2WD-4WD Shifting the stopper under the 2WD-4WD shift lever • Pull knob and while holding it against the knob, move j • the shift lever to the all way down to "4WD". To shift back into "2WD" position, pull and hold the stopper, then move the shift lever all the way up to "2WD".
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 66
    HOW TO OPERATE 65 Shifting the Differential Shifting to Differential (Unlocked-Axle) Mode and hold the stopper, then move the shift lever • Pull all the way up (UN-LOCK). j żDo not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph). NOTE żWhen the shift
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 67
    66 HOW TO OPERATE Converting Rear Seat and Cargo Bed This vehicle can be converted to accommodate more passengers and less cargo or fewer passengers and more cargo. The seats and the cargo bed can be converted in the following way. j 2. 3. Push the rear seat back forward. Release the latches on
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 68
    HOW TO OPERATE 67 j A. Rear Seat (Stored position) B. Front Seat Back A. Cargo Bed Side Plates B. Latch 5. Swing open the cargo bed side plates and fasten the latches on the both sides. 6. Slide the stopper pins towards inside at the bottom of the removable screen.
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    68 HOW TO OPERATE j A. Stopper Pin B. Screen A. Screen B. Sockets 7. Pull and remove the screen from the sockets, move forward and insert into the sockets at the end of the side plates. 8. Latch the stopper pins at the bottom of the screen. From 2-person to 4-person Mode the procedure for
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 70
    HOW TO OPERATE 69 Raising & Lowering the Cargo Bed j WARNING Reduced clearance between cargo bed and cab frame can cause hand injury. Do not hold cab frame in the location of the label when raising or lowering the cargo bed. Raising the cargo bed (Shortened Condition) : 1. Pull the rear seat
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    70 HOW TO OPERATE j A. Latch B. Rear Seat Back (lowered position) A. Rear Seat (Stored position) B. Front Seat Back 4. Push the rear seat assembly forward into the stored position. 5. Holding the hand grip and cargo bed top, raise the cargo bed.
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    HOW TO OPERATE 71 j A. Handgrip B. Hold here. A. Supporting Rod B. Cargo Bed (Raised Position ) 6. Support the bed in the tilted position with the supporting rod. żTo lower the cargo bed, follow the reverse procedure for raising. Be sure to restore the seat as before and put the latches on.
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    72 HOW TO OPERATE 2. 3. Holding the handgrip and cargo bed on the top edge, raise the cargo bed. Support the bed in the tilted position with the supporting rod. j żTo lower the cargo bed, follow the reverse procedure for raising. Be sure to attach the latches to the cargo bed. NOTE WARNING A.
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    your vehicle may result in an unsafe operating condition. Before operation, make sure that the vehicle is not overloaded and that you have followed the instructions in the "Loading Information" chapter.
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    74 SAFE OPERATION Driving in Reverse Start the engine following the procedure in the "Starting the Engine" section. Before shifting into reverse, stop the vehicle completely. Refer to the Gear Shift Lever in the "Shift Levers" section and "Reversing Gears" section. Turn around and look behind you
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    SAFE OPERATION 75 Turning the Vehicle The vehicle will turn in a smaller radius with the differential unlocked (in differential mode). In this mode, the rear wheels can turn at different speeds allowing the vehicle to turn tighter and more smoothly. Even in this mode, however, avoid sharp turns to
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 77
    76 SAFE OPERATION Climbing Hills Do not attempt to climb hills or steep inclines until you have mastered the controls and basic operating maneuvers of this vehicle. Always go straight uphill and, if the incline is steep and/or the surface is loose, use "4WD" with the differential locked for greater
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    SAFE OPERATION 77 Descending Hills Slow down or stop at the top of a hill so you can pick a straight, safe path for descent to avoid any obstacles. Normally you should descend straight down a hill since driving at an angle could cause the vehicle to lean to one side and possibly tip over. Proceed
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    78 SAFE OPERATION Traversing Hillsides When driving across the side of a hill, reduce vehicle speed and exercise extreme caution to prevent tipping or loss of control. Avoid hills with slippery sides that will cause you to lose traction. Also avoid traversing hillsides covered with rocks or other
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    SAFE OPERATION 79 Driving through Water Avoid driving through water whenever it is possible. When driving across shallow water, choose a location to enter and exit the water where the banks are not too steep or slippery. Check before entering for rocks, holes or other obstacles which may cause you
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    80 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the Mule in good running condition. The initial maintenance is vitally important and
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    more frequently when operated in mud, dust, or other harsh riding conditions. = Emission Related FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use j OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    82 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    MAINTENANCE AND ADJUSTMENT 83 FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    84 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    all the oil to drain down. • Park the vehicle on level ground. żIf the vehicle is in 2-person mode, first raise the NOTE cargo bed, support with the rod and pull the stored rear seat and place it onto the engine.
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    86 MAINTENANCE AND ADJUSTMENT j A. Rear Seat (Folded) B. Dipstick out the dipstick and check the oil level. The • Pull oil level should be between the "F" (Full) and "L" (Low) lines on the dipstick. A. Dipstick B. "F" (Full) Line C. "L" (Low) Line the dipstick until it bottoms into the tube •
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    fold the rear seat and push its assembly into the stored position, and then raise the cargo bed and support it with the rod. żIn 2-person mode, raise the cargo bed and support it with the rod. NOTE • Remove the oil filler cap. j A. Drain Plug the vehicle held level, let the oil
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    88 MAINTENANCE AND ADJUSTMENT j A. Oil Filter Cartridge A. Gasket a thin film of oil to the gasket and screw the • Apply cartridge in until the gasket touches the engine, then turn it 3/4 turn. the drain plug with its gasket. Tighten it to • Install the specified torque. Tightening Torque Drain
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    MAINTENANCE AND ADJUSTMENT 89 Recommended Engine Oil Capacity Grade: API SF or SG class API SH, SJ or SL with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 żDo not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 91
    90 MAINTENANCE AND ADJUSTMENT Front Final Gear Case Oil In order for the differential, pinion, and ring gears to function properly, check the oil level and change the oil in accordance with the Periodic Maintenance Chart. j WARNING Vehicle operation with insufficient, deteriorated, or
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    MAINTENANCE AND ADJUSTMENT 91 the vehicle level front-to-rear and side-to • With -side, remove the filler cap from the front final gear case. j A. B. C. D. A. Front Final Gear Case B. Filler Cap Front Final Gear Case Filler Opening Bottom Thread Drain Plug CAUTION Be careful not to allow any
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 93
    92 MAINTENANCE AND ADJUSTMENT Oil Change Tightening Torque Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb) the gear case up to the bottom thread of the • Fill filler opening with a high quality oil as specified in the table. Front Final Gear Case Oil about 400 mL Oil Capacity (0.4 US qt) Oil Type API "GL
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 94
    • Pull oil level should be between the "H" (High) and "L" (Low) lines on the dipstick. • • • Park the vehicle on level ground. Lift the cargo bed and support it with the rod. Unscrew the oil filler plug, wipe the dipstick dry, and insert it into the filler hole but DO NOT SCREW IT
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 95
    . NOTE A. Transmission Case B. Drain Plug WARNING To avoid a serious burn, never touch a hot muffler or exhaust pipe during oil draining. • Lift the cargo bed and support it with the rod.
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 96
    MAINTENANCE AND ADJUSTMENT 95 • Remove the filler plug. WARNING When draining or filling the transmission case, be careful that no oil gets on the tires or rims. Oil on tires can make them slippery which can cause an accident and injury. Clean off any oil that inadvertently gets on them with soap
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 97
    96 MAINTENANCE AND ADJUSTMENT Cooling System WARNING Do not touch the radiators when they are hot, nor open the radiator caps. Hot coolant inside will cause you severe burns. Radiator and Cooling Fan Check and clean the screen and radiator fins for obstruction by insects or mud in accordance with
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 98
    MAINTENANCE AND ADJUSTMENT 97 Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer damage. Check the coolant level each day before operating the vehicle, and replenish coolant if the
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 99
    98 MAINTENANCE AND ADJUSTMENT żIn an emergency you can add water alone to the coolant reserve tank, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible. NOTE Spark Plugs The standard spark plug is shown in the table. The spark
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 100
    MAINTENANCE AND ADJUSTMENT 99 Spark Plug Removal the cargo bed to support it with the rod. • Lift Carefully • plugs. pull the spark plug caps from the spark j Spark Plug Standard Plug Plug Gap NGK BPR2ES 0.7 ∼ 0.8 mm (0.028 ∼ 0.
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 101
    gauge shows whether the air cleaner is clogged. Whenever the red band shows in the gauge window, the air filter element should be cleaned. After servicing the air filter element, the restriction gauge should be reset by pushing the button at the top of the gauge.
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 j A. Air Filter Restriction Gauge Element Removal A. Air Cleaner Housing B. Cap C. Snaps up the snaps and remove the air cleaner hous• Pull ing cap from the housing. the air cleaner element out of the housing. • Pull Push a clean, lint-free towel into the air
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 103
    102 MAINTENANCE AND ADJUSTMENT CAUTION If dirt gets into the engine, excessive engine wear and possible engine damage may occur. away the remaining dust by applying com• Blow pressed air from the inside to the outside (from the the element material for damage. If any • Inspect part of the element
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 104
    the "Periodic Maintenance Chart". Spark Arrester This vehicle is equipped with a spark arrester approved for off-highway use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. Clean the spark arrester in accordance with the Periodic Maintenance Chart. CAUTION The
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 105
    104 MAINTENANCE AND ADJUSTMENT WARNING Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. the engine. • Stop • Install the drain plug. j A. Spark
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 106
    pedal does not return properly, check the throttle cable routing, pedal free play, and cable damage. Then lubricate the throttle cable. the cargo bed and support it with the rod. • Lift and turn the throttle cable mounting nuts • Loosen at the end of the throttle cable. the adjuster until the
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 107
    106 MAINTENANCE AND ADJUSTMENT j A. Throttle Cable B. Mounting Nuts A. Cover B. Bolt • Tighten the mounting nuts securely. Throttle Pedal Stop Position Adjustment The full throttle pedal stop position can be adjusted to prevent pulling the throttle cable more than required. Remove the cover by
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 j A. Pully (Fully Opened Position) B. Stopper the throttle pedal stop bolt until the bolt head • Turn lightly touches the bottom of the throttle pedal. the locknut securely. • Tighten Be sure • smoothly. to check the throttle cable moves A. Throttle Pedal B.
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 109
    108 MAINTENANCE AND ADJUSTMENT Idle Adjustment Idle adjustment is controlled by the ECU and cannot be adjusted. If the idle speed is unstable, have your dealer inspect the throttle body. Specified Idle Speed: 950 ±50 rpm Fuel Tank Vent The fuel tank vent hoses must be routed as specified. The
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 110
    MAINTENANCE AND ADJUSTMENT 109 Belt Drive Torque Converter The vehicle is equipped with a belt drive torque converter type automatic transmission. The belt, driven pulley shoes and drain cap should be checked in accordance with the Periodic Maintenance Chart. The belt and driven pulley shoes
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 111
    110 MAINTENANCE AND ADJUSTMENT Belt Drive Torque Converter Air Cleaner A clogged belt drive torque converter air cleaner may cause the torque converter to malfunction. CAUTION A clogged air cleaner may allow dirt and dust to enter the belt drive torque converter causing excessive wear of the inner
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 112
    MAINTENANCE AND ADJUSTMENT 111 CAUTION If dirt gets into the belt drive torque converter, excessive wear and loss of driving power may result. away the remaining dust by applying com• Blow pressed air from the inside to the outside (from the the element material for damage. If any • Inspect part
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 113
    112 MAINTENANCE AND ADJUSTMENT Brakes The vehicle is equipped with hydraulically activated drum brakes on all four wheels. Brake Pedal the brake pedal has more or less free play • If than specified or the pedal action feels rough or "catchy," have the brake system inspected immediately by an
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 114
    MAINTENANCE AND ADJUSTMENT 113 WARNING Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not mix two types of fluid for use in the brakes. This lowers the brake fluid boiling point and could reduce brake
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 115
    brake lines or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, have the brake system serviced immediately. A. Cap Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. A. Brake Fluid Reservoir B. Upper Level Line (MAX) C. Lower
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 Brake Light Switch When the brake pedal is depressed, the brake light goes on. The brake light switch should be inspected in accordance with the Periodic Maintenance Chart. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 117
    116 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. 8 to 12 clicks of lever travel, the vehicle • After should not roll while
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for the specified free play and smooth operation. Free Play Inspection A. Locknut B. Nut the vehicle on level ground. • Park turn the steering wheel left and right. • Lightly
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 119
    happen when the engine starts; inspect the battery voltage. Cable harness or connectors may have been disconnected. See an authorized dealer for service. • • • • j żIf the steering becomes irregular or unusual for NOTE A. Steering Column Bracket B. Nuts any reason other than above, have an
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 120
    or impair the handling of the vehicle. żInstallation of tubeless tires on rims requires compressed air and is normally recommended as a dealer service operation. Nevertheless, a tube can be inserted into the tire by the operator as an emergency repair. j Maximum Tire Air Pressure for Seating
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 121
    120 MAINTENANCE AND ADJUSTMENT WARNING Inflate both front tires to the same pressure and both rear tires to the same pressure. Operating with unequally or improperly pressurized tires can adversely affect steering or handling. Minimum Tread Depth: 3 mm (0.12 in.) inspect the tire for cracks and
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 122
    MAINTENANCE AND ADJUSTMENT 121 Joint Boots In accordance with the Periodic Maintenance Chart, inspect the joint boots on the front axles, tie rod ends, steering knuckles, and rear axle shafts for cracks, holes, damage or deterioration. If there is any one of them, have the joint boot replaced by an
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 123
    122 MAINTENANCE AND ADJUSTMENT Suspension Rear Shock Absorber Spring Force Adjustment The spring adjusting sleeves on the rear shock absorbers have 5 positions so that the springs can be adjusted for different riding and loading conditions. j A. Adjusting Sleeve (Turn here with a hook wrench) If
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 124
    MAINTENANCE AND ADJUSTMENT 123 Spring Action PosiSpring tion Force 1 2 3 4 5 | | | Ļ Stronger Setting Load Soft Ĺ | Ļ Hard Light Ĺ | Ļ Heavy Surface Good Ĺ | Ļ Bad Speed Low Ĺ | Ļ High Seat Belts In accordance with the Periodic Maintenance Chart, check that each seat belt functions properly.
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 125
    124 MAINTENANCE AND ADJUSTMENT Cargo Bed Latches Depending on the cargo loading and/or passenger riding conditions, latch lever compression needs to be adjusted. Release the fitting bolts and adjust the position of the latch assembly so that the latch lever will be secured without rattling and
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 126
    MAINTENANCE AND ADJUSTMENT 125 Battery The battery is located under the left end of the front seat. WARNING Heed the battery safety label shown here. j A. Adjusting Screws Battery Removal • Remove the cover under the front seat left end.
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 127
    126 MAINTENANCE AND ADJUSTMENT j A. Cover • Remove the battery holder. A. Holder B. (+) Terminal C. (-) Terminal the cables from the battery, first from • Disconnect the (-) terminal and then the (+) terminal. żThere is no need to separate the smaller cables clamped with the main battery
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 128
    a sealed type, and the sealing strip should not be removed at any time after the specified electrolyte has been installed in the battery for initial service. It is not necessary to check the battery electrolyte level or add distilled water. However, in order to maximize battery life and ensure that
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 129
    128 MAINTENANCE AND ADJUSTMENT Current Drain (Y50-N18L-A) Days from 100% DischargCharged to 50% ing Ampere Discharged 7 mA 10 mA 15 mA 20 mA 30 mA 60 Days 42 Days 28 Days 21 Days 14 Days Days from 100% Charged to 100% Discharged 119 Days 83 Days 56 Days 42 Days 28 Days Battery Maintenance It is the
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 130
    the wiring harness and electrical equipment for bare wires or other possible causes. żIf you charge the sealed battery, never fail to observe the instructions shown on the label on the battery and charger. NOTE CAUTION Do not use a fuse of a higher capacity than the specified fuse rating, or
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 131
    blown, steering becomes heavy. Replace the blown fuse with a fuse of the same specific amperage and type. If a replaced fuse blows again, there can be trouble with the ECU or harness/connectors. See an authorized dealer for inspection. You can check the 40 A fuse if it is blown at the top
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 132
    MAINTENANCE AND ADJUSTMENT 131 Breaker The breaker for the radiator fan is located under the seat near the fuse box. If the fan does not function, inspect the breaker. In order to reset the breaker, push the button at the side of the breaker case. Before resetting, however, check that the radiator
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 133
    In accordance with the Periodic Maintenance Chart, have the general lubrication performed by an authorized Kawasaki dealer or perform it referring to the Service Manual for this vehicle. Cleaning To prolong the life of your vehicle, wash it down immediately after it has been splashed with sea water
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 134
    MAINTENANCE AND ADJUSTMENT 133 CAUTION Coin operated, high pressure spray washers are not recommended. Water may be forced into bearings and other components causing eventual failure from rust and corrosion. Some soaps are highly alkaline and may leave a residue or cause spotting. Bolt and Nut
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 135
    engine oil. • • żAs an alternative to draining the fuel system, a fuel stabilizer, such as STA-BIL, may be used. Follow the manufacturer's instructions for use. NOTE WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 136
    STORAGE 135 oil on all unpainted metal surfaces to pre• Spray vent rusting. Avoid getting oil on rubber parts or in all the cables as indicated in the General • Lubricate Lubrication section. the battery, and store it where it will not • Remove be exposed to direct sunlight, moisture, or freezing
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 137
    136 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE j • • • Engine Cranks, But Won't Start fuel in tank • No Water in fuel • Air filter clogged or inlet blocked • Engine flooded • Fuel tank vent clogged • Spark
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 138
    receipt of your correspondence we will contact the dealership and work with them in resolving your problem. In order to provide a permanent record, all warranty and service resolutions take place only through written correspondence. Please send your correspondence to: CONSUMER RELATIONS KAWASAKI
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 139
    138 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 140
    MAINTENANCE RECORD 139 MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Traveled Distance Maintenance Performed
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 141
    140 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 142
    MAINTENANCE RECORD 141 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 143
    142 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 144
    MAINTENANCE RECORD 143 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 145
    144 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 146
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