2010 Kawasaki MULE 4000 Owners Manual

2010 Kawasaki MULE 4000 Manual

Get 2010 Kawasaki MULE 4000 PDF manuals and user guides View all 2010 Kawasaki MULE 4000 manuals

2010 Kawasaki MULE 4000 manual content summary:

  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 1
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 2
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 3
    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.
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 4
    Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. CAUTION CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 5
    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 and
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 6
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 7
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 8
    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...
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 9
    Tires ...Joint Boots...Seat Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System (KAF620M) ...Breaker...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE... 86 88 90 90 93 93 95 98 98 99 100 102 102 105 106 107 108 109 109 109 109 111 112
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 10
    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's Manual if you have any questions. Off-Highway Use Only This vehicle is not an
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 11
    BASIC SAFE DRIVING 9 Wearing Seat Belt Both the operator and passenger should wear the seat belts whenever the vehicle is operated. This will reduce the severity of injury in case of a sudden stop or collision. Also, to reduce chance of injury, always keep arms and legs inside the cab frame while
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 12
    10 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance 47 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2 ft) 2 persons 3 005
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 13
    SPECIFICATIONS 11 Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type 4WD gear, (P) 2WD gear 2-speed & reverse, automatic,
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 14
    12 SPECIFICATIONS Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Steering Castor Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light 12 V 14 Ah 12 V 35 W × 2 12 V
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 15
    SPECIFICATIONS 13 LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load (M): KAF620M : California model only MODEL INFORMATION MULE4010 4 × 4...KAF620M MULE4000...KAF620P Specifications subject to change without notice. 603 kg (1 330 lb) 363 kg (800 lb) (P):
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 16
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 17
    LOCATION OF PARTS 15 LOCATION OF PARTS 1. 2. 3. 4. 5. 6. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Seat 7. 8. 9. 10. 11. 12. Seat Belts Cargo Bed Front Bumper Radiator Parking Brake Battery 13. Latch 14. Air Cleaner (Belt Drive Torque Converter) 15. Belt
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 18
    16 LOCATION OF PARTS 17. 18. 19. 20. Screen Latch Handle Tail Gate Dashboard 21. 22. 23. 24. Coolant Reserve Tank Tail/Brake Lights Trailer Hitch Bracket Muffler (Spark Arrester) 25. 26. 27. 28. Fuel Tank Fuel Tank Cap Fuel Gauge Air Cleaner
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 19
    LOCATION OF PARTS 17 29. 30. 31. 32. 33. 34. 35. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Parking Brake Warning Light 37. Right Glove Compartment 38. FI Warning Light 39. Power Steering Warning Light (
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 20
    18 LOCATION OF LABELS LOCATION OF LABELS 1. Warning (Off-Highway Utility Vehicle) 2. Warning (Front Cargo Hood) 3. Notice (Shifting) 4. Specification 5. Warning (General) 6. Important Information (Tires/Max. Load) 7. Warning (Cargo Bed) 8. Warning (Cargo Bed) 9. Warning (Hot Surfaces) 10. Warning
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 21
    LOCATION OF LABELS 19
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 22
    20 LOCATION OF LABELS (1) (2) (3) (4) (KAF620M) (4) (KAF620P)
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 23
    LOCATION OF LABELS 21 (5)
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 24
    22 LOCATION OF LABELS (6) (8) (7) (9)
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 25
    LOCATION OF LABELS 23 (10)
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 26
    24 LOCATION OF LABELS (11) (12) (13)
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 27
    LOCATION OF LABELS 25 (14) (15) California model only
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 28
    the vehicle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki 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 increases
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 29
    LOADING INFORMATION 27 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, passenger, and cargo must not exceed 603 kg (1 330 lb). vehicle is not designed to carry
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 30
    28 GENERAL INFORMATION j GENERAL INFORMATION Lighting/Electrical Accessory Connector The lighting/electrical accessory 12 volt connectors are located on the dashboard. An auxiliary light or an accessary may be connected to this connector. Light Switch Turn on the headlights and taillights by
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 31
    GENERAL INFORMATION 29 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 32
    30 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. NOTICE If the engine oil
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 33
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 34
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 35
    GENERAL INFORMATION 33 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 36
    34 GENERAL INFORMATION the handgrips. Support the bed in the tilted position with the rod. j A. Supporting Rod A. Latch B. Handgrip NOTICE Do not carry more than the maximum load stated here in the cargo bed. Maximum Load: 363 kg (800 lb)
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 37
    GENERAL INFORMATION 35 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 38
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 39
    all fuel from the fuel tank. See the "STORAGE" chapter in this manual. j NOTICE Avoid using blends of unleaded gasoline and methanol (wood alcohol) whenever " containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 40
    38 GENERAL INFORMATION j Fuel Gauge The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank. When the red indicator needle comes near the empty mark (red line) , refuel at the earliest opportunity. Glove Compartment A glove compartment is provided at the each end of the dashboard
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 41
    GENERAL INFORMATION 39 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 42
    40 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 front hood. NOTE WARNING An open front cargo hood can distract or impair visibility of the operator, causing
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 43
    GENERAL INFORMATION 41 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 44
    42 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,
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 45
    GENERAL INFORMATION 43 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 (KAF620M only) and the differential shift
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 46
    44 GENERAL INFORMATION maximum torque at low speeds, for climbing hills, pulling a trailer, or keeping constant low speeds for agricultural use. The high gearing raises the speed range for ordinary off-highway use. Stop the vehicle before moving the Hi-Lo shift lever. j NOTICE Use of the high
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 47
    GENERAL INFORMATION 45 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 48
    46 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 49
    GENERAL INFORMATION 47 j Seat The seat can be raised for vehicle maintenance and adjustment. Pull up on the rear edge of the seat. Seat Belts The vehicle is equipped with lap-style seat belts both for the operator and passenger. Always wear the seat belts when operating and riding in the vehicle.
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 50
    48 GENERAL INFORMATION To wear the seat belt properly, follow this procedure: 1. Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted. 2. Push the latch plate into the buckle until it clicks. 3. Adjust the seat belt for a SNUG FIT. j WARNING Too
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 51
    GENERAL INFORMATION 49 To unfasten the belt, press the red button in the buckle. 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 52
    50 GENERAL INFORMATION j Trailer Hitch Bracket This vehicle is equipped with a bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, observe the following precautions: WARNING Improper towing of a loaded trailer could cause an
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 53
    operation of a winch could cause an accident resulting in serious injury or death. Do not install or operate a winch without reading and understanding the operator's manual supplied with the winch. A. Front Bumper Cover B. Screws
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 54
    four bolts. 3. You can see the bracket attached to a cross -member. j A. Front Bumper B. Bolts C. Winch Bracket 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 55
    . 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 before operation may result
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 56
    54 HOW TO OPERATE Front Final Gear Case ...Transmission Case Oil ...Coolant ...Throttle ...No oil leaks. Oil level between H and L lines, no leaks. Coolant level between level lines (when engine is cold), no leaks. Throttle pedal free play 5 ∼ 10 mm (0.2 ∼ 0.4 in.). Throttle pedal operates smoothly
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 57
    HOW TO OPERATE 55 Starting the Engine żThe NOTE DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. the seat belts (
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 58
    56 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 DANGER Battery acid
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 59
    HOW TO OPERATE 57 WARNING Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive. Do not make this last connection at the battery. Take care not to touch the positive and negative cables together, and do not lean over the battery when making this
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 60
    58 HOW TO OPERATE Moving Off the brake pedal. • Depress Put the gear shift lever into the "H" (High) or "L" • (Low; KAF620M only) position. Release the parking brake. • Gradually increase engine speed by pressing on • the throttle pedal. Braking j żPractice starting and stopping (using the
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 61
    HOW TO OPERATE 59 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 62
    60 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 (
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 63
    HOW TO OPERATE 61 Shifting to High Range the vehicle completely. • Stop Put the gear shift lever in neutral. • Move the shift lever "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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 64
    62 HOW TO OPERATE 2WD-4WD Shifting (KAF620M) 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 "4WD". To shift back into "2WD" position, pull and hold the stopper, then move the shift lever all the way up "
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 65
    HOW TO OPERATE 63 Shifting the Differential j żDo not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph). NOTE Shifting to Locked-Axle Mode the stopper under the differential shift lever • Pull knob and while holding it against the knob, move the shift
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 66
    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.
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 67
    SAFE OPERATION 65 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 68
    66 SAFE OPERATION 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 69
    SAFE OPERATION 67 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 70
    68 SAFE OPERATION 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 71
    SAFE OPERATION 69 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 72
    70 SAFE OPERATION 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 73
    MAINTENANCE AND ADJUSTMENT 71 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 74
    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 OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 75
    MAINTENANCE AND ADJUSTMENT 73 FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use D OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 76
    74 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 (
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 77
    MAINTENANCE AND ADJUSTMENT 75 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 (
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 78
    , accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart in the owner's manual. Oil Level Inspection the oil has just been changed, start the engine • If and run it for several minutes at idle speed. This fills the
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 79
    . Contact your local authorities for approved disposal methods or possible recycling. the oil filter is to be changed, first lift the cargo • If bed to support it with the rod, and then remove the oil filter cartridge and replace it with a new one. • Oil and/or Oil Filter Change up the
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 80
    78 MAINTENANCE AND ADJUSTMENT j A. Cartridge A. Packing a thin film of oil to the packing and screw the • Apply cartridge in until the packing 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 Plug:
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 81
    MAINTENANCE AND ADJUSTMENT 79 Recommended Engine Oil Capacity Grade: API SG, SH, SJ, SL, or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 żDo not add any chemical additive to the oil. NOTE Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for the
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 82
    front and rear tires, with consequent loss of control, accident, and injury. Check the oil level and change the oil according to the owner's manual. A. Guard B. Nuts (Front Side) Oil Level Inspection the front final gear case guard by remov• Remove ing the mounting bolts and nuts. A. Bolts (Rear
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 83
    MAINTENANCE AND ADJUSTMENT 81 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 NOTICE Be careful not to allow any dirt
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 84
    82 MAINTENANCE AND ADJUSTMENT Oil Change WARNING NOTE Oil on tires can make them slippery which can cause an accident and injury. When draining or filling the gear case, be careful that no oil gets on the tires or rims. Clean off any oil that inadvertently gets on them with soap and water. the oil
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 85
    Check the oil level and change the oil according to the owner's manual. j A. Transmission Case B. Oil Filler Plug NOTICE Be careful not . Oil Level Inspection the vehicle on level ground. • Park the cargo bed and support it with the rod. • Lift the oil filler plug, wipe its dipstick dry,
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 86
    84 MAINTENANCE AND ADJUSTMENT Oil Change żBefore draining the oil, warm it up by running the vehicle. Warm oil drains easily and picks up any sediment. the vehicle level, place an oil pan beneath the • With transmission case. • Remove the drain plug. NOTE j A. Dipstick B. "H" (High) Line C. "L"
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 87
    normal operation and cause serious burns. To avoid a serious burn, never touch a hot muffler or exhaust pipe during oil draining. the cargo bed and support it with the rod. • Lift • Remove the filler plug. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) Transmission Case Oil Type API "GL
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 88
    86 MAINTENANCE AND ADJUSTMENT Cooling System WARNING The cooling system can get extremely hot during normal operation and cause serious burns. Do not touch the radiator when it is hot, nor open the radiator cap. Hot coolant inside will cause severe burns. Radiator and Cooling Fan Check and clean
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 89
    MAINTENANCE AND ADJUSTMENT 87 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 90
    88 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 91
    MAINTENANCE AND ADJUSTMENT 89 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.
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 92
    gauge show 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 end of the gauge.
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 93
    MAINTENANCE AND ADJUSTMENT 91 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT NOTICE If dirt gets into the engine, excessive engine 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 is
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 95
    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. NOTICE The
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 96
    94 MAINTENANCE AND ADJUSTMENT DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. the engine. • Stop • Install the drain
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 97
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 98
    96 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 99
    MAINTENANCE AND ADJUSTMENT 97 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. Locknut
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 100
    98 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 101
    MAINTENANCE AND ADJUSTMENT 99 Belt Drive Torque Converter The vehicle is equipped with a belt drive torque converter type automatic transmission. The belt, driven pulley shoes and drain hose should be checked in accordance with the Periodic Maintenance Chart. The belt and driven pulley shoes
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 102
    100 MAINTENANCE AND ADJUSTMENT Belt Drive Torque Converter Air Cleaner A clogged belt drive torque converter air cleaner may cause the torque converter to malfunction. NOTICE A clogged air cleaner may allow dirt and dust to enter the belt drive torque converter causing excessive wear of the inner
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 103
    MAINTENANCE AND ADJUSTMENT 101 NOTICE 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 of
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 104
    102 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 105
    MAINTENANCE AND ADJUSTMENT 103 WARNING Over time, brake fluid can absorb moisture, lowering its boiling point and reducing brake effectiveness. 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 and brands of fluid for use in
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 106
    104 MAINTENANCE AND ADJUSTMENT WARNING Mixing two types and brands of fluid for use in the brake lowers the brake fluid boiling point and could reduce brake effectiveness. Change the fluid in the brake system completely if the fluid level is low but the type and brand of the fluid already in the
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 107
    MAINTENANCE AND ADJUSTMENT 105 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 108
    106 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 109
    MAINTENANCE AND ADJUSTMENT 107 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 110
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 111
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 112
    110 MAINTENANCE AND ADJUSTMENT WARNING Operating with unequally or improperly pressurized tires can adversely affect steering or handling. Inflate both front tires to the same pressure and both rear tires to the same pressure. Minimum Tread Depth: 3 mm (0.12 in.) inspect the tire for cracks and
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 113
    MAINTENANCE AND ADJUSTMENT 111 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 114
    112 MAINTENANCE AND ADJUSTMENT Seat Belts In accordance with the Periodic Maintenance Chart, check that each seat belt functions properly. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. The click sound shows it is securely latched. Push
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 115
    MAINTENANCE AND ADJUSTMENT 113 Battery The battery is located under the left end of the seat. DANGER Battery contains sulfuric acid and produces hydrogen gas. Sulfuric acid can cause burns and hydrogen gas can cause an explosion. Read and heed the battery safety label. j A. Adjusting Screws
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 116
    114 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 117
    death. Make sure the battery terminal screws are tightened securely and the covers are installed over the terminals. 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 118
    116 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 119
    check 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 NOTICE Do not use a fuse of a higher capacity than the specified fuse rating, or
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 120
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 121
    MAINTENANCE AND ADJUSTMENT 119 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 122
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 123
    MAINTENANCE AND ADJUSTMENT 121 NOTICE 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 124
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 125
    STORAGE 123 oil on all unpainted metal surfaces to pre• Spray vent rusting. Avoid getting oil on rubber parts or in • • the brakes. Lubricate all the cables as indicated in the General Lubrication section. Remove the battery, and store it where it will not be exposed to direct sunlight, moisture,
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 126
    124 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 127
    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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 128
    126 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 129
    MAINTENANCE RECORD 127 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
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 130
    128 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 131
    MAINTENANCE RECORD 129 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 132
    130 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 133
    MAINTENANCE RECORD 131 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 134
    132 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2010 Kawasaki MULE 4000 | Owners Manual - Page 135
  • 1
  • 2
  • 3
  • 4
  • 5
  • 6
  • 7
  • 8
  • 9
  • 10
  • 11
  • 12
  • 13
  • 14
  • 15
  • 16
  • 17
  • 18
  • 19
  • 20
  • 21
  • 22
  • 23
  • 24
  • 25
  • 26
  • 27
  • 28
  • 29
  • 30
  • 31
  • 32
  • 33
  • 34
  • 35
  • 36
  • 37
  • 38
  • 39
  • 40
  • 41
  • 42
  • 43
  • 44
  • 45
  • 46
  • 47
  • 48
  • 49
  • 50
  • 51
  • 52
  • 53
  • 54
  • 55
  • 56
  • 57
  • 58
  • 59
  • 60
  • 61
  • 62
  • 63
  • 64
  • 65
  • 66
  • 67
  • 68
  • 69
  • 70
  • 71
  • 72
  • 73
  • 74
  • 75
  • 76
  • 77
  • 78
  • 79
  • 80
  • 81
  • 82
  • 83
  • 84
  • 85
  • 86
  • 87
  • 88
  • 89
  • 90
  • 91
  • 92
  • 93
  • 94
  • 95
  • 96
  • 97
  • 98
  • 99
  • 100
  • 101
  • 102
  • 103
  • 104
  • 105
  • 106
  • 107
  • 108
  • 109
  • 110
  • 111
  • 112
  • 113
  • 114
  • 115
  • 116
  • 117
  • 118
  • 119
  • 120
  • 121
  • 122
  • 123
  • 124
  • 125
  • 126
  • 127
  • 128
  • 129
  • 130
  • 131
  • 132
  • 133
  • 134
  • 135