2011 Kawasaki MULE 4010 Trans4x4 Diesel Owners Manual

2011 Kawasaki MULE 4010 Trans4x4 Diesel Manual

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  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 1
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 2
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | 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.
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  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 5
    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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 6
    . As the owner of the Mule, 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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 7
    Tampering with Emission Control System is Prohibited Federal law and California state law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 8
    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
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    Bracket ...Winch Installation ...HOW TO OPERATE ...Daily Safety Checks ...Starting the Engine ...Cold Weather Starting ...Starting After Fuel System Service ...Jump Starting ...Moving Off ...Braking ...Stopping the Engine ...Parking the Mule ...Hi-Lo Shifting ...Reversing Gears ...2WD-4WD Shifting
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    Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System...Breaker...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...YOUR WARRANTY/OWNER SATISFACTION ...ENVIRONMENTAL PROTECTION ...MAINTENANCE RECORD ... 124 124 126 127 128 129 130 134 134
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    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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 12
    10 BASIC SAFE DRIVING 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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 13
    SPECIFICATIONS 11 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) ENGINE Type Displacement Bore × Stroke Diesel, 3 cylinder,
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    12 SPECIFICATIONS Compression Ratio Starting System Cylinder Numbering Method Firing Order Injection Pump Lubrication System Engine Oil: Grade 24.8 : 1 Electric starter Right to left, 1-2-3 1-2-3 Denso VE Type Forced Lubrication (wet sump) Kawasaki Performance 4-Stroke ATV/UTV Oil* Kawasaki
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    SPECIFICATIONS 13 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 Steering Castor Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake
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    surface treatment. *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. Specifications subject to change without notice.
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    SERIAL NUMBER LOCATIONS 15 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
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    16 LOCATION OF PARTS 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 (
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    LOCATION OF PARTS 17 (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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    18 LOCATION OF PARTS 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. Left Glove Compartment Light Switch Front Cargo Hood Knob Oil Pressure Warning Light Coolant Temperature Warning Light Speedometer Parking Brake Warning Light Glow Plug Light Power Steering Warning Light Hour Meter 40. 41. 42. 43. 44.
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    LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 18. 20. Warning (Off-Highway Utility Vehicle) Notice (Shifting) Warning (Front Cargo Hood) Notice (Maximum Downhill Speed) Warning (General) Specification Warning (Pinching Fingers: both sides) Important Information (
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    20 LOCATION OF LABELS 13. 14. 15. 16. 17. 19. Warning (Trailer Hitch Bracket) Warning (Hot Surfaces) Notice (Engine Oil Level) Notice (Engine Oil Fill) Important Engine Information Warning (Passengers in Cargo Bed)
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    LOCATION OF LABELS 21 (1) (3) (2) (4)
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    22 LOCATION OF LABELS (5)
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    LOCATION OF LABELS 23 (6) (KAF950G) (8) (6) (KAF950H) (7) (9)
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    24 LOCATION OF LABELS (10) (11)
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    LOCATION OF LABELS 25 (12) (15) (14)
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    26 LOCATION OF LABELS (13)
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    LOCATION OF LABELS 27 (16) (18) (17)
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    28 LOCATION OF LABELS (19) (20)
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    you operate it, make sure that the vehicle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design work and fenders are not designed to carry cargo or to support your weight. They may break.
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    30 LOADING INFORMATION 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 740 kg (1 630 lb). vehicle is not designed to carry
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 33
    or aftermarket cetane improver additives to diesel fuel. Damage to the fuel injection system may result. Engine Oil Use only oils conforming to API Service CF or CF -4. Use the proper SAE viscosity grade of engine oil for the expected ambient temperature range as indicated in the following chart
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    32 GENERAL INFORMATION j Lighting/Electrical Accessory Connectors The lighting 12 volt connector is located on the dashboard. An auxiliary light may be connected to this connector. Other connectors for electrical accessory are located under the left side dashboard. Optional items such as wiper and
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    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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 36
    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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | 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
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    36 GENERAL INFORMATION j 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. If it stays on, stop the engine and check the coolant level in the reserve tank after the engine cools
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    GENERAL INFORMATION 37 Fuel Tank The fuel tank is mounted under the right side of the seat. This engine is certified to operate on Diesel Fuel. Use clean, fresh diesel fuel (ASTM D975) for good performance of this vehicle. Avoid refilling the tank in the rain or where heavy dust is blowing, so that
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 40
    38 GENERAL INFORMATION j NOTICE Do not use gasoline, gasohol or any other fuel, except diesel fuel. Improper fuel can cause severe fuel injection system and engine damage. Fuel Gauge The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank. When the red indicator needle comes
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    GENERAL INFORMATION 39 j Air Filter Restriction Gauge The air filter restriction gauge is on right side under the rear seat. It shows whether the air cleaner is clogged. The air cleaner element should be cleaned. Whenever the red band shows in the gauge window, the air filter element should be
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    40 GENERAL INFORMATION 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 in it. A. Right Glove Compartment A. Front
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    GENERAL INFORMATION 41 Hood Opening Pull the latch release knob and raise the hood until it stops. Hood Closing Close the hood until it locks. After the hood is closed, push the two parts of the hood to ensure the hood is latched. j • • A. Latch Release Knob NOTE A. Push here. B. Latches żWhen
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    42 GENERAL INFORMATION 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. Main 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
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    GENERAL INFORMATION 43 OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. Hour meter works. j Keys This UV has a key, which is used for the ignition switch, and one spare key. Included with the key is a key number, which is stamped on the key itself. Record the
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 46
    44 GENERAL INFORMATION dealer may have the number in its records. If the key number is lost completely, you will need to replace the ignition switch and all other locks operated by that key. Contact your Kawasaki dealer to purchase additional spare keys either using your original key as a master or
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 47
    GENERAL INFORMATION 45 j Light Switch Turn on the headlights and taillights by pushing the light switch in, with the main switch key in the "ON" position. The lights go off when the switch is pushed out. Speedometer The speedometer shows the speed of the vehicle. In the speedometer face is the
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    46 GENERAL INFORMATION j Oil Pressure Warning Light The oil pressure warning light goes on whenever the oil pressure is dangerously low or the main 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 gets
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 49
    GENERAL INFORMATION 47 j 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 Shift Lever The gear shift lever is located on the dashboard, to the right of the steering shaft. The gear shift
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    48 GENERAL INFORMATION 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 range for heavy loads, climbing hills, and pulling a trailer can lead to premature wear of the torque converter belt and pulleys. Use low range
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    GENERAL INFORMATION 49 Differential Shift Lever This vehicle is equipped with a dual-mode rear differential. The differential shift lever is located on the dashboard, to the left of the steering shaft. Move the shift lever up or down as indicated on the label next to the shift lever. Refer to the "
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    50 GENERAL INFORMATION j WARNING If the vehicle should move after it is parked, it might be damaged or cause injury. Be sure to apply the parking brake before leaving the vehicle. Parking Brake Warning Light The parking brake warning light goes on when the parking brake is applied with the main
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    GENERAL INFORMATION 51 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 NOTE żConverting the rear seat must be made in combi- nation with cargo bed conversion. See the
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 54
    52 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
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    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
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    54 GENERAL INFORMATION 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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 57
    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. Trailer Hitch Bracket
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    56 GENERAL INFORMATION Installing procedure for a winch 1. Remove the front bumper cover screws, and front bumper cover. 2. Remove the front bumper and side plate to gain access by releasing bolts and screws. j A. Front Bumper Cover B. Screws A. Front Bumper B. Bolts C. Winch Bracket
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    GENERAL INFORMATION 57 3. You can see the bracket attached to a cross -member. j A. Side Plate B. Screws A. Winch Bracket 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
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    . 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
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    HOW TO OPERATE 59 Transmission Case Oil ...Oil level between H and L lines, no leaks. Coolant ...Coolant level between level lines (when engine is cold), no leaks. Throttle ...Throttle pedal free play 5 a 10 mm (0.2 a 0.4 in.). Throttle pedal operates smoothly and returns to rest position when
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 62
    60 HOW TO OPERATE Starting the Engine NOTICE Do not operate the electric starter continuously for more than 5 seconds, or the starter may overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power.
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    ON again. Repeat this 2 or 3 times to thoroughly preheat the combustion chambers. Finally, crank the engine to start it. Starting After Fuel System Service Air bleeding of the fuel system may be required before engine starting if air was introduced into the fuel system during maintenance. (Fuel
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    62 HOW TO OPERATE Jump Starting If your vehicle 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. j DANGER Battery acid generates hydrogen gas which is flammable and explosive under
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    HOW TO OPERATE 63 j A. Battery B. Cap Cover a jumper cable from the positive (+) ter• Connect minal of the booster battery to the positive (+) terminal of the vehicle battery. A. Vehicle Battery Positive (+) Terminal B. From Booster Battery Positive (+) Terminal C. Unpainted Metal Surface D.
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    64 HOW TO OPERATE DANGER 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 last
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    HOW TO OPERATE 65 Braking NOTE 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 main switch key to the "OFF" position. j żWhen the throttle pedal
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    66 HOW TO OPERATE Parking the Mule WARNING If the vehicle should move after it is parked, it might be damaged or cause injury. Be sure to apply the parking brake before leaving the vehicle. the main switch key to prevent unautho• Remove rized use. parking inside a garage or other structure, • When
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    HOW TO OPERATE 67 Hi-Lo Shifting Shifting to Low Range the vehicle completely. • Stop easy Hi-Lo shifting, put the gear shift lever in • For neutral. • Move the shift lever "L" (Low) position. the vehicle completely. • Stop Put the gear shift lever in neutral. • Move the shift lever "H" (High)
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    68 HOW TO OPERATE Reversing Gears the throttle pedal, and stop the vehicle. • Release When you want to operate the vehicle in reverse, • stop the vehicle completely, allowing the engine to slow to idling speed, and move the gear shift lever to the "R" (Reverse) position. 2WD-4WD Shifting the
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    HOW TO OPERATE 69 Shifting the Differential NOTE j żDo not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph). Shifting to Locked-Axle Mode the stopper under the differential shift lever • Pull knob and while holding it against the knob, move the shift
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    70 HOW TO OPERATE Shifting to Differential (Unlocked-Axle) Mode and hold the stopper, then move the shift lever • Pull all the way up (UN-LOCK). 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
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    HOW TO OPERATE 71 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. Swing open the cargo bed side plates and fasten the latches on the both sides.
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    72 HOW TO OPERATE j A. Cargo Bed Side Plates B. Latch A. Stopper Pin B. Screen 6. Slide the stopper pins towards inside at the bottom of the removable screen. 7. Pull and remove the screen from the sockets, move forward and insert into the sockets at the end of the side plates.
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    HOW TO OPERATE 73 j A. Screen B. Sockets A. Projections B. Cargo Bed Side Plate (folded) 8. Latch the stopper pins at the bottom of the screen. From 2-person to 4-person Mode the procedure for 4-person to 2-person • Reverse mode conversion. NOTE żWhen folding the cargo bed end side plates,
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    74 HOW TO OPERATE Raising & Lowering the Cargo Bed j 2. 3. Push the rear seat back forward. Release the latches on both sides. 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
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    HOW TO OPERATE 75 j A. Rear Seat (Stored position) B. Front Seat Back A. Handgrip B. Hold here. 5. Holding the hand grip and cargo bed top, raise the cargo bed. 6. Support the bed in the tilted position with the supporting rod.
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    Condition): 1. Release the side latches. 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. NOTE żTo lower the cargo bed, follow the reverse procedure for raising. Be sure to attach the latches to the
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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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    78 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 79 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
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    80 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 "4 WD" with the differential locked for
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    SAFE OPERATION 81 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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    82 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 83 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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    84 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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    Safety Checks listed in the HOW TO OPERATE chapter. = Clean, adjust, lubricate, replace parts as necessary. D = Service to be performed by an authorized Kawasaki Dealer. * = Service more frequently when operated in mud, dust, or other harsh riding conditions. ż = Emission Related FREQUENCY First
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    50 hrs. or 600 miles of use 1 year Every 100 hrs. or 1,200 miles of use Regular Service Every 250 hrs. or 3,000 miles of use Every Every 800 500 hrs. hrs. or or 6,000 10,000 miles of miles of use use
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    50 hrs. or 600 miles of use Every 100 hrs. or 1,200 miles of use Regular Service Every 250 hrs. or 3,000 miles of use Every Every 800 500 hrs. hrs. or or 6,000 10,000 miles of miles of use use
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    50 hrs. or 600 miles of use 1 year Every 100 hrs. or 1,200 miles of use Regular Service Every 250 hrs. or 3,000 miles of use Every Every 800 500 hrs. hrs. or or 6,000 10,000 miles of miles of use use
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    use and change the oil and filter according to the periodic maintenance chart in the owner's manual. Oil Level Inspection the oil level is inspected, start the en• Whenever gine and run , first raise the cargo bed, support with the rod and pull the stored rear seat and place it onto the engine.
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    90 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) holes on the dipstick. A. Dipstick B. F (Full) Hole C. L (Low) Hole the oil level is too high, remove the excess oil, • If
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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. • Remove the oil filler cap. j A. Drain Plug • Let the oil drain completely. WARNING Engine oil
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    92 MAINTENANCE AND ADJUSTMENT j A. Oil Filter Cartridge B. Engine Oil Case C. Transmission Case A. Gasket a thin film of oil to the gasket and screw the • Apply cartridge in until the gasket touches the engine, the engine up to the F (full) hole on the dipstick • Fill with good quality engine
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    MAINTENANCE AND ADJUSTMENT 93 NOTICE If the oil level in the cylinder head cover gets too high because of filling too fast or filling too much (overfilling), oil may overflow from the filler hole and/or may flow through the crankcase ventilation tube into the intake manifold. Oil in the intake
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    Inspection *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. the front final gear case guard by remov• Remove ing the
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    MAINTENANCE AND ADJUSTMENT 95 the vehicle level front-to-rear and side-to • With -side, remove the filler cap from the front final gear case. j A. Guard B. Nuts A. Front Final Gear Case B. Filler Cap NOTICE Be careful not to allow any dirt or foreign materials to enter the gear case. the oil
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    96 MAINTENANCE AND ADJUSTMENT Oil Change NOTE żBefore draining the oil, warm it up by running the vehicle. Warm oil drains easily and picks up any sediment. the front final gear case guard. • Remove With the vehicle • gear case. level, place an oil pan beneath the • Remove the filler cap and drain
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    loss of control, accident, and injury. Check the oil level and change the oil according to the owner's manual. j Oil Level Inspection the vehicle on level ground. • Park Lift the cargo bed and support it with the rod. • Unscrew the oil filler plug, wipe its dipstick dry, and • insert it into the
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    98 MAINTENANCE AND ADJUSTMENT j A. Transmission Case B. Oil Filler Plug NOTICE Be careful not to allow any dirt or foreign materials to enter the transmission case. out the dipstick and check the oil level. The • Pull oil level should be between the "H" (High) and "L" (Low) lines on the dipstick.
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    during 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. żBefore draining the oil, warm it up by running the vehicle. Warm oil drains easily
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    100 MAINTENANCE AND ADJUSTMENT Transmission Case Oil Type API "GL-5" Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Transmission Case Oil Capacity 2.5 L (2.6 US qt) Cooling System WARNING The cooling system can get extremely hot during normal operation and cause serious burns. Do
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    MAINTENANCE AND ADJUSTMENT 101 the front cargo hood up. Refer to the "Front • Lift Cargo Compartment" section in the "General Information" chapter. NOTICE Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair the radiator's effectiveness. Do not obstruct
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    102 MAINTENANCE AND ADJUSTMENT the coolant level through the coolant level • Check gauge on the reserve tank. The coolant level should be between the "F" (Full) and "L" (Low) marks. the filler opening to the "F" (Full) mark. Install the cap. Recommended Coolant Solution Coolant Mixture Ratio: Water
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    MAINTENANCE AND ADJUSTMENT 103 Maintenance Chart. It may break if operated without maintenance. Inspection should be done by an authorized Kawasaki dealer. Valve Clearance Valve and valve seat wear decrease valve clearance, upsetting valve timing. NOTICE If valve clearance is left unadjusted, wear
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    's air intake, increasing fuel consumption, reducing engine power. red band shows in the gauge window, the air cleaner element should be cleaned. After servicing the air cleaner element, the restriction gauge should be reset by pushing the button at the end of the gauge. WARNING A clogged air
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    MAINTENANCE AND ADJUSTMENT 105 NOTICE If dirt gets into the engine, excessive engine and possible engine damage may occur. j A. Air Cleaner Housing B. Cap C. Snaps the air cleaner element out of the housing. • Pull Push a clean, lint-free towel into the air cleaner • housing to keep dirt or
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    106 MAINTENANCE AND ADJUSTMENT Element Cleaning the element (see Element Removal). • Remove Clean the paper element by tapping it lightly to • loosen dust. 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 •
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    MAINTENANCE AND ADJUSTMENT 107 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
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    108 MAINTENANCE AND ADJUSTMENT the engine. • Stop Install the drain plug. • Throttle Pedal If the throttle pedal has excessive play due to either cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle may not open fully. If the
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    AND ADJUSTMENT 109 j A. Throttle Pedal B. 5 a 10 mm (0.2 a 0.4 in.) A. Throttle Cable Adjuster B. Mounting Nuts Throttle Pedal Play Adjustment the cargo bed and support it with the rod. • Lift the adjuster mounting nuts at the end of • Loosen the throttle cable. the adjuster until the proper
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    can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. the cargo bed and support it with the rod. • Lift a suitable tachometer to measure the idle • Use RPM. If it does not match the specification, pro- • ceed as follows. Remove
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    MAINTENANCE AND ADJUSTMENT 111 j A. Cover Bolts B. Pump Cover the locknut and the accelerator lever stop• Loosen per screw on the injection pump. A. Accelerator Lever Stopper Screw B. Locknut C. Accelerator Lever the idle speed by turning the accelerator • Adjust lever stopper screw. Idle Speed
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    filter • Turn clockwise 1 turn to loosen it. Allow any water and sediment to drain out of the tube. the engine. • Stop Lift the bed and support it with the rod. • Place acargo suitable container under the fuel filter. • Open the air vent plug counterclockwise several • turns.
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    MAINTENANCE AND ADJUSTMENT 113 a suitable container under the fuel filter to • Place catch spilled fuel. the drain cap at the bottom end of the fuel • Remove filter. Discard the O-ring. the fuel filter element with a filter wrench. • Remove Replace old filter element with a new one. • Tighten it the
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    114 MAINTENANCE AND ADJUSTMENT Fuel Tank Vent The fuel tank vent hoses must be routed as specified. The engine may stall or lose power if the fuel tank vent is plugged or if the vent hoses are pinched. Inspect the vent hoses before riding and whenever the engine seems to lose power. If the fuel
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    MAINTENANCE AND ADJUSTMENT 115 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
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    116 MAINTENANCE AND ADJUSTMENT NOTICE If dirt gets into the belt drive torque converter, excessive wear and loss of driving power may result. the element material for damage. If any • Inspect part of the element is damaged, the element must be replaced. NOTE żElement installation order of
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 119
    MAINTENANCE AND ADJUSTMENT 117 Brakes The vehicle is equipped with hydraulically activated drum brakes on all four wheels. Brake Pedal "catchy," have the brake system inspected immediately by an authorized Kawasaki dealer. Brake Shoe Linings Brake Shoe Lining Wear Inspection In accordance with
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    118 MAINTENANCE AND ADJUSTMENT NOTICE Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immediately. Fluid Level Inspection • the vehicle on level ground, check that, • With through the inspection hole in the dashboard, the fluid level in the reservoir is between the upper (
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 121
    MAINTENANCE AND ADJUSTMENT 119 the brake forcefully for a few seconds and • Apply check for fluid leakage around the fittings. 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.
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    120 MAINTENANCE AND ADJUSTMENT Adjustment is best-performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is hard to access for adjustment. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. In accordance with the Periodic
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 123
    MAINTENANCE AND ADJUSTMENT 121 j A. 8 a 12 clicks • If it rolls, adjust the parking brake lever. Adjustment the locknut (upper nut) on the middle of • Loosen the parking brake lever, and turn the nut next to the locknut until the brake lever will only move 8 a 12 clicks upward. A. Locknut B. Nut
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    122 MAINTENANCE AND ADJUSTMENT Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for the specified free play and smooth operation. Steering Position Adjustment The steering wheel position can be adjusted to suit the operator. Loosen the upper and lower nuts
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    happen when the engine starts; inspect the battery voltage. Cable harness or connectors may have been disconnected. See an authorized dealer for service. Cargo Bed Latches Depending on the cargo loading and/or passenger riding conditions, latch lever compression needs to be adjusted. Release the
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    change 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. Maximum Tire Air Pressure for Seating
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    MAINTENANCE AND ADJUSTMENT 125 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
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    126 MAINTENANCE AND ADJUSTMENT 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
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    MAINTENANCE AND ADJUSTMENT 127 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 B. Turn here with a hook wrench
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    128 MAINTENANCE AND ADJUSTMENT Spring Action PosiSpring tion Force 1 2 3 4 5 | | | Ļ Stronger Surface Good Ĺ | Ļ Bad Setting Load Soft Ĺ | Ļ Hard Light Ĺ | Ļ Heavy Speed Low Ĺ | Ļ High Seat Belts In accordance with the Periodic Maintenance Chart, check that each seat belt functions properly. Push
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    MAINTENANCE AND ADJUSTMENT 129 Headlight Beam • The headlight beams can be adjusted vertically. Remove the holder. j A. Adjusting Screws A. Holder the adjusting screw on each headlight rim in • Turn or out to adjust the headlight vertically.
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    130 MAINTENANCE AND ADJUSTMENT Battery The battery is located under the left end of the front seat. Battery Removal eight (8) screws and remove the rear • Release cover for access DANGER Battery contains sulfuric acid and produce hydrogen gas. Sulfuric acid can cause burns and hydrogen gas can
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    to a sealed type battery. The sealing strip should never be removed after the specified electrolyte has been installed in the battery for initial services. However, in order to maximize battery life and ensure that it will provide the power needed to start your vehicle you must properly maintain
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    132 MAINTENANCE AND ADJUSTMENT charge. When used regularly, the charging system in your vehicle helps keep the battery fully charged. If your vehicle is only used occasionally or for short periods of time, the battery is more likely to discharge. Due to their internal composition, batteries
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 135
    in this vehicle, or the electrical system cannot work properly. j NOTE żIf you charge the sealed battery, never fail to observe the instructions shown on the label on the battery and charger. WARNING Lead is a toxic substance. Battery posts, terminals and related accessories contain lead and
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    134 MAINTENANCE AND ADJUSTMENT Fuse There are three fuse boxes under the front seat. If the electrical systems do not function, inspect the fuses. Before replacing a fuse, check the wiring harness and electrical equipment for bare wires or other possible causes. j NOTICE Do not use a fuse of a
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 137
    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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 138
    136 MAINTENANCE AND ADJUSTMENT Breaker The breaker for the radiator fan is located under the front 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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 139
    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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 140
    138 MAINTENANCE AND ADJUSTMENT 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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 141
    żAs an alternative to draining the fuel system, a fuel stabilizer designed specifically for diesel fuel may be used. follow the manufacturer's instructions for use. j WARNING Fuel stabilizers may contain poisonous substances. Heed the manufacturer's warnings for use. each cylinder with 3 cc engine
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 142
    140 STORAGE • Reattach the fuel solenoid switch connector. j A. Glow Plugs NOTE A. Fuel Solenoid Switch Connector żDo not use more than 3 cc of engine oil in each cylinder. Too much oil could cause hydraulic lock and engine damage. • Install the glow plugs. Tightening Torque Glow Plug: 17 N·m
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    STORAGE 141 NOTICE Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged a battery becomes, the more easily it freezes. a plastic bag over the exhaust pipe and air • Tie cleaner intake (rear cab frame top) to
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 144
    142 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Starter Motor Won't Turn Fuse failed (be sure to check filter clogged Air filter clogged or intake blocked Engine oil incorrect Water in fuel Drive train trouble j Engine Cranks, But Won't Start No fuel in tank Fuel filter clogged Water in fuel
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    Am I Responsible For? You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner's manual. You are responsible for notifying your dealer immediately if there is a problem, and you, as the owner, will need to authorize the dealer to inspect the unit.
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 146
    , be sure to record your service in the Maintenance Record section of this Owner's Manual. Keep all receipts for the service and/or items necessary to perform vehicle if there is a failure, investigating the cause of the problem, and getting any needed authorization from Kawasaki if the repair is
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 147
    YOUR WARRANTY/OWNER SATISFACTION 145 How Do I Get Warranty Service? If there is a problem with your vehicle within the limited warranty period, you will need to schedule a service appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and diagnosis. You can
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 148
    ? This owner's manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you. Please send your correspondence to:. Consumer Services Kawasaki Motors Corp
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 149
    ENVIRONMENTAL PROTECTION 147 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
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 150
    148 MAINTENANCE RECORD MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Key Code ...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Traveled Distance
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    MAINTENANCE RECORD 149 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 152
    150 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
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    MAINTENANCE RECORD 151 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 154
    152 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 155
    MAINTENANCE RECORD 153 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki MULE 4010 Trans4x4 Diesel | Owners Manual - Page 156
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