2011 Kawasaki MULE 610 4X4 Owners Manual

2011 Kawasaki MULE 610 4X4 Manual

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  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 1
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 2
  • 2011 Kawasaki MULE 610 4X4 | 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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    Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. DANGER DANGER
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    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) and evaporative emission (3) control systems in compliance with applicable regulations of the United States Environmental Protections Agency and
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 6
    in the appropriate Kawasaki Service Manual. Maintenance and Warranty Proper maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should verification of this maintenance. If there is a problem with the emission control system within the warranty
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 7
    Tampering with Emission Control System Prohibited Federal law prohibits 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 incorporated into any new
  • 2011 Kawasaki MULE 610 4X4 | 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 9
    TABLE OF CONTENTS BASIC SAFE DRIVING ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Choke Knob...Engine Oil Temperature Warning Light (
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 10
    Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ...Battery ...Fuse ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...YOUR WARRANTY/OWNER SATISFACTION 87 87 89 89 92 93 95 97 100 101 101 103 104 106 106 108 110
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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 610 4X4 | Owners Manual - Page 12
    10 BASIC SAFE DRIVING Wearing Seat Belt Both the operator and passenger should wear the seat belts whenever the vehicle is operated. This will help prevent 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 the vehicle
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 13
    SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) 1 051 mm (41.38 in.) 999 mm (39
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 14
    12 SPECIFICATIONS ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Grade Kawasaki Performance 4-Stroke ATV/UTV Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 15
    SPECIFICATIONS 13 Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio: Forward Reverse Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Castor Trail Steel
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 16
    14 SPECIFICATIONS Tire Size: Front Rear Rim Size: Front Rear Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load (A): KAF400A (B): KAF400B 420 kg (924 lb) 181 kg (400 lb) 12 V 14 Ah 12 V
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 17
    SPECIFICATIONS 15 *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.
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 18
    16 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 19
    LOCATION OF PARTS 17 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 Grille (Front Bumper) Air Cleaner Intake Parking Brake Air Cleaner (Carburetor) 13. 14. 15. 16. 17. Battery
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 20
    18 LOCATION OF PARTS 18. Handgrip 19. Air Cleaner (Belt Drive Torque Converter) 20. Belt Drive Torque Converter 21. 22. 23. 24. Latch Dashboard Tail/Brake Light Muffler 25. Fuel Tank 26. Fuel Tank Cap 27. Fuel Gague
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 21
    LOCATION OF PARTS 19 28. 29. 30. 31. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Parking Brake Warning Light 33. 34. 35. 36. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A) 37. Ignition Switch 38. Accessory Connector 39.
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    20 LOCATION OF LABELS LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Warning (Off-Highway Utility Vehicle) Notice (Shifting) Warning (General) Warning (Front Cargo Hood) Warning (Passengers in Cargo Bed) Warning (Cargo Bed) Important Information (Tires/Max. Load) Carrier
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    LOCATION OF LABELS 21
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 24
    22 LOCATION OF LABELS
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    LOCATION OF LABELS 23 (1) (4) (2) (5)
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    24 LOCATION OF LABELS (3)
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    LOCATION OF LABELS 25 (6) (8) (7) (KAF400A) (7) (KAF400B)
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    26 LOCATION OF LABELS (9) (KAF400A, Other than California model) (10) (9) (KAF400B, Other than California model) (9) (KAF400A, California model only) (11) (9) (KAF400B, California model only)
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    LOCATION OF LABELS 27 (12) (Other than California model) (13) (12) (California model only) (14)
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    28 LOCATION OF LABELS (15)
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    the vehicle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has front body work and fenders are not designed to carry cargo or to support your weight. They may break. Because any vehicle is sensitive to
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 32
    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 420 kg (926 lb). vehicle is not designed to carry
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 33
    GENERAL INFORMATION 31 GENERAL INFORMATION Lighting/Electrical Accessory Connector The lighting/electrical accessory 12 volt connector is located on the dashboard. An auxiliary light or an accessory may be connected to this connector. j Brake Pedal The brake pedal is the left pedal on the foot
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 34
    loops. A. Wire Loop The cargo bed can be tilted by releasing the latch on the right side, and then lifting the bed with the handgrips. Support the bed in the tilted position with the supporting hook provided on the bottom of the cargo bed. A. Tail Gate B. Latch
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 35
    Hook B. Cargo Bed Bottom (Tilted Condition) NOTE WARNING The cargo bed requires a supporting hook to remain in the raised position and will fall down if not supported, creating the potential for injury. Always latch the supporting hook when lifting the bed for engine or other maintenance below the
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 36
    34 GENERAL INFORMATION Maximum Load: 181 kg (400 lb) j Choke Knob 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 37
    GENERAL INFORMATION 35 Engine Oil Temperature Warning Light (KAF400A) The oil temperature warning light comes on whenever the engine oil temperature rises too high while the vehicle is in operation. If it stays on, stop the engine and check the engine oil level after the engine cools down. Refer to
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 38
    on unleaded regular grade gasoline only. Use clean, fresh unleaded 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 of its resistance to detonation or "knocking." The Antiknock Index is an
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 39
    unleaded gasoline and methanol (wood alcohol) whenever possible, and never use "gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTBE). You may use gasoline containing up
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 40
    the fuel system. Before storage it is recommended that you drain all fuel from the fuel tank and carburetors. See the "STORAGE" chapter in this manual. 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 41
    GENERAL INFORMATION 39 j Glove Compartment A glove compartment is provided at the right end of the dashboard. Store only light items to avoid damage to the inside of the compartment. Release the plug in the bottom of the glove compartment to remove any water that may have entered. Do not put items
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 42
    40 GENERAL INFORMATION j A. Latch Release Button B. Hood A. Latch Lever B. Hood Hood Closing While lifting the latch lever at the front of the cargo hood, push and close the cargo hood. the hood is closed, push the two parts of the • After hood to ensure the hood is latched.
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    GENERAL INFORMATION 41 j 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. Push here. WARNING An open front cargo hood can distract or impair visibility of the operator, causing loss of vehicle control
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 44
    42 GENERAL INFORMATION OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. Hour meter works. 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"
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 45
    GENERAL INFORMATION 43 you purchased your Kawasaki UV. It's possible the 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 46
    44 GENERAL INFORMATION j Light Switch Turn on the headlights and taillights by pushing the light switch in, with the ignition switch key in the "ON" position. The lights go off when the switch is pushed again. Shift Levers This vehicle is equipped with three different shift levers: the gear shift
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 47
    GENERAL INFORMATION 45 The KAF400A is equipped with a sub-transmission to allow maximum transmission efficiency. Use the low gearing for maximum torque at low speeds, for climbing hills, pulling a trailer, or keeping constant low speeds. The high gearing raises the speed range for ordinary off-
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 48
    46 GENERAL INFORMATION 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 49
    GENERAL INFORMATION 47 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
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    48 GENERAL INFORMATION j Parking Brake Warning Light The parking brake warning light goes on when the parking brake is applied with the ignition switch in the "ON" position. Seat The seat can be raised for vehicle maintenance and adjustment. Pull up on the rear edge of the seat. • NOTE żThis
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 51
    GENERAL INFORMATION 49 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. To wear the seat belt properly, follow this procedure: 1. Place the belt across your lap as low on your hips
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    50 GENERAL INFORMATION To unfasten the belt, press the red button in the buckle. j WARNING Too much belt slack could reduce its protection effectiveness in an accident. Always adjust the belt to a SNUG FIT. A. Red Button
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    GENERAL INFORMATION 51 j Throttle Pedal The throttle pedal is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. In
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 54
    operation of a winch could cause an accident resulting in serious injury or death. Do not operate or install winch without reading and understanding the operators manual supplied with the winch.
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    GENERAL INFORMATION 53 j A. Winch-installing position
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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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 57
    HOW TO OPERATE 55 Transmission Case Oil ...Oil level between H and L lines, no leaks. Throttle ...Throttle pedal free play 2 a 5 mm (0.1 a 0.2 in.). Throttle pedal operates smoothly and returns to rest position when released. Steering ...Steering wheel free play 0 a 20 mm (0 a 0.8 in.). Action
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    56 HOW TO OPERATE Starting the Engine Throttle-linked choke system This vehicle is equipped with the choke that controls the throttle operation without pressing the throttle pedal when starting the engine. Using this choke system, start the engine with the following procedure. j DANGER Exhaust
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    HOW TO OPERATE 57 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 battery power to recover. Jump Starting If your
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 60
    58 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 carburetor or battery. Take care not to touch the positive and negative cables together, and do not lean over the battery when
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 61
    HOW TO OPERATE 59 Moving Off the brake pedal. • Depress Put the gear shift lever into the "H" (High) and "L" • (Low) position for KAF400A or "F" (Forward) posi- Braking NOTE j żWhen the throttle pedal is released completely and • • tion for KAF400B. Release the parking brake. Gradually
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 62
    60 HOW TO OPERATE 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 j • Stop the
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 63
    HOW TO OPERATE 61 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 (
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    62 HOW TO OPERATE żWhen shifting the lever from "L" to "N", if it is hard j to move the shift lever passing "H" position and does not move to "N" position, return the shift lever to "L" once and repeat to move the lever to "N" position slowly. Reversing Gears the throttle pedal, and stop the
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 65
    HOW TO OPERATE 63 2WD-4WD Shifting (KAF400A) 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 "
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    64 HOW TO OPERATE Shifting the Differential NOTE Shifting to Differential (Unlocked-Axle) Model j and hold the stopper, then move the shift lever • Pull all the way up (UN-LOCK). NOTE żDo not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph). Shifting to
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 67
    HOW TO OPERATE 65 Catalytic Converter (California model only) This vehicle is equipped with a catalytic converter in the exhaust system. Platinum and rhodium in the converter react with carbon monoxide, hydrocarbons and nitrogen oxides to convert them into carbon dioxide, water, nitrogen and oxygen
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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.
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 69
    SAFE OPERATION 67 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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    68 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 71
    SAFE OPERATION 69 Climbing Hills Do not attempt to climb hills or steep inclines until you have mastered the controls and basic operating maneuvers of this vehicle. Always go straight uphill and, if the incline is steep and/or the surface is loose, use "4WD" with the differential locked for greater
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    70 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 73
    SAFE OPERATION 71 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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    72 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
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    listed in the HOW TO OPERATE chapter. D * • ż = Clean, adjust, lubricate, replace parts as necessary. = Service to be performed by an authorized Kawasaki Dealer or someone equally competent. = Service more frequently when operated in mud, dust, or other harsh riding conditions. = Emission Related
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    74 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 500 hrs. or 10 000 km of use OPERATION After 50 hrs. Every 250 or 1 000 km hrs. or 5 000 km of use of
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    MAINTENANCE AND ADJUSTMENT 75 FREQUENCY First Service Regular Service Every 500 hrs. or 10 000 km of use OPERATION After 50 hrs. Every 250 or 1 000 km hrs. or 5 000 km of use of
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    76 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 500 hrs. or 10 000 km of use OPERATION After 50 hrs. Every 250 or 1 000 km hrs. or 5 000 km of use of
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    supporting hook to remain in the raised position and will fall down if not supported, creating the potential for injury. Always latch the supporting oil and filter according to the periodic maintenance chart in the owner's manual. A. Dipstick & Oil Filler Hole B. Seatback Oil Level Inspection the
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    78 MAINTENANCE AND ADJUSTMENT NOTE żIt is important to insert the dipstick with its chamfered cap edge facing rearwards. j A. Dipstick B. "H" (High) Line C. "L" (Low) Line A. Dipstick B. Oil Filler Hole out the dipstick and check the oil level. The • Pull oil level should be between the "F" (
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    MAINTENANCE AND ADJUSTMENT 79 the oil filter is to be changed, first lift the cargo • If bed to support it with the hook, and then remove the oil filter cartridge and replace it with a new one. j A. Drain Plug B. Torque Converter Case the vehicle held
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    80 MAINTENANCE AND ADJUSTMENT Recommended Engine Oil Grade: Kawasaki Performance 4-Stroke ATV/UTV Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with API SG, SH, SJ, SL, SM and JASO MA, MA1, MA2 rating Viscosity: SAE
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 83
    j *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. Oil Level Inspection gear case. the vehicle level front-to-rear and
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    82 MAINTENANCE AND ADJUSTMENT j A. Front Final Gear Case B. Filler Cap (on the left side) C. Front Axle A. Front Final Gear Case B. Filler Opening C. Bottom Thread NOTICE Be careful not to allow any dirt or foreign materials to enter the gear case. the oil level. The oil level should come to •
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    MAINTENANCE AND ADJUSTMENT 83 WARNING 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 has completely
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    • Pull oil level should be between the "H" (High) and "L" (Low) lines on the dipstick. the vehicle on level ground. • Park Lift the cargo bed and support it with the hook. • Unscrew the oil filler plug, and dipstick, wipe its • dipstick dry, and insert it into the filler hole but DO NOT
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    MAINTENANCE AND ADJUSTMENT 85 Oil Change NOTE żBefore draining the oil, warm it up by running the vehicle. Warm oil drains easily and picks up any sediment. the vehicle level, apply the parking brake se• With curely. an oil pan beneath the transmission case. • Place Remove the drain plug. • j
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    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 hook. • Lift • Remove the filler plug. Transmission Case Oil Type API "GL-5" Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41
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    MAINTENANCE AND ADJUSTMENT 87 Cooling Fan The engine is cooled by the cooling fan attached to the left side of the engine. Check and clean the screen for mud and other debris. Spark Plug The standard spark plug is shown in the table. The spark plug should be taken out periodically in accordance
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    88 MAINTENANCE AND ADJUSTMENT j Spark Plug Standard Plug Plug Gap NGK BPR5ES 0.7 a 0.8 mm (0.028 a 0.032 in.) A. Spark Plug Cap B. Engine Oil Dipstick Cap • Unscrew the spark plug. NOTE Tightening Torque 17 N·m (1.7 kgf·m, 12.0 ft·lb) żWhen installing the spark plug, fit the plug cap se-
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    MAINTENANCE AND ADJUSTMENT 89 Valve Clearance Valve and valve seat wear decrease valve clearance, upsetting valve timing. Engine Air Cleaner A clogged engine air cleaner restricts the engine's air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. NOTICE
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    90 MAINTENANCE AND ADJUSTMENT NOTICE If dirt gets into the engine, excessive engine wear and possible engine damage may occur. j A. Air Cleaner Housing Cover B. Snaps the screw and pull the air cleaner element • Remove out of the housing. a clean, lint-free towel into the air cleaner • Push
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    MAINTENANCE AND ADJUSTMENT 91 the foam element in a bath of high flash • Clean -point solvent using a soft bristle brush. it dry in a clean towel. Do not wring the • Squeeze element or blow it dry; the element can be dam- • aged. Inspect the foam element for damage. If it is torn, punctured, or
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT 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. j NOTICE The
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    MAINTENANCE AND ADJUSTMENT 93 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 96
    94 MAINTENANCE AND ADJUSTMENT j A. Throttle Pedal B. 2 a 5 mm (0.1 a 0.2 in.) A. Throttle Cable B. Mounting Nuts Throttle Pedal Play Adjustment the cargo bed and support it with the hook. • Lift and turn the throttle cable mounting nuts • Loosen located above the transmission case until the
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 97
    the engine is cold. If starting is difficult or rich fuel mixture trouble occurs, inspect the choke knob, and adjust it if necessary. the choke cable checked by an authorized Kawasaki dealer. Lift the cargo bed and support it with the hook. Raise the seat. Remove the guard plate by releasing
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 98
    96 MAINTENANCE AND ADJUSTMENT j A. Guard Plate B. Air Intake Ducts (2 p.c.s.) C. Clamps D. Quick Rivets (6 p.c.s.) E. Cap A. B. C. D. Starter Lever Mounting Nuts Choke Cable Throttle Link • • Make sure the choke knob is all the way into its released position. To determine the amount of choke
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 99
    MAINTENANCE AND ADJUSTMENT 97 Carburetor The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. The following procedure covers the idle speed adjustment. Idle Speed Adjustment the parking brake. • Apply Raise the seat
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 100
    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 to support it with the hook. • Lift Remove • screw. the cover plate on the idle adjusting the axel lever stopper screw on the base • Loosen plate above
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 101
    MAINTENANCE AND ADJUSTMENT 99 and release the throttle pedal a few times • Depress to make sure that the idle speed does not change. Readjust if necessary. High Altitude Use The original carburetor settings for this vehicle are best for sea level use. When the vehicle is used at high altitude, the
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 102
    explosive under certain conditions and cause severe burns. Before performing any service, turn the ignition switch "OFF". Do not smoke. Make D. Quick Rivets (6 p.c.s.) E. Cap Dust and/or Water Inspection the cargo bed to support it with the hook. • Lift Raise the seat. • Remove the guard plate by
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 103
    MAINTENANCE AND ADJUSTMENT 101 j A. Drain Screw B. Carburetor A. Fuel Filter B. Fuel Tank • Tighten the drain screw. NOTE żIf any water or dirt appears during the above oper- ation, have the fuel system checked by an authorized Kawasaki dealer. Fuel Filter The vehicle is equipped the fuel
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 104
    102 MAINTENANCE AND ADJUSTMENT j
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 105
    MAINTENANCE AND ADJUSTMENT 103 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 106
    should be replaced if they are damaged. j Element Removal A. Guard Plate B. Air Intake Ducts (2 p.c.s.) C. Clamps D. Quick Rivets (6 p.c.s.) E. Cap the cargo bed and support it with the hook. • Lift Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and the 6 quick
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 107
    MAINTENANCE AND ADJUSTMENT 105 NOTICE If dirt gets into the belt drive torque converter, excessive wear and loss of driving power may result. NOTE żElement installation order of removal. is performed in the reverse j Element Cleaning A. Air Cleaner Housing Cover B. Snaps the element (see
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 108
    106 MAINTENANCE AND ADJUSTMENT 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 109
    MAINTENANCE AND ADJUSTMENT 107 NOTICE Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immediately. brake fluid reservoir is inside the access hole, • The and using a funnel fill the reservoir to the upper level line. Fluid Level Inspection the vehicle on level ground, check
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 110
    108 MAINTENANCE AND ADJUSTMENT WARNING Air in brake line can make the brake feel mushy or soft. This may cause reduced braking performance or brake failure and result in an accident. If brake lever travel is excessive or the brake feels mushy, have an authorized Kawasaki dealer inspect it
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 111
    MAINTENANCE AND ADJUSTMENT 109 j A. Brake Light Switch B. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. A. B. C. D. Brake Light Switch Adjusting Nut Lights sooner. Lights later. NOTICE To avoid damaging the electrical
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 112
    110 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. the locknut (upper nut) on the middle of • Loosen the parking brake lever
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 113
    MAINTENANCE AND ADJUSTMENT 111 Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for the specified free play and smooth operation. Wheels Rims The rims are a drop-center, tubeless tire design. Take care not to damage the sealing surfaces of the tire or rim
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 114
    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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 115
    MAINTENANCE AND ADJUSTMENT 113 Tire Wear, Damage As tire tread wears down, tires become more susceptible to puncture and failure. In accordance with the Periodic Maintenance Chart, measure the depth of the tread with a depth gauge, and replace any tire that has worn down to the minimum allowable
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 116
    114 MAINTENANCE AND ADJUSTMENT Suspension Rear Shock Absorber Spring Force Adjustment The spring adjusting sleeves on the rear shock absorbers have 5 positions so that the springs can be adjusted for different riding and loading conditions. j A. Adjusting Sleeve If the spring action feels too
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 117
    MAINTENANCE AND ADJUSTMENT 115 Spring Action Position 1 2 3 4 5 Spring Force | | | Ļ Stronger Setting Load Soft Ĺ | Ļ Hard Light Ĺ | Ļ Heavy Surface Good Ĺ | Ļ Bad Seat Belts Speed Low Ĺ | Ļ High In accordance with the Periodic Maintenance Chart, check that each seat belt functions properly. Push
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 118
    116 MAINTENANCE AND ADJUSTMENT Headlight Beam Battery The battery is located under the left end of the seat. • The headlight beams can be adjusted vertically. Turn the adjusting screw on each headlight rim to adjust the headlight vertically. DANGER Battery contains sulfuric acid and produce
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 119
    MAINTENANCE AND ADJUSTMENT 117 the battery in place, and route the battery vent • Put hose through the hole in the floor board. the capped lead to the (+) terminal, and • Connect then connect the black lead to the (-) terminal. a light coat of grease on the terminals to pre• Put vent corrosion. the
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 120
    118 MAINTENANCE AND ADJUSTMENT charged. If your Mule is only used occasionally or for short periods of time, the battery is more likely to discharge. Due to their internal composition, batteries continually self discharge. The discharge rate depends on the type of battery and ambient temperature. As
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 121
    MAINTENANCE AND ADJUSTMENT 119 Sulfation also occurs when the battery is left in a discharged condition for an extended time. Sulfate is a normal byproduct of the chemical reactions within a battery. But when continuous discharge allows the sulfate to crystallize in the cells, the battery plates
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 122
    120 MAINTENANCE AND ADJUSTMENT quick charger that may overcharge the battery and damage it. Battery Charging the battery from the vehicle (See Battery • Remove Removal). NOTICE Always remove the battery from the vehicle for charging. If the battery is charged while still installed, battery
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 123
    contain lead and lead compounds. Wash hands after handling. NOTICE Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charging rate can be reduced to the level required for this vehicle's battery. Charging the battery at a rate higher than
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 124
    122 MAINTENANCE AND ADJUSTMENT Fuse There are two plastic fuse cases next to the parking brake under the left end of the seat, one for the main (30 A) and the other for the accessory connector (10 A). If the electrical systems do not function, inspect the fuse. Before replacing a fuse, check the
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 125
    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 610 4X4 | Owners Manual - Page 126
    124 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 610 4X4 | Owners Manual - Page 127
    . NOTE 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. j WARNING Fuel stabilizers may contain poisonous substances. Heed the manufacturer's warnings for use. the spark plug and spray fogging oil
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 128
    126 STORAGE WARNING An air/oil mist may be forcibly ejected from the spark plug hole and could get into your eyes. Do not lean over the engine when performing this procedure. If you do get oil in your eyes, wash them immediately with liberal amounts of clean, fresh water and consult a physician as
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 129
    TROUBLESHOOTING GUIDE 127 TROUBLESHOOTING GUIDE Starter Motor Won't Turn Fuse failed (be sure to check for cause of failure) Battery leads do not make good electrical contact with battery terminals
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 130
    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 610 4X4 | Owners Manual - Page 131
    , 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 610 4X4 | Owners Manual - Page 132
    130 YOUR WARRANTY/OWNER SATISFACTION 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 610 4X4 | Owners Manual - Page 133
    ? 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 610 4X4 | Owners Manual - Page 134
    132 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 135
    MAINTENANCE RECORD 133 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
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 136
    134 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 137
    MAINTENANCE RECORD 135 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 138
    136 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 139
    MAINTENANCE RECORD 137 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 140
    138 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki MULE 610 4X4 | Owners Manual - Page 141
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