2012 Kawasaki MULE 4010 Trans4x4 Owners Manual

2012 Kawasaki MULE 4010 Trans4x4 Manual

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  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 1
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    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, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in
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    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1), exhaust emission (2) and evaporative emission (3) control systems in compliance with applicable regulations of the United States Environmental Protections Agency and
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    is carried out according to the instructions in this Owner's Manual at your own expense. You of this maintenance. If there is a problem with the emission control system within the warranty Services Kawasaki Motors Corp., U.S.A. P.O. Box 25252 Santa Ana, CA 92799-5252 (866) 802-9381 consumer.services
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    • • Among those acts presumed to constitute tampering are the acts listed below: Do not tamper with the original emission related parts: Fuel injection system and internal parts Magneto or electronic battery ignition system Spark plugs Fuel filter Air cleaner element • • • PLEASE DO NOT TAMPER
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    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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    TABLE OF CONTENTS BASIC SAFE DRIVING ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Light Switch ...Coolant Temperature Warning Light...Oil Pressure Warning Light...
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    120 122 123 124 125 125 126 Fuse ...Power Steering System...Breaker...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...YOUR WARRANTY/OWNER SATISFACTION ...ENVIRONMENTAL PROTECTION ...MAINTENANCE RECORD ... 130 131 132 133 133 134 135 137 138 142 143
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    your new Kawasaki vehicle, so drive carefully, safely, and exercise good judgement. Practice basic maneuvers so you can drive confidently and safely. Read the Owner's Manual Read and understand this Owner's Manual. This is especially important for inexperienced drivers. Refer to this Owner
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    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
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    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) Front Rear 3 305 mm (130.12 in.) 1 486 mm (58.50 in.) 1 925
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    12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Grade Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5°/750 a 22°/4 000 (BTDC /rpm) NGK BPR2ES
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    SPECIFICATIONS 13 Overall Drive Ratio: Forward Reverse 8.404 (High) 17.303 (Low) 19.475 1.821 (High) 3.750 (Low) 4.220 API GL-5 or API GL-6 Hypoid gear oil for Limited Slip Differentials, SAE90 or SAE140 0.4 L (0.4 US qt) API GL-5 Hypoid gear oil, SAE 90 [above 5°C (41°F)] SAE 80 [below 5°C (41
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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. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 37. Parking Brake Warning Light 38. Right Glove Compartment 39. FI Warning Light 40. Power Steering Warning Light 41.
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    LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Warning (Pinching Fingers: both sides) Important Information (Tires/Max. Load)
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    20 LOCATION OF LABELS
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    LOCATION OF LABELS 21
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    22 LOCATION OF LABELS (1) (2) (3) (4) (KAF620R) (4) (KAF620S)
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    LOCATION OF LABELS 23 (5)
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    24 LOCATION OF LABELS (6) (8) (7) (9)
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    LOCATION OF LABELS 25 (10) (11) (13)
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    26 LOCATION OF LABELS (12)
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    LOCATION OF LABELS 27 (14) (15)
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    28 LOCATION OF LABELS (16) (17)
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    the vehicle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has front body work and fenders are not designed to carry cargo or to support your weight. They may break. Because any vehicle is sensitive to
  • 2012 Kawasaki MULE 4010 Trans4x4 | 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, passengers, and cargo must not exceed 603 kg (1 330 lb). vehicle is not designed to carry
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    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 Light Switch Turn on the headlights and taillights by
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    32 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 or when the ignition switch key is turned to ON. If it stays on, stop the engine and check the coolant
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    GENERAL INFORMATION 33 j Oil Pressure Warning Light The oil pressure warning light goes on whenever the oil pressure is dangerously low or the ignition switch key is in the ON position with the engine not running, and goes off when the engine oil pressure is high enough. NOTICE If the engine oil
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 36
    switch key is turned to "ON" and goes off soon after ensuring that its circuit functions properly. The warning light also goes on whenever the troubles occur in digital fuel injection system (DFI). If the warning light comes on, have the DFI system checked by an authorized Kawasaki dealer. Parking
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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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    36 GENERAL INFORMATION 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
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    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
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    38 GENERAL INFORMATION j 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
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    gasoline with a minimum Antiknock Index of 87. The Antiknock Index is posted on service station pumps in the U.S.A. The octane rating of a gasoline is a measure standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or
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    all fuel from the fuel tank. See the "STORAGE" chapter in this manual. NOTICE Avoid using blends of unleaded gasoline and methanol (wood alcohol) whenever " containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is
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    GENERAL INFORMATION 41 j Fuel Gauge The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank. Raise the front seat and check the fuel amount left. When the red indicator needle comes near the empty mark (red line), refuel at the earliest opportunity. Glove Compartment A glove
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    42 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 inside. A. Right Glove Compartment A. Front
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    GENERAL INFORMATION 43 j A. Latch Release Knob A. Push here B. Latches NOTE żWhen the hood is hard to open, pull and lift up the front hood center portion with pulling the knob to open the hood. Hood Closing Close the hood until it locks. After the hood is closed, push the two edges of the hood
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    44 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. Ignition Switch This is a three-position, key-operated switch. The key can be removed from the switch only when it is in the "OFF" position. A. Horn
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    GENERAL INFORMATION 45 OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is in "N" (neutral) position. Upon release, key will return to "ON" position. j Keys
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    46 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | 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 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 for these
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    GENERAL INFORMATION 49 j Parking Brake Lever The parking brake lever is located at the left side of the seat. Pull the lever up and to the rear to apply the parking brake. To release, push in and hold the knob on the end of the lever and push the lever all the way down. Spring pressure helps return
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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. Seats There are front and rear seats on this vehicle. It can be transformed from 2-passenger to 4-passenger by
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 53
    GENERAL INFORMATION 51 4-passenger mode 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 NOTE ż
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    52 GENERAL INFORMATION j WARNING Seat belts reduce injury. Always wear your seat belt. The lap-style seat belt may not provide adequate protection for small children. Special care is recommended when carrying a child passenger. To wear the seat belt properly, follow this procedure: 1. Place the
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 55
    GENERAL INFORMATION 53 j Trailer Hitch Bracket This vehicle is equipped with a bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, observe the following precautions: WARNING Improper towing of a loaded trailer could cause an
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    operation of a winch could cause an accident resulting in serious injury or death. Do not install or operate a winch without reading and understanding the operator's manual supplied with the winch. A. Front Bumper Cover B. Screws
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    four bolts. 3. You can see the bracket attached to a cross -member. j A. Front Bumper B. Bolts C. Winch Bracket A. Winch Bracket B. Bolt Holes 4. 5. Follow a manual to be supplied by the winch maker for installing the winch and other accessory as necessary. After installing the winch, be sure
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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 57 Front Final Gear Case ...Transmission Case Oil ...Coolant ...Throttle ...No oil leaks. Oil level between "H" and "L" lines on the dipstick, no leaks. Coolant level between level lines (when engine is cold), no leaks. Throttle pedal free play 5 a 10 mm (0.2 a 0.4 in.). Throttle
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    58 HOW TO OPERATE Starting the Engine NOTE żThe j DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. the seat belts (
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    HOW TO OPERATE 59 Jump Starting If your vehicle's battery is "run down," it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. the cover under the left end of the front • Remove seat. j DANGER Battery acid
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    60 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 61 Moving Off the brake pedal. • Depress Put the gear shift lever into the "H" (High) or "L" • (Low) position. the parking brake. • Release increase engine speed by pressing on • Gradually the throttle pedal. Braking NOTE j żWhen the throttle pedal is released completely and NOTE
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    62 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
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    HOW TO OPERATE 63 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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    64 HOW TO OPERATE Shifting to High Range the vehicle completely. • Stop Put the gear shift lever in neutral. • Move the shift lever to the "H" (High) position. • Reversing Gears the throttle pedal, and stop the vehicle. • Release When you want to operate the vehicle in reverse, • stop the vehicle
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    HOW TO OPERATE 65 2WD-4WD Shifting the stopper under the 2WD-4WD shift lever • Pull knob and while holding it against the knob, move j • the shift lever to the all way down to "4WD". To shift back into "2WD" position, pull and hold the stopper, then move the shift lever all the way up to "2WD".
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    66 HOW TO OPERATE Shifting the Differential NOTE Shifting to Differential (Unlocked-Axle) Mode 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). żWhen the
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    HOW TO OPERATE 67 Converting Rear Seat and Cargo Bed This vehicle can be converted to accommodate more passengers and less cargo or fewer passengers and more cargo. The seats and the cargo bed can be converted in the following way. 2. 3. Push the rear seat back forward. Release the latches on
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    68 HOW TO OPERATE j A. Rear Seat (Stored position) B. Front Seat Back A. Cargo Bed Side Plates B. Latch 5. Swing open the cargo bed side plates and fasten the latches on the both sides. 6. Slide the stopper pins towards inside at the bottom of the removable screen.
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    HOW TO OPERATE 69 j A. Stopper Pin B. Screen A. Screen B. Sockets 7. Pull and remove the screen from the sockets, move forward and insert into the sockets at the end of the side plates. 8. Latch the stopper pins at the bottom of the screen. From 2-person to 4-person Mode the procedure for
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 72
    70 HOW TO OPERATE Raising & Lowering the Cargo Bed j WARNING Reduced clearance between cargo bed and cab frame can cause hand injury. Do not hold cab frame in the location of the label when raising or lowering the cargo bed. Raising the cargo bed (Shortened Condition) : 1. Pull the rear seat
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    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. Holding the hand grip and cargo bed top, raise the cargo bed.
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    72 HOW TO OPERATE j A. Handgrip B. Hold here. A. Supporting Rod B. Cargo Bed (Raised Position ) 6. Support the bed in the tilted position with the supporting rod. NOTE żTo lower the cargo bed, follow the reverse procedure for raising. Be sure to restore the seat as before and put the latches
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    HOW TO OPERATE 73 2. 3. Holding the handgrip and cargo bed on the top edge, raise the cargo bed. Support the bed in the tilted position with the supporting rod. j NOTE żTo lower the cargo bed, follow the reverse proceWARNING A. Latch B. Rear Seat (Stored position) dure for raising. Be sure to
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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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    SAFE OPERATION 75 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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    76 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
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    SAFE OPERATION 77 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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    78 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
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    SAFE OPERATION 79 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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    80 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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    MAINTENANCE AND ADJUSTMENT 81 MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the Mule in good running condition. The initial maintenance is vitally important and
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    more frequently when operated in mud, dust, or other harsh riding conditions. = Emission Related FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    MAINTENANCE AND ADJUSTMENT 83 FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    84 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    MAINTENANCE AND ADJUSTMENT 85 FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    use and change the oil and filter according to the periodic maintenance chart in the owner's manual. Oil Level Inspection the oil has just been changed, start the engine • If and run mode, 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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    MAINTENANCE AND ADJUSTMENT 87 j A. Rear Seat (Folded) B. Dipstick out the dipstick and check the oil level. The • Pull oil level should be between the "F" (Full) and "L" (Low) lines on the dipstick. A. Dipstick B. "F" (Full) Line C. "L" (Low) Line the dipstick until it bottoms into the tube •
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    fold the rear seat and push its assembly into the stored position, and then raise the cargo bed and support it with the rod. żIn 2-person mode, raise the cargo bed and support it with the rod. • Remove the oil filler cap. j A. Drain Plug the vehicle held level, let the oil drain
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    MAINTENANCE AND ADJUSTMENT 89 j A. Oil Filter Cartridge A. Gasket a thin film of oil to the gasket and screw the • Apply cartridge in until the gasket touches the engine, then turn it 3/4 turn. the drain plug with its gasket. Tighten it to • Install the specified torque. Tightening Torque Drain
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    *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. to be changed to accommodate atmospheric conditions in your riding area
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    front and rear tires, with consequent loss of control, accident, and injury. Check the oil level and change the oil according to the owner's manual. j A. Guard B. Nuts (Front Side) Oil Level Inspection the front final gear case guard by remov• Remove ing the mounting bolts and nuts. A. Bolts
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    92 MAINTENANCE AND ADJUSTMENT the vehicle level front-to-rear and side-to • With -side, remove the filler cap from the front final gear case. j A. B. C. D. A. Front Final Gear Case B. Filler Cap Front Final Gear Case Filler Opening Bottom Thread Drain Plug NOTICE Be careful not to allow any dirt
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 95
    MAINTENANCE AND ADJUSTMENT 93 Oil Change NOTE Tightening Torque Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb) the gear case up to the bottom thread of the • Fill filler opening with a high quality oil as specified in the table. Front Final Gear Case Oil 0.4 L Oil Capacity (0.4 US qt) Oil Type API "GL
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 96
    Check the oil level and change the oil according to the owner's manual. A. Transmission Case B. Oil Filler Plug NOTICE Be careful not to dipstick. Oil Level Inspection the vehicle on level ground. • Park the cargo bed and support it with the rod. • Lift the oil filler plug, wipe the dipstick dry,
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 97
    MAINTENANCE AND ADJUSTMENT 95 Oil Change NOTE żBefore draining the oil, warm it up by running the the vehicle level, place an oil pan beneath the • With transmission case. • Remove the drain plug. vehicle. Warm oil drains easily and picks up any sediment. j A. Oil Filler Plug and Dipstick B.
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 98
    normal operation and cause serious burns. To avoid a serious burn, never touch a hot muffler or exhaust pipe during oil draining. the cargo bed and support it with the rod. • Lift • Remove the filler plug. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) Transmission Case Oil Type API "GL
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 99
    MAINTENANCE AND ADJUSTMENT 97 Cooling System WARNING The cooling system can get extremely hot during normal operation and cause serious burns. Do not touch the radiator when it is hot, nor open the radiator cap. Hot coolant inside will cause severe burns. Radiator and Cooling Fan Check and clean
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 100
    98 MAINTENANCE AND ADJUSTMENT Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer damage. Check the coolant level each day before operating the vehicle, and replenish coolant if the
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 101
    MAINTENANCE AND ADJUSTMENT 99 NOTE żIn an emergency you can add water alone to the Spark Plugs The standard spark plug is shown in the table. The spark plug should be taken out periodically in accordance with the Periodic Maintenance Chart for cleaning, inspection, and resetting of the plug gap.
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 102
    100 MAINTENANCE AND ADJUSTMENT Spark Plug Removal the cargo bed to support it with the rod. • Lift Carefully • plugs. pull the spark plug caps from the spark j Spark Plug Standard Plug Plug Gap NGK BPR2ES 0.7 a 0.8 mm (0.028 a 0.
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 103
    gauge shows whether the air cleaner is clogged. Whenever the red band shows in the gauge window, the air filter element should be cleaned. After servicing the air filter element, the restriction gauge should be reset by pushing the button at the top of the gauge.
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 104
    102 MAINTENANCE AND ADJUSTMENT j A. Air Filter Restriction Gauge Element Removal A. Air Cleaner Housing B. Cap C. Snaps up the snaps and remove the air cleaner hous• Pull ing cap from the housing. the air cleaner element out of the housing. • Pull Push a clean, lint-free towel into the air
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 105
    MAINTENANCE AND ADJUSTMENT 103 NOTICE If dirt gets into the engine, excessive engine wear and possible engine damage may occur. away the remaining dust by applying com• Blow pressed air from the inside to the outside (from the the element material for damage. If any • Inspect part of the element
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 106
    "Periodic Maintenance Chart". Spark Arrester This vehicle is equipped with a spark arrester approved for off-highway use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. Clean the spark arrester in accordance with the Periodic Maintenance Chart. j Inspection
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 107
    MAINTENANCE AND ADJUSTMENT 105 DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. the engine. • Stop Install the drain
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 108
    pedal does not return properly, check the throttle cable routing, pedal free play, and cable damage. Then lubricate the throttle cable. the cargo bed and support it with the rod. • Lift and turn the throttle cable mounting nuts • Loosen at the end of the throttle cable. the adjuster until the
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 109
    MAINTENANCE AND ADJUSTMENT 107 j A. Throttle Cable B. Mounting Nuts A. Cover B. Bolt • • Tighten the mounting nuts securely. Throttle Pedal Stop Position Adjustment The full throttle pedal stop position can be adjusted to prevent pulling the throttle cable more than required. Remove the cover
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 110
    108 MAINTENANCE AND ADJUSTMENT j A. Pully (Fully Opened Position) B. Stopper the throttle pedal stop bolt until the bolt head • Turn lightly touches the bottom of the throttle pedal. the locknut securely. • Tighten Be sure • smoothly. to check the throttle cable moves A. Throttle Pedal B.
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 111
    MAINTENANCE AND ADJUSTMENT 109 Idle Adjustment Idle adjustment is controlled by the ECU and cannot be adjusted. If the idle speed is unstable, have your dealer inspect the throttle body. Specified Idle Speed: 950 ±50 rpm Fuel Tank Vent The fuel tank vent hoses must be routed as specified. The
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 112
    110 MAINTENANCE AND ADJUSTMENT Belt Drive Torque Converter The vehicle is equipped with a belt drive torque converter type automatic transmission. The belt, driven pulley shoes and drain cap should be checked in accordance with the Periodic Maintenance Chart. The belt and driven pulley shoes
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 113
    MAINTENANCE AND ADJUSTMENT 111 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 114
    112 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 115
    MAINTENANCE AND ADJUSTMENT 113 Brakes The vehicle is equipped with hydraulically activated drum brakes on all four wheels. Brake Pedal the brake pedal has more or less free play • If than specified or the pedal action feels rough or "catchy," have the brake system inspected immediately by an
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 116
    114 MAINTENANCE AND ADJUSTMENT WARNING Over time, brake fluid can absorb moisture, lowering its boiling point and reducing brake effectiveness. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not mix two types and brands of fluid for use in
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 117
    MAINTENANCE AND ADJUSTMENT 115 WARNING Mixing two types and brands of fluid for use in the brake lowers the brake fluid boiling point and could reduce brake effectiveness. Change the fluid in the brake system completely if the fluid level is low but the type and brand of the fluid already in the
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 118
    116 MAINTENANCE AND ADJUSTMENT Brake Light Switch When the brake pedal is depressed, the brake light goes on. The brake light switch should be inspected in accordance with the Periodic Maintenance Chart. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 119
    MAINTENANCE AND ADJUSTMENT 117 Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. 8 to 12 clicks of lever travel, the vehicle • After should not roll while
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 120
    118 MAINTENANCE AND ADJUSTMENT Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for the specified free play and smooth operation. j A. Locknut B. Nut the vehicle on level ground. • Park turn the steering wheel left and right. • Lightly There should be 0
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 121
    happen when the engine starts; inspect the battery voltage. Cable harness or connectors may have been disconnected. See an authorized dealer for service. j NOTE żIf the steering becomes irregular or unusual for A. Steering Column Bracket B. Nuts any reason other than above, have an authorized
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 122
    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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 123
    MAINTENANCE AND ADJUSTMENT 121 Payload and Tire Pressure Failure to maintain proper inflation pressures or observe payload limits for your tires can change or impair handling and performance of the vehicle. The maximum recommended load carrying capacity is 603 kg (1 330 lb). Use a tire pressure
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 124
    122 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 125
    MAINTENANCE AND ADJUSTMENT 123 Suspension Rear Shock Absorber Spring Force Adjustment The spring adjusting sleeves on the rear shock absorbers have 5 positions so that the springs can be adjusted for different riding and loading conditions. j A. Adjusting Sleeve (Turn here with a hook wrench) If
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 126
    124 MAINTENANCE AND ADJUSTMENT Spring Action PosiSpring tion Force 1 2 3 4 5 | | | Ļ Strong 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 127
    MAINTENANCE AND ADJUSTMENT 125 Cargo Bed Latches Depending on the cargo loading and/or passenger riding conditions, latch lever compression needs to be adjusted. Release the fitting bolts and adjust the position of the latch assembly so that the latch lever will be secured without rattling and
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 128
    126 MAINTENANCE AND ADJUSTMENT Battery The battery is located under the left end of the front seat. DANGER Battery contains sulfuric acid and produces hydrogen gas. Sulfuric acid can cause burns and hydrogen gas can cause an explosion. Read and heed the battery safety label. j A. Adjusting
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 129
    MAINTENANCE AND ADJUSTMENT 127 j A. Cover • Remove the battery holder. A. Holder B. (+) Terminal C. (-) Terminal the cables from the battery, first from • Disconnect the (-) terminal and then the (+) terminal. NOTE żThere is no need to separate the smaller cables clamped with the main battery
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 130
    a sealed type, and the sealing strip should not be removed at any time after the specified electrolyte has been installed in the battery for initial service. It is not necessary to check the battery electrolyte level or add distilled water. However, in order to maximize battery life and ensure that
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 131
    MAINTENANCE AND ADJUSTMENT 129 Current Drain (Y50-N18L-A) Days from 100% DischargCharged to 50% ing Ampere Discharged 7 mA 10 mA 15 mA 20 mA 30 mA 60 Days 42 Days 28 Days 21 Days 14 Days Days from 100% Charged to 100% Discharged 119 Days 83 Days 56 Days 42 Days 28 Days Battery Maintenance It is the
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 132
    Refer to the Fuse Location label on the other side fuse case lid. 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 lead
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 133
    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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 134
    132 MAINTENANCE AND ADJUSTMENT Breaker The breaker for the radiator fan is located under the seat near the fuse box. If the fan does not function, inspect the breaker. In order to reset the breaker, push the button at the side of the breaker case. Before resetting, however, check that the radiator
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 135
    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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 136
    134 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 137
    oil. • • 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. WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 138
    136 STORAGE oil on all unpainted metal surfaces to pre• Spray vent rusting. Avoid getting oil on rubber parts or in • • the brakes. Lubricate all the cables as indicated in the General Lubrication section. Remove the battery, and store it where it will not be exposed to direct sunlight, moisture,
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 139
    TROUBLESHOOTING GUIDE 137 TROUBLESHOOTING GUIDE Starter Motor Won't Turn Fuse failed (be sure to check for cause of failure) Battery cables do not make good electrical contact with battery terminals
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 140
    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.
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 141
    , 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 142
    140 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 143
    ? 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 144
    142 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands. When using your Kawasaki Utility Vehicle (UV), please follow
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 145
    MAINTENANCE RECORD 143 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
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 146
    144 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 147
    MAINTENANCE RECORD 145 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 148
    146 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 149
    MAINTENANCE RECORD 147 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 150
    148 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki MULE 4010 Trans4x4 | Owners Manual - Page 151
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