2012 Kawasaki Mule 610 4x4 XC Realtree APG HD Owners Manual
2012 Kawasaki Mule 610 4x4 XC Realtree APG HD Manual
2012 Kawasaki Mule 610 4x4 XC Realtree APG HD manual content summary:
- 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 1
- 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 2
- 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | 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. - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 4
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 5
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | 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...Fuel - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 10
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 ENVIRONMENTAL PROTECTION ... 84 86 86 89 90 92 94 97 98 99 99 100 103 103 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 11
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | 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 Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio Starting - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 14
12 SPECIFICATIONS Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 15
SPECIFICATIONS 13 Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Castor Trail Tire Size: Front Rear Rim Size: Front Rear Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery 12 V 14 Ah - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 16
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. - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 17
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 18
16 LOCATION OF PARTS 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 19
LOCATION OF PARTS 17 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 20
18 LOCATION OF PARTS 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. 37. 38. 39. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 21
LOCATION OF LABELS 19 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 22
20 LOCATION OF LABELS - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 23
LOCATION OF LABELS 21 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 24
22 LOCATION OF LABELS (1) (4) (2) (5) - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 25
LOCATION OF LABELS 23 (3) - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 26
24 LOCATION OF LABELS (6) (7) (KAF400E) (7) (KAF400D) (8) - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 27
LOCATION OF LABELS 25 (9) (KAF400D) (11) (9) (KAF400E) (10) (12) - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 28
26 LOCATION OF LABELS (13) (14) (15) - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 29
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 610 4x4 XC Realtree APG HD | Owners Manual - Page 30
28 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 31
GENERAL INFORMATION 29 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 32
with the cargo bed. To close the tail gate, lift into upright position and secure firmly with the latches. handgrips. Support the bed in the tilted position with the supporting hook provided on the bottom of the cargo bed. A. Latch B. Handgrip C. Fuel Tank Cap NOTE A. Tail Gate B. Latch Handle - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 33
Hook B. Cargo Bed Bottom (Tilted Condition) 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 bed - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 34
32 GENERAL INFORMATION j Choke Knob The choke knob located on the dashboard, to the left of the steering wheel, provides a rich mixture for cold starting. Pull the choke knob all the way to start the engine. Warm the engine up using the choke and throttle until the idle speed is stable, and then - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 35
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 36
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 37
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. j Fuel Gauge The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank. When the red indicator needle comes near - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 38
36 GENERAL INFORMATION 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 39
GENERAL INFORMATION 37 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. - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 40
38 GENERAL INFORMATION 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 41
GENERAL INFORMATION 39 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" - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 42
40 GENERAL INFORMATION In the event you lose your keys, you will need the key number to have a duplicate made. If you cannot locate your key number, contact the dealer where you purchased your Kawasaki UV. It's possible the dealer may have the number in its records. If the key number is lost - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 43
GENERAL INFORMATION 41 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 44
42 GENERAL INFORMATION 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-highway use. Stop the vehicle before moving the Hi-Lo shift lever. j NOTICE Use of the high range for - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 45
GENERAL INFORMATION 43 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 46
44 GENERAL INFORMATION j Parking Brake Lever The parking brake lever is located at the left side of the seat. Pull the lever up and to the rear to apply the parking brake. To release, push in and hold the knob on the end of the lever and push the lever all the way down. Spring pressure helps return - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 47
GENERAL INFORMATION 45 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 48
46 GENERAL INFORMATION j 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 49
GENERAL INFORMATION 47 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 50
48 GENERAL INFORMATION j Throttle Pedal The throttle pedal is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. In - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 51
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. - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 52
50 GENERAL INFORMATION j A. Winch-installing position - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 53
. 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 54
52 HOW TO OPERATE Throttle ...Throttle pedal free play 2 ∼ 5 mm (0.1 ∼ 0.2 in.). Throttle pedal operates smoothly and returns to rest position when released. Steering ...Steering wheel free play 0 ∼ 20 mm (0 ∼ 0.8 in.). Action smooth without excessive play, rough spots, or strange noises. Brakes ... - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 55
HOW TO OPERATE 53 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. DANGER Exhaust gas - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 56
54 HOW TO OPERATE 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 57
HOW TO OPERATE 55 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 58
56 HOW TO OPERATE Moving Off the brake pedal. • Depress Put the gear shift lever into the "H" (High) and "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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 59
HOW TO OPERATE 57 Stopping the Engine the throttle pedal completely. • Release Put the gear shift lever into the "N" (Neutral) posi• tion. the parking brake to help prevent the vehicle • Apply from rolling. • Turn the ignition switch key to the "OFF" position. Parking the Mule • Stop the vehicle - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 60
58 HOW TO OPERATE the ignition switch key to prevent unau• Remove thorized use. parking inside a garage or other structure, • When be sure the structure is well ventilated and the vehicle is not close to any source of flame or sparks. This includes any appliance with a pilot light. Hi-Lo Shifting - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 61
HOW TO OPERATE 59 żWhen shifting the lever from "L" to "N", if it is hard 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 62
60 HOW TO OPERATE 2WD-4WD Shifting the stopper under the 2WD-4WD shift lever • Pull knob and while holding it against the knob, move j • the shift lever to the all way down "4WD". To shift back into "2WD" position, pull and hold the stopper, then move the shift lever all the way up "2WD". NOTE - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 63
HOW TO OPERATE 61 Shifting the Differential NOTE Shifting to Differential (Unlocked-Axle) Model and hold the stopper, then move the shift lever • Pull all the way up (UN-LOCK). j NOTE żDo not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph). żWhen the - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 64
62 HOW TO OPERATE Catalytic Converter This vehicle is equipped with a catalytic converter in the exhaust system. The converter react with carbon monoxide, hydrocarbons and nitrogen oxides to convert them into carbon dioxide, water, nitrogen and oxygen resulting in much cleaner exhaust gases to be - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 65
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. - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 66
64 SAFE OPERATION Driving in Reverse Start the engine following the procedure in the "Starting the Engine" section. Before shifting into reverse, stop the vehicle completely. Refer to the Gear Shift Lever in the "Shift Levers" section and "Reversing Gears" section. Turn around and look behind you - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 67
SAFE OPERATION 65 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 68
66 SAFE OPERATION Climbing Hills Do not attempt to climb hills or steep inclines until you have mastered the controls and basic operating maneuvers of this vehicle. Always go straight uphill and, if the incline is steep and/or the surface is loose, use "4WD" with the differential locked for greater - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 69
SAFE OPERATION 67 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 70
68 SAFE OPERATION Traversing Hillsides When driving across the side of a hill, reduce vehicle speed and exercise extreme caution to prevent tipping or loss of control. Avoid hills with slippery sides that will cause you to lose traction. Also avoid traversing hillsides covered with rocks or other - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 71
SAFE OPERATION 69 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 72
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 73
MAINTENANCE AND ADJUSTMENT 71 FREQUENCY First Service Regular Service OPERATION After 50 hrs. Every 250 Every 500 or 1 000 km hrs. or 5 000 hrs. or 10 km (3 000 000 km (6 000 (600 mile) of - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 74
72 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service OPERATION After 50 hrs. Every 250 Every 500 or 1 000 km hrs. or 5 000 hrs. or 10 km (3 000 000 km (6 000 (600 mile) of - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 75
MAINTENANCE AND ADJUSTMENT 73 FREQUENCY First Service Regular Service OPERATION After 50 hrs. Every 250 Every 500 or 1 000 km hrs. or 5 000 hrs. or 10 km (3 000 000 km (6 000 (600 mile) of - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 76
supporting hook to remain in the raised position and will fall down if not supported, creating the potential for injury. Always latch the supporting filter according to the periodic maintenance chart in the owner's manual. A. Dipstick & Oil Filler Hole B. Seatback up the dipstick, wipe it - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 77
MAINTENANCE AND ADJUSTMENT 75 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" ( - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 78
76 MAINTENANCE AND ADJUSTMENT 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 79
MAINTENANCE AND ADJUSTMENT 77 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 80
periodic maintenance chart. *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. - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 81
MAINTENANCE AND ADJUSTMENT 79 Oil Level Inspection gear case. the vehicle level front-to-rear and side-to • With -side, remove the filler cap from the front final j A. Front Final Gear Case B. Filler Opening C. Bottom Thread A. Front Final Gear Case B. Filler Cap (on the left side) C. Front Axle - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 82
80 MAINTENANCE AND ADJUSTMENT 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 83
• 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 84
82 MAINTENANCE AND ADJUSTMENT Oil Change NOTE żBefore draining the oil, warm it up by running the vehicle. Warm oil drains easily and picks up any sediment. the vehicle level, apply the parking brake se• With curely. an oil pan beneath the transmission case. • Place Remove the drain plug. • j A. - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 85
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 86
84 MAINTENANCE AND ADJUSTMENT 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 87
MAINTENANCE AND ADJUSTMENT 85 Spark Plug Removal the seat. • Raise Carefully • plug. pull the spark plug cap from the spark j Spark Plug Standard Plug Plug Gap NGK BPR5ES 0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.) Tightening Torque 22 N·m (2.2 kgf·m, 16 ft·lb) A. Spark Plug Cap B. Engine Oil Dipstick - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 88
86 MAINTENANCE AND ADJUSTMENT 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 89
MAINTENANCE AND ADJUSTMENT 87 Element Removal • • NOTICE If dirt gets into the engine, excessive engine wear and possible engine damage may occur. Raise the seat. Release the snaps and remove the air cleaner housing cover from the housing. j A. Air Cleaner Housing Cover B. Snaps the screw and - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 90
88 MAINTENANCE AND ADJUSTMENT Element Cleaning the element (see Element Removal). • Remove Remove the urethane foam element from the pa• per element. 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 91
MAINTENANCE AND ADJUSTMENT 89 Spark Arrester This vehicle is equipped with a spark arrester approved for off-highway use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. Clean the spark arrester in accordance with the Periodic Maintenance Chart. NOTICE The spark - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 92
90 MAINTENANCE AND ADJUSTMENT the engine. • Stop Install the drain plug. • Throttle Pedal If the throttle pedal has excessive play due to either cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle may not open fully. If the - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 93
distance the throttle pedal moves before the engine begins to pick up speed. Free play should be 2 ∼ 5 mm (0.1 ∼ 0.2 in.). the cargo bed and support it with the hook. • Lift Loosen turn the throttle cable mounting nuts • located and above the transmission case until the proper amount of throttle - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 94
the choke knob makes the carburetor provide a rich mixture for easy starting when the engine is cold. If starting is difficult or rich fuel mixture trouble occurs, inspect the choke knob, and adjust it if necessary. j A. Throttle Pedal B. Locknut C. Throttle Pedal Stop Bolt - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 95
the inner cable slides smoothly. If there is any irregularity, have 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 the two air intake ducts and the 6 quick rivets. sure the choke - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 96
94 MAINTENANCE AND ADJUSTMENT The proper amount of play is 0 ∼ 1 mm (0.00 ∼ • 0.04 in.) at the choke knob. If there is too much or too little play, adjust the choke cable. The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 97
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 98
96 MAINTENANCE AND ADJUSTMENT 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 99
the Periodic Maintenance Chart. Dust and/or Water Inspection the cargo bed to support it with the hook. • Lift Raise the seat. • Remove the guard be explosive under certain conditions and cause severe burns. Before performing any service, turn the ignition switch "OFF". Do not smoke. Make sure the - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 100
98 MAINTENANCE AND ADJUSTMENT a suitable container under the carburetor. • Place Turn out the drain screw a few turns to drain the • carburetor, and check to see if water or dirt has accumulated in the carburetor. Fuel Filter The vehicle is equipped the fuel filter at the middle of the fuel line to - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 101
MAINTENANCE AND ADJUSTMENT 99 Evaporative Emission Control System This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are requited, a thorough visual inspection must be made at the - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 102
100 MAINTENANCE AND ADJUSTMENT High Altitude Use original belt drive torque converter settings of • The this vehicle are best for seal level use. when the vehicle is used at high altitude, the engine performance will decrease. This is why readjustment of the weights of the torque converter are - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 103
MAINTENANCE AND ADJUSTMENT 101 Element Removal 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 rivets. j A. Air Cleaner - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 104
102 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 610 4x4 XC Realtree APG HD | Owners Manual - Page 105
MAINTENANCE AND ADJUSTMENT 103 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 106
104 MAINTENANCE AND ADJUSTMENT 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 107
MAINTENANCE AND ADJUSTMENT 105 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 108
106 MAINTENANCE AND ADJUSTMENT Adjustment light • Brake pedal. switch is located above the brake j A. B. C. D. A. Brake Light Switch B. Throttle Pedal Brake Light Switch Adjusting Nut Lights sooner. Lights later. adjust the brake light switch, move the switch • To forward or rearward, by turning - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 109
MAINTENANCE AND ADJUSTMENT 107 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 110
108 MAINTENANCE AND ADJUSTMENT Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for the specified free play and smooth operation. the vehicle on level ground. • Park Lightly turn the steering wheel left and right. • There should be 0 ∼ 20 mm (0 ∼ 0.8 in.) - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 111
or impair the handling of the vehicle. żInstallation of tubeless tires on rims requires compressed air and is normally recommended as a dealer service operation. Nevertheless, a tube can be inserted into the tire by the operator as an emergency repair. WARNING Operating with unequally or improperly - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 112
110 MAINTENANCE AND ADJUSTMENT 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 113
MAINTENANCE AND ADJUSTMENT 111 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 114
112 MAINTENANCE AND ADJUSTMENT Spring Action Position 1 2 3 4 5 Spring Force | | | Ļ Strong 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 the - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 115
MAINTENANCE AND ADJUSTMENT 113 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 116
114 MAINTENANCE AND ADJUSTMENT Battery Removal • • • Raise the seat. The battery is located under the left end of the seat. Remove the rubber mud cover on the battery. Unscrew the battery holder. terminal posts or cables. Replace battery and/or cables immediately if any damage is found. Battery - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 117
MAINTENANCE AND ADJUSTMENT 115 Battery Characteristics The battery installed in this Mule is a conventional type and requires regular inspection to maintain the proper electrolyte level and a full charge. In order to maximize battery life and ensure that it will provide the power needed to start - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 118
116 MAINTENANCE AND ADJUSTMENT Battery Sulfation A common cause of battery failure is sulfation. Sulfate is a normal byproduct of the chemical reactions within a battery. Sulfation occurs when the electrolyte level is low and exposes the plates within the battery to air. The active lead on the - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 119
MAINTENANCE AND ADJUSTMENT 117 at a rate of 1/10th of the battery capacity. If you will not be using your vehicle for longer than two weeks, the battery should be charged using an appropriate charger. Do not use an automotive-type quick charger that may overcharge the battery and damage it. Battery - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 120
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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 121
MAINTENANCE AND ADJUSTMENT 119 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 122
In accordance with the Periodic Maintenance Chart, have the general lubrication performed by an authorized Kawasaki dealer or perform it referring to the Service Manual for this vehicle. Cleaning To prolong the life of your vehicle, wash it down immediately after it has been splashed with sea water - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 123
MAINTENANCE AND ADJUSTMENT 121 NOTICE Coin operated, high pressure spray washers are not recommended. Water may be forced into bearings and other components causing eventual failure from rust and corrosion. Some soaps are highly alkaline and may leave a residue or cause spotting. Bolt and Nut - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 124
. 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 125
STORAGE 123 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 126
124 TROUBLESHOOTING GUIDE 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 - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 127
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 610 4x4 XC Realtree APG HD | Owners Manual - Page 128
, 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 610 4x4 XC Realtree APG HD | Owners Manual - Page 129
YOUR WARRANTY/OWNER SATISFACTION 127 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 610 4x4 XC Realtree APG HD | Owners Manual - Page 130
? 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 610 4x4 XC Realtree APG HD | Owners Manual - Page 131
ENVIRONMENTAL PROTECTION 129 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 610 4x4 XC Realtree APG HD | Owners Manual - Page 132
130 MAINTENANCE RECORD MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Key Code ...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Traveled Distance - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 133
MAINTENANCE RECORD 131 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 134
132 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 135
MAINTENANCE RECORD 133 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 136
134 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 137
MAINTENANCE RECORD 135 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Mule 610 4x4 XC Realtree APG HD | Owners Manual - Page 138