2013 Kawasaki MULE 4010 4x4 Diesel Owners Manual

2013 Kawasaki MULE 4010 4x4 Diesel Manual

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  • 2013 Kawasaki MULE 4010 4x4 Diesel | 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. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING
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    . As the owner of the Mule, you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have provided
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 6
    Tampering with Emission Control System is Prohibited Federal law and California state law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design
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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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    Bracket ...Winch Installation ...HOW TO OPERATE ...Daily Safety Checks ...Starting the Engine...Cold Weather Starting ...Starting After Fuel System Service ...Jump Starting ...Moving Off ...Braking ...Stopping the Engine ...Parking the Mule ...Hi-Lo Shifting...Reversing Gears ...2WD-4WD Shifting
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    114 114 116 117 118 119 120 Fuse ...Power Steering System...Breaker ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...YOUR WARRANTY/OWNER SATISFACTION ...ENVIRONMENTAL PROTECTION ...MAINTENANCE RECORD ... 124 124 125 126 127 128 129 132 133 137 138
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    judgement. Practice basic maneuvers so you can drive confidently and safely. Read the Owner's Manual Read and understand this Owner's Manual. This is especially important for inexperienced drivers. Refer to this Owner's Manual if you have any questions. Off-Highway Use Only This vehicle is not an
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 11
    BASIC SAFE DRIVING 9 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 thus
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 12
    10 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke
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    SPECIFICATIONS 11 Engine Oil: Type Viscosity Capacity API CF or CF-4 class SAE 10W-40 3.3 L (3.5 US qt) 4.1 L (4.3 US qt) 4WD/2WD, gear 2-speed & reverse, automatic 3.7 ∼ 0.98 (Belt drive torque converter) 5.200 5.429 9.69 (High) 19.95 (Low) 22.454 (Low) 1.821 (High) 3.750 (Low) 4.220 (Low) LSD OIL
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    12 SPECIFICATIONS Rim Size: Fuel Tank Capacity Front & Rear 10 × 8.5 24 L (6.3 US gal) 12 V 52 Ah 12 V 35 W × 2 12 V 5/21 W × 2 740 kg (1 632 lb) 499 kg (1 100 lb) ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum
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    SERIAL NUMBER LOCATIONS 13 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 16
    14 LOCATION OF PARTS LOCATION OF PARTS 1. Headlights 2. ROPS 3. Front Cargo Hood 4. Front Cargo Compartment 5. Steering Wheel 6. Seat 7. Seat Belts 8. Front Bumper 9. Radiator 10. Parking Brake 11. Battery 12. Latch 13. Air Cleaner (Belt Drive Torque Converter) 14. Belt Drive Torque Converter 15
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    LOCATION OF PARTS 15 16. Air Cleaner (Engine) 17. Screen 18. Tail Gate 19. Cargo Bed 20. Dashboard 21. Coolant Reserve Tank 22. Tail/Brake Lights 23. Trailer Hitch Bracket 24. Muffler (Spark Arrester) 25. Fuel Tank 26. Fuel Tank Cap
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    16 LOCATION OF PARTS 27. Left Glove Compartment 28. Light Switch 29. Front Cargo Hood Knob 30. Oil Pressure Warning Light 31. Coolant Temperature Warning Light 32. Speedometer 33. Parking Brake Warning Light 34. Glow Plug Light 35. Power Steering Warning Light 36. Fuel Gauge/Hour Meter 37. Main
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    LOCATION OF LABELS 17 LOCATION OF LABELS All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your vehicle. Therefore, it
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    18 LOCATION OF LABELS 7. Important Information (Tires/Max. Load) 8. Warning (Cargo Bed) 9. Specification (ROPS) 10. Warning (Hot Surfaces) 11. Notice (Engine Oil Fill) 12. Notice (Engine Oil Level) 13. Important Engine Information 14. Warning (Towing Bracket) 17. Warning (Passengers in Cargo Bed)
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    LOCATION OF LABELS 19 15. Warning (Refueling) 19. Battery Danger/Poison
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    20 LOCATION OF LABELS (1) (3) (2) (4)
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    LOCATION OF LABELS 21 (5)
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    22 LOCATION OF LABELS (6) (8) (7) (9)
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    LOCATION OF LABELS 23 (10) (12) (11) (13)
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    24 LOCATION OF LABELS (14) (16) (15) (17)
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    LOCATION OF LABELS 25 (18) (19)
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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
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    LOADING INFORMATION 27 subtract trailer tongue weight from the • Always Maximum Load capacity. Refer to the "Trailer Hitch Bracket" section in the "General Information" chapter. Maximum Vehicle Load Weight of operator, passenger, and cargo must not exceed 740 kg (1 630 lb). vehicle is not designed
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    or aftermarket cetane improver additives to diesel fuel. Damage to the fuel injection system may result. Engine Oil Use only oils conforming to API Service CF or CF -4. Use the proper SAE viscosity grade of engine oil for the expected ambient temperature range as indicated in the following chart
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    GENERAL INFORMATION 29 Lighting/Electrical Accessory Connectors The lighting 12 volt connector is located on the dashboard. An auxiliary light may be connected to this connector. Other connectors for electrical accessory are located under the left side dashboard. Optional items such as wiper and
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    30 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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    GENERAL INFORMATION 31 the handgrips. Support the bed in the tilted position with the rod. j A. Supporting Rod A. Latch B. Handgrip NOTICE Do not carry more than the maximum load stated here in the cargo bed. Maximum Cargo Bed Load: 499 kg (1 100 lb)
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    32 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 35
    GENERAL INFORMATION 33 Coolant Temperature Warning Light The coolant temperature warning light (TEMP) comes on whenever the coolant temperature rises too high while the vehicle is in operation. If it stays on, stop the engine and check the coolant level in the reserve tank after the engine cools
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    34 GENERAL INFORMATION j Fuel Tank The fuel tank is mounted under the right side of the seat. This engine is certified to operate on Diesel Fuel. Use clean, fresh diesel fuel (ASTM D975) for good performance of this vehicle. Avoid refilling the tank in the rain or where heavy dust is blowing, so
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 37
    whether the air cleaner is clogged. The air cleaner element should be cleaned if the restriction gauge window band changes from yellow to red. After servicing the air cleaner element, the restriction gauge should be reset by pushing the button at the end of the gauge. Lower Sulfur Sulfur content is
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    36 GENERAL INFORMATION j Glove Compartment A glove compartment is provided at each end of the dashboard. Store only light items to avoid damage to the inside of the compartments. Release the plug in the bottom of the left and right glove compartments to remove any water that may have entered. Do
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    GENERAL INFORMATION 37 j Front Cargo Compartment The front cargo compartment is located under the front cargo hood. Store only light-weight items in it to avoid damage to the inside of the compartment. Do not put items which must not get wet or dirty in it. A. Latch Release Knob NOTE żWhen the
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    38 GENERAL INFORMATION j Horn Button Push the horn button to sound the horn. A. Push here. B. Latches WARNING An open front cargo hood can distract or impair visibility of the operator, causing loss of vehicle control and potential serious injury or death. Latch the hood securely before operating
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    GENERAL INFORMATION 39 Main Switch This is a three-position, key-operated switch. The key can be removed from the switch only when it is in the "OFF" position. OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. Fuel gauge works. Electric starter is engaged by
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 42
    40 GENERAL INFORMATION j Keys This UV has a key, which is used for the ignition switch, and one spare key. Included with the key is a key number, which is stamped on the key itself. Record the key number in the space provided and store the number in a safe place. locate your key number, contact
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 43
    GENERAL INFORMATION 41 Fuel Gauge/Hour Meter Fuel Gauge (LED) The fuel in the fuel tank is shown by the number of segments displayed. When the fuel tank is full, all the segments are displayed. As the fuel level in the tank goes down, the segments disappear one by one from F (full) to E (empty).
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    42 GENERAL INFORMATION j Light Switch Turn on the headlights and taillights by pushing the light switch in, with the main switch key in the "ON" position. The lights go off when the switch is pushed out. Speedometer The speedometer shows the speed of the vehicle. In the speedometer face is the
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 45
    GENERAL INFORMATION 43 j Oil Pressure Warning Light The oil pressure warning light goes on whenever the oil pressure is dangerously low or the main key is in the ON position with the engine not running, and goes off when the engine oil pressure is high enough. NOTICE If the engine oil gets
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 46
    44 GENERAL INFORMATION 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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    GENERAL INFORMATION 45 raises the speed range for ordinary off-highway use. Stop the vehicle before moving the Hi-Lo shift lever. j NOTICE Use of the high range for heavy loads, climbing hills, and pulling a trailer can lead to premature wear of the torque converter belt and pulleys. Use low range
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    46 GENERAL INFORMATION Differential Shift Lever This vehicle is equipped with a dual-mode rear differential. The differential shift lever is located on the dashboard, to the left of the steering shaft. Move the shift lever up or down as indicated on the label next to the shift lever. Refer to the "
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    GENERAL INFORMATION 47 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. j Parking Brake Warning Light The parking brake warning light goes on when the parking brake is applied with the main
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    48 GENERAL INFORMATION j Seat The seat can be raised for vehicle maintenance and adjustment. Pull up on the rear edge of the seat. Seat Belts The vehicle is equipped with lap-style seat belts both for the operator and passenger. Always wear the seat belts when operating and riding in the vehicle.
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    GENERAL INFORMATION 49 To wear the seat belt properly, follow this procedure: 1. Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted. 2. Push the latch plate into the buckle until it clicks. 3. Adjust the seat belt for a SNUG FIT. j WARNING Too
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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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    procedure. A. Power Steering Warning Light A. Throttle Pedal NOTE żIf the warning light does not go on when the main switch is "ON", there may be a problem with the light itself. See a dealer for inspection.
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    52 GENERAL INFORMATION j Trailer Hitch Bracket This vehicle is equipped with a bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, observe the following precautions: WARNING Improper towing of a loaded trailer could cause an
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 55
    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. Winch Bracket 2. 3. Follow a manual to be supplied by the winch maker for installing the winch and other accessory as necessary. After installing the
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 56
    . 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 55 Transmission Case Oil ...Oil level between H and L, no leaks. Coolant ...Coolant level between level lines (when engine is cold), no leaks. Throttle ...Throttle pedal free play 5 ∼ 10 mm (0.2 ∼ 0.4 in.). Throttle pedal operates smoothly and returns to rest position when released.
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    56 HOW TO OPERATE Starting the Engine NOTICE Do not operate the electric starter continuously for more than 5 seconds, or the starter may overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power.
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    ON again. Repeat this 2 or 3 times to thoroughly preheat the combustion chambers. Finally, crank the engine to start it. Starting After Fuel System Service Air bleeding of the fuel system may be required before engine starting if air was introduced into the fuel system during maintenance. (Fuel
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    58 HOW TO OPERATE Jump Starting If your vehicle battery is "run down," it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. j DANGER Battery acid generates hydrogen gas which is flammable and explosive under
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    HOW TO OPERATE 59 j A. Battery B. Cap Cover a jumper cable from the positive (+) ter• Connect minal of the booster battery to the positive (+) terminal of the vehicle battery. A. Vehicle Battery Positive (+) Terminal B. From Booster Battery Positive (+) Terminal C. Unpainted Metal Surface D.
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    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 Braking NOTE Stopping the Engine the throttle pedal completely. • Release the gear shift lever into the "N" (Neutral) posi• Put tion. the parking brake to help prevent the vehicle • Apply from rolling. • Turn the main switch key to the "OFF" position. j żWhen the throttle pedal
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    62 HOW TO OPERATE Parking the Mule j WARNING Operating or parking the vehicle near flammable materials can cause a fire, and can result in property damage or severe personal injury. Do not idle or park your vehicle in an area where tall or dry vegetation, or other flammable materials could come
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    HOW TO OPERATE 63 WARNING Diesel fuel is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks, including the pilot light of any appliance. Hi-Lo Shifting
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    64 HOW TO OPERATE NOTE żBefore j shifting make certain that the vehicle is completely stopped. The Hi-Lo shift lever cannot be shifted when the vehicle is in motion. Reversing Gears the throttle pedal, and stop the vehicle. • Release you want to operate the vehicle in reverse, • When stop the
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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 "4WD". To shift back into "2WD" position, pull and hold the stopper, then move the shift lever all the way up "2WD". NOTE
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    66 HOW TO OPERATE Shifting the Differential NOTE j żDo not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph). Shifting to Locked-Axle Mode the stopper under the differential shift lever • Pull knob and while holding it against the knob, move the shift
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    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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    68 SAFE OPERATION Driving in Reverse Start the engine following the procedure in the "Starting the Engine" section. Before shifting into reverse, stop the vehicle completely. Refer to the Gear Shift Lever in the "Shift Levers" section and "Reversing Gears" section. Turn around and look behind you
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    SAFE OPERATION 69 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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    70 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
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    SAFE OPERATION 71 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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    72 SAFE OPERATION Traversing Hillsides When driving across the side of a hill, reduce vehicle speed and exercise extreme caution to prevent tipping or loss of control. Avoid hills with slippery sides that will cause you to lose traction. Also avoid traversing hillsides covered with rocks or other
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    SAFE OPERATION 73 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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    74 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the Mule in good running condition. The initial maintenance is vitally important and
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    * Converter drive belt deflection -inspect* Converter driven pulley shoe -inspect* Converter air cleaner element -clean* Valve clearance-inspect Engine oil-change* 1 year D D D Regular Service j Every Every Every 800 After 50 Every 100 hrs. or 250 hrs. 500 hrs. hrs. or hrs. or 1,000 km 2,000 km or
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    element - change* Fuel filter water - drain* Fuel hoses and connections-inspect * Spark arrester-clean Radiator-clean* Radiator hoses and connections-inspect* 1 year D Regular Service Every Every Every After 50 Every 100 hrs. or 250 hrs. 500 hrs. 800 hrs. hrs. or 1,000 km 2,000 km or 5,000 or 10
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    level-inspect Parking brake lever-inspect Brake hose and pipe-inspect Brake wear-inspect* Tire wear-inspect* Battery-inspect Brake light switch-inspect 2 years (D) D Regular Service Every Every Every After 50 Every 100 hrs. or 250 hrs. 500 hrs. 800 hrs. hrs. or 1,000 km 2,000 km or 5,000 or 10
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    -change Brake master cylinder cup and dust seal-replace Brake wheel cylinder assembly -replace Brake hose-replace 1 year 2 years (D) 2 years (D) 2 years (D) 4 years (D) D Regular Service Every Every Every After 50 Every 100 hrs. or 250 hrs. 500 hrs. 800 hrs. hrs. or 1,000 km 2,000 km or 5,000 or 10
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    , and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart in the owner's manual. A. Dipstick Oil Level Inspection • whenever the oil level is inspected, start the engine and run it for several minutes at idle speed. Stop the
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    80 MAINTENANCE AND ADJUSTMENT j A. Dipstick B. F (Full) Hole C. L (Low) Hole A. Oil Filler Cap Oil and/or Oil Filter Change When changing or adding oil, use the chart on page 83 to select the correct viscosity grade for the temperature expected. Warm up the engine thoroughly, and then stop the
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    MAINTENANCE AND ADJUSTMENT 81 j A. Drain Plug A. Cartridge • Let the oil drain completely. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. the oil filter is to be changed, remove the oil
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    82 MAINTENANCE AND ADJUSTMENT 2. Raise the filling funnel a little from the cylinder head. j A. Gasket the engine up to the F (full) hole on the dipstick • Fill with good quality engine oil as specified in the following table. A. Dipstick Tube B. about 5 cm or 2 inches C. Funnel NOTE żWhen
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    MAINTENANCE AND ADJUSTMENT 83 NOTICE If the oil level in the cylinder head cover gets too high because of filling too fast or filling too much (overfilling), oil may overflow from the filler hole and/or may flow through the crankcase ventilation tube into the intake manifold. Oil in the intake
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    84 MAINTENANCE AND ADJUSTMENT Front Final Gear Case Oil In order for the differential, pinion, and ring gears to function properly, check the oil level and change the oil in accordance with the Periodic Maintenance Chart. j WARNING Gasoline and low-flash point solvents can be flammable and/or
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    MAINTENANCE AND ADJUSTMENT 85 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
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    86 MAINTENANCE AND ADJUSTMENT Oil Change NOTE Tightening Torque Drain Plug: 20 N·m (2.0 kgf·m, 14.0 ft·lb) the gear case up to the bottom thread of the • Fill filler opening with a good quality oil as specified in the table. Front Final Gear Case Oil about 400 mL Oil Capacity (0.4 US qt) Oil Type
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    Check the oil level and change the oil according to the owner's manual. j A. Transmission Case B. Oil Filler Plug NOTICE Be careful not . Oil Level Inspection the vehicle on level ground. • Park the cargo bed and support it with the rod. • Lift the oil filler plug, wipe its dipstick dry,
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    88 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, place an oil pan beneath the • With transmission case. • Remove the drain plug. j A. Oil Filler Plug and Dipstick B.
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    normal operation and cause serious burns. To avoid a serious burn, never touch a hot muffler or exhaust pipe during oil draining. the cargo bed and support it with the 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
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    90 MAINTENANCE AND ADJUSTMENT Cooling System WARNING The cooling system can get extremely hot during normal operation and cause serious burns. Do not touch the radiator when it is hot, nor open the radiator cap. Hot coolant inside will cause severe burns. Radiator Lift the front cargo hood up.
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    MAINTENANCE AND ADJUSTMENT 91 NOTICE Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair the radiator's effectiveness. Do not obstruct or deflect airflow through the radiator by installing unauthorized accessories in front of the radiator or behind the
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    92 MAINTENANCE AND ADJUSTMENT the filler opening to the "F" (Full) mark. Install the cap. Recommended Coolant Solution Coolant Mixture Ratio: Water 50%: Antifreeze 50% (1 : 1) Recommended Antifreeze: Permanent type antifreeze (ethylene glycol plus corrosion and rust inhibitor chemicals for cast-iron
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 95
    gauge shows whether the air cleaner is clogged. Whenever the red band shows in the gauge window, the air cleaner element should be cleaned. After servicing the air cleaner element, the restriction gauge should be reset by pushing the button at the end of the gauge.
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 96
    94 MAINTENANCE AND ADJUSTMENT j A. Air Filter Restriction Gauge Element Removal A. Air Cleaner Housing B. Cap C. Snaps the seat. • Raise up the snaps and remove the air cleaner hous• Pull ing cap from the housing. the air cleaner element out of the housing. • Pull a clean, lint-free towel into
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 97
    MAINTENANCE AND ADJUSTMENT 95 NOTICE If dirt gets into the engine, excessive engine and possible engine damage may occur. Element Cleaning the element (see Element Removal). • Remove the paper element by tapping it lightly to • Clean loosen dust. away the remaining dust by applying com• Blow
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    96 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with a spark arrester approved for off-highway use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. Clean the spark arrester in accordance with the Periodic Maintenance Chart. j NOTICE The
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    MAINTENANCE AND ADJUSTMENT 97 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 100
    MAINTENANCE AND ADJUSTMENT j A. Throttle Pedal B. 5 ∼ 10 mm (0.2 ∼ 0.4 in.) A. Throttle Cable Adjuster B. Mounting Nuts Throttle Pedal Play Adjustment the cargo bed and support it with the rod. • Lift the adjuster mounting nuts at the end of • Loosen the throttle cable. the adjuster until the
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 101
    can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. the cargo bed and support it with the rod. • Lift a suitable tachometer to measure the idle • Use RPM. If it does not match the specification, pro- • ceed as follows. Remove
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 102
    100 MAINTENANCE AND ADJUSTMENT j A. Cover Bolts B. Pump Cover the locknut and the accelerator lever stop• Loosen per screw on the injection pump. A. Accelerator Lever Stopper Screw B. Locknut C. Accelerator Lever the idle speed by turning the accelerator • Adjust lever stopper screw. Idle Speed
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 103
    MAINTENANCE AND ADJUSTMENT 101 Fuel Filter Accumulation of moisture or sediment in the fuel system can restrict the flow of fuel and cause injection pump damage. The system should be checked in accordance with the Periodic Maintenance Chart. WARNING Fuel is extremely flammable and can be explosive
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    102 MAINTENANCE AND ADJUSTMENT a suitable container under the fuel filter to • Place catch spilled fuel. the drain cap at the bottom end of the fuel • Remove filter. Discard the O-ring. the fuel filter element with a filter wrench. • Remove the old filter element with a new one. • Replace Tighten it
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 105
    MAINTENANCE AND ADJUSTMENT 103 Fuel Tank Vent The fuel tank vent hoses must be routed as specified. The engine may stall or lose power if the fuel tank vent is plugged or if the vent hoses are pinched. Inspect the vent hoses before riding and whenever the engine seems to lose power. If the fuel
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 106
    104 MAINTENANCE AND ADJUSTMENT Belt Drive Torque Converter Air Cleaner A clogged belt drive torque converter air cleaner may cause the torque converter to malfunction. NOTICE A clogged air cleaner may allow dirt and dust to enter the belt drive torque converter causing excessive wear of the inner
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 107
    MAINTENANCE AND ADJUSTMENT 105 NOTICE If dirt gets into the belt drive torque converter, excessive wear and loss of driving power may result. the element material for damage. If any • Inspect part of the element is damaged, the element must be replaced. NOTE żElement installation order of
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 108
    106 MAINTENANCE AND ADJUSTMENT Brakes The vehicle is equipped with hydraulically activated drum brakes on all four wheels. Brake Pedal the brake pedal has more or less free play • If than specified or the pedal action feels rough or "catchy," have the brake system inspected immediately by an
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 109
    MAINTENANCE AND ADJUSTMENT 107 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 110
    108 MAINTENANCE AND ADJUSTMENT WARNING Air in brake line can make the brake feel mushy or soft. This may cause reduced braking performance or brake failure and result in an accident. If brake lever travel is excessive or the brake feels mushy, have an authorized Kawasaki dealer inspect it
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 111
    MAINTENANCE AND ADJUSTMENT 109 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 112
    110 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. the parking brake lever up and to the rear. • Pull 8 to 12 clicks of
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 113
    MAINTENANCE AND ADJUSTMENT 111 Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for the specified free play and smooth operation. A. Locknut B. Nut the vehicle on level ground. • Park turn the steering wheel left and right. • Lightly There should be 0 ∼
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 114
    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
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    MAINTENANCE AND ADJUSTMENT 113 Cargo Bed Latches • Retighten the mounting bolts. NOTE żAdjustment must be made on both sides. j A. Cargo Bed Hook B. Latch and Lever C. Mounting Bolts Cargo bed latches must rest securely on the cargo bed hooks without rattling. If there is rattling or not snug
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 116
    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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 117
    MAINTENANCE AND ADJUSTMENT 115 WARNING Operating with unequally or improperly pressurized tires can adversely affect steering or handling. Inflate both front tires to the same pressure and both rear tires to the same pressure. Minimum Tread Depth: 3 mm (0.12 in.) inspect the tire for cracks and
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 118
    116 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 119
    MAINTENANCE AND ADJUSTMENT 117 Suspension j A. Adjusting Sleeve B. Turn here with a hook wrench A. Shock Absorber B. Adjusting Sleeve 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 120
    118 MAINTENANCE AND ADJUSTMENT WARNING Improper shock absorber adjustment can cause poor handling and loss of stability, which could lead to an accident. Always adjust the shock absorbers on the left and right side to the same setting. Seat Belts In accordance with the Periodic Maintenance Chart,
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 121
    MAINTENANCE AND ADJUSTMENT 119 Headlight Beam • The headlight beams can be adjusted vertically. Remove the holder. j A. Adjusting Screws A. Holder the adjusting screw on each headlight rim in • Turn or out to adjust the headlight vertically.
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    120 MAINTENANCE AND ADJUSTMENT Battery The battery is located under the left end of the seat. the cables from the battery, first from • Disconnect the (-) terminal and then the (+) terminal. the battery from the case. • Remove the battery using a solution of baking soda • Clean and water. Be sure
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 123
    to a sealed type battery. The sealing strip should never be removed after the specified electrolyte has been installed in the battery for initial services. However, in order to maximize battery life and ensure that it will provide the power needed to start your vehicle you must properly maintain
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 124
    122 MAINTENANCE AND ADJUSTMENT Current Drain (Y50-N18L-A) Days from 100% Days from 100% DischargCharged to 50% charged to 100 % ing Ampere Discharged Discharged 7 mA 10 mA 15 mA 20 mA 30 mA 60 Days 42 Days 28 Days 21 Days 14 Days 119 Days 83 Days 56 Day 42 Days 28 Days Battery Maintenance It is the
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 125
    install a conventional battery in this vehicle, or the electrical system cannot work properly. NOTE żIf you charge the sealed battery, never fail to observe the instructions shown on the label on the battery and charger.
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 126
    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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 127
    MAINTENANCE AND ADJUSTMENT 125 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 128
    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. connect the (-) cable of the battery, since the cooling fan can turn automatically even with the main switch off
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 129
    cause malfunction. • • • WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 130
    128 MAINTENANCE AND ADJUSTMENT Bolt and Nut Tightening In accordance with the Periodic Maintenance Chart, have the tightness of the bolts, nuts, and fasteners checked by an authorized Kawasaki dealer. j
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 131
    żAs an alternative to draining the fuel system, a fuel stabilizer designed specifically for diesel fuel may be used. follow the manufacturer's instructions for use. j WARNING Fuel stabilizers may contain poisonous substances. Heed the manufacturer's warnings for use. each cylinder with 3 cc engine
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 132
    130 STORAGE • Reattach the fuel solenoid switch connector. j A. Glow Plugs NOTE A. Fuel Solenoid Switch Connector żDo not use more than 3 cc of engine oil in each cylinder. Too much oil could cause hydraulic lock and engine damage. • Install the glow plugs. Tightening Torque Glow Plug: 17 N·m
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 133
    STORAGE 131 NOTICE Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged a battery becomes, the more easily it freezes. a plastic bag over the exhaust pipe and air • Tie cleaner intake (rear ROPS top) to prevent
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 134
    132 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Starter Motor Won't Turn Fuse failed (be sure to check for cause Air filter clogged or intake blocked Engine oil incorrect Water in fuel Drive train trouble • j • • • Power Steering Won't Work ECU functioned to prevent overheating
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 135
    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.
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 136
    , 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 137
    YOUR WARRANTY/OWNER SATISFACTION 135 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 138
    ? 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 139
    ENVIRONMENTAL PROTECTION 137 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 140
    138 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
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 141
    MAINTENANCE RECORD 139 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 142
    140 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 143
    MAINTENANCE RECORD 141 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 144
    142 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 145
    MAINTENANCE RECORD 143 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2013 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 146
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