2014 Kawasaki Mule 610 4x4 XC Owners Manual

2014 Kawasaki Mule 610 4x4 XC Manual

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  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 1
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 2
    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.
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 3
    Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. WARNING Engine exhaust, some of not related to personal injury. ○NOTE indicates information that may help or guide you in the operation or service of the vehicle. NOTE
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 4
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 5
    Owner's Manual contains those out according to the instructions in this Owner's Manual at your own expense. space at the end of this manual where an authorized Kawasaki dealer, maintenance. If there is a problem with the emission control system within to resolve any problem after consulting with
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 6
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 7
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 8
    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 ...Tailgate ...Cargo Bed ...Choke Knob...Engine Oil
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 9
    ...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam...Battery ...Fuse ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE... 85 88 88 90 90 93 94 96 98 100 102 102 103 103 106 106 108 110 111 111 111 111 111
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 10
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 11
    10 BASIC SAFE DRIVING Protect Yourself, Use Proper Riding Gear As appropriate to your operating conditions, wear approved helmet, eye protection, and protective clothing. Operating in a recreational setting, like trail driving or any aggressive riding, could increase the risk of head injury, and
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 12
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 13
    12 SPECIFICATIONS Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Viscosity Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio: Front Rear Overall Drive Ratio: Forward Reverse Transmission Gear Ratio: Forward Reverse 3.464
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 14
    SPECIFICATIONS 13 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 Headlight Tail/Brake Light 12 V 14 Ah 12 V 35 W × 2
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 15
    14 SPECIFICATIONS LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load (D): KAF400D 420 kg (924 lb) 181 kg (400 lb) (E): KAF400E ○The KAF400E is identical to the KAF400D in every aspect: controls, features, and specifications except for the camouflage surface
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 16
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 17
    16 LOCATION OF PARTS LOCATION OF PARTS 1. 2. 3. 4. 5. 6. Headlights ROPS 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. 18. Battery
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 18
    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 Gauge
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 19
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 20
    LOCATION OF LABELS 19 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 21
    20 LOCATION OF LABELS 5. 6. 7. 8. 9. 15. Warning (Passengers in Cargo Bed) Warning (Cargo Bed) Important Information (Tires/Max. Load) Carrier Hook Operation Specification Specification
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 22
    LOCATION OF LABELS 21 10. 11. 12. 13. Warning (Refueling) Warning (Hot Surface) Important Emission Control Information Engine Oil Information
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 23
    22 LOCATION OF LABELS 14. Important Emission Information 16. Battery Danger/Poison (On the backside) 17. Brake Fluid
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 24
    LOCATION OF LABELS 23 (1) (4) (2) (5)
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    24 LOCATION OF LABELS (3)
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 26
    LOCATION OF LABELS 25 (6) (7) (KAF400E) (7) (KAF400D) (8)
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    26 LOCATION OF LABELS (9) (11) (10) (12)
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    LOCATION OF LABELS 27 (13) (15) (14) (16)
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    28 LOCATION OF LABELS (17)
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 30
    you operate it, make sure that the vehicle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design work and fenders are not designed to carry cargo or to support your weight. They may break.
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 31
    30 LOADING INFORMATION subtract trailer tongue weight from the • Always Maximum Load capacity. Refer to the "Trailer Hitch Bracket" section in the "General Information" chapter. Maximum Vehicle Load Weight of operator, passenger, and cargo must not exceed 420 kg (924 lb). vehicle is not designed
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 32
    GENERAL INFORMATION 31 GENERAL INFORMATION Lighting/Electrical Accessory Connector The lighting/electrical accessory 12 volt connector is located on the dashboard. An auxiliary light or an accessory may be connected to this connector. j Brake Pedal The brake pedal is the left pedal on the foot
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 33
    bed, select a firm level surface and set the parking brake. ○Raise the seat first before releasing the latch. A. Tailgate B. Latch NOTE Support the bed in the tilted position with the supporting rod provided on the bottom of the cargo bed. Do not drive the vehicle with the front end of the cargo
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 34
    GENERAL INFORMATION 33 Check that the both latches have locked the bed into place. Do not leave the cargo bed unlatched. j A. Supporting Rod B. Cargo Bed Bottom (Tilted Condition) A. Latch B. Handgrip C. Fuel Tank Cap NOTICE Do not carry more than 181 kg (400 lb) in the cargo bed.
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 35
    34 GENERAL INFORMATION or improper use of the cargo • Overloading bed can cause changes in handling which j WARNING 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 36
    GENERAL INFORMATION 35 Engine Oil Temperature Warning Light The oil temperature warning light comes on whenever the engine oil temperature rises too high while the vehicle is in operation. If it stays on, stop the engine and check the engine oil level after the engine cools down. Refer to the "
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 37
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 38
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 39
    the fuel system. Before storage it is recommended that you drain all fuel from the fuel tank and carburetors. See the "STORAGE" chapter in this manual. Fuel Gauge The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank. When the red indicator needle comes near
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 40
    GENERAL INFORMATION 39 j Glove Compartment A glove compartment is provided at the right end of the dashboard. Store only light items to avoid damage to the inside of the compartment. Release the plug in the bottom of the glove compartment to remove any water that may have entered. Do not put items
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 41
    40 GENERAL INFORMATION j A. Latch Release Button B. Hood A. Latch Lever B. Hood Hood Closing While lifting the latch lever at the front of the cargo hood, push and close the cargo hood. the hood is closed, push the two parts of the • After hood to ensure the hood is latched.
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 42
    GENERAL INFORMATION 41 j Ignition Switch This is a three-position, key-operated switch. The key can be removed from the switch only when it is in the "OFF" position. A. Push here. WARNING An open front cargo hood can distract or impair visibility of the operator, causing loss of vehicle control
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 43
    42 GENERAL INFORMATION OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. Hour meter works. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is in "N" (neutral) position. Upon release, key will return to "ON"
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 44
    GENERAL INFORMATION 43 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 45
    44 GENERAL INFORMATION j Light Switch Turn on the headlights and taillights by pushing the light switch in, with the ignition switch key in the "ON" position. The lights go off when the switch is pushed again. Shift Levers This vehicle is equipped with three different shift levers: the gear shift
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 46
    GENERAL INFORMATION 45 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 47
    46 GENERAL INFORMATION j A. B. C. D. 2WD-4WD Shift Lever Stopper "2WD" Position "4WD" Position A. Differential Shift Lever B. Stopper C. Differential (Unlocked-Axle) Mode Position (UN-LOCK) D. Locked-Axle Mode Position (LOCK) Differential Shift Lever This vehicle is equipped with a dual-mode
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 48
    GENERAL INFORMATION 47 Parking Brake Lever The parking brake lever is located at the left side of the seat. Pull the lever up and to the rear to apply the parking brake. To release, push in and hold the knob on the end of the lever and push the lever all the way down. Spring pressure helps return
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 49
    48 GENERAL INFORMATION j Parking Brake Warning Light The parking brake warning light goes on when the parking brake is applied with the ignition switch in the "ON" position. Seat The seat can be raised for vehicle maintenance and adjustment. Pull up on the rear edge of the seat. ○This light shows
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 50
    GENERAL INFORMATION 49 Seat Belts The vehicle is equipped with lap-style seat belts for operator and passenger. Always wear the seat belts when operating and riding in the vehicle. WARNING Operator and passenger must be able to place both feet flat on the floorboards while seated upright with
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 51
    50 GENERAL INFORMATION To tighten the belt, pull on the end of the belt coming from the latch plate. To loosen the belt, pull the latch plate at a right angle to the belt. To unfasten the belt, press the red button in the buckle. j A. Red Button WARNING Too much belt slack could reduce its
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 52
    GENERAL INFORMATION 51 j Throttle Pedal The throttle pedal is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. In
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 53
    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.
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 54
    GENERAL INFORMATION 53 j A. Winch-installing position
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 55
    . 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 56
    HOW TO OPERATE 55 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 ...
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 57
    56 HOW TO OPERATE Starting the Engine Throttle-linked choke system This vehicle is equipped with the choke that controls the throttle operation without pressing the throttle pedal when starting the engine. Using this choke system, start the engine with the following procedure. j DANGER Exhaust
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 58
    HOW TO OPERATE 57 NOTICE Do not operate the electric starter continuously for more than 5 seconds, or the starter may overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and for battery power to recover. Jump Starting If your
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 59
    58 HOW TO OPERATE DANGER Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive. Do not make this last connection at the carburetor or battery. Take care not to touch the positive and negative cables together, and do not lean over the battery when
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 60
    HOW TO OPERATE 59 Moving Off the brake pedal. • Depress Put the gear shift lever into the "H" (High) and "L" • (Low) position. the parking brake. • Release Gradually engine speed by pressing on • the throttleincrease pedal. Braking ○When the throttle pedal is released completely and NOTE j ○
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 61
    60 HOW TO OPERATE Stopping the Engine the throttle pedal completely. • Release Put the gear shift lever into the "N" (Neutral) posi• tion. the parking brake to help prevent the vehicle • Apply from rolling. • Turn the ignition switch key to the "OFF" position. Parking the Mule j WARNING
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 62
    HOW TO OPERATE 61 WARNING Gasoline is extremely flammable and can be explosive under certain conditions. j A. Parking Brake Lever WARNING If the vehicle should move after it is parked, it might be damaged or cause injury. Be sure to apply the parking brake before leaving the vehicle. the
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 63
    62 HOW TO OPERATE Hi-Lo Shifting Shifting to High or Low Range the vehicle completely. • Stop Move the shift lever to the "L" (Low) or "H" (High) • positions. j ○Before NOTE shifting make certain that the vehicle is completely stopped. The gear shift lever cannot be shifted when the vehicle is
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 64
    HOW TO OPERATE 63 Reversing Gears the throttle pedal, and stop the vehicle. • Release When you want to operate the vehicle in reverse, • stop the vehicle completely, allowing the engine to slow to idling speed, and move the gear shift lever to the "R" (Reverse) position. 2WD-4WD Shifting the
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 65
    64 HOW TO OPERATE Shifting the Differential j ○Do not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph). NOTE Shifting to Locked-Axle Mode the stopper under the differential shift lever • Pull knob and while holding it against the knob, move the shift
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 66
    HOW TO OPERATE 65 Shifting to Differential (Unlocked-Axle) Model NOTE and hold the stopper, then move the shift lever • Pull all the way up (UN-LOCK). Catalytic Converter This vehicle is equipped with a catalytic converter in the exhaust system. The converter react with carbon monoxide,
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 67
    66 HOW TO OPERATE only unleaded gasoline. Never use leaded • Use gasoline. Leaded gasoline significantly reduces NOTICE In order to protect the emission control parts, do not turn off the ignition switch when the vehicle is in motion. j • the capability of the catalytic converter. Do not coast
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 68
    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.
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 69
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 70
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 71
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 72
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 73
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 74
    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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    listed in the HOW TO OPERATE chapter. D * • ○ = 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 76
    OPERATION ENGINE Converter belt-inspect* Converter driven pulley shoe-inspect* Converter air cleaner element-clean* Converter dust or water-drain* D D Regular Service Every 500 After 50 hrs. Every 250 or 1 000 km hrs. or 5 000 hrs. or 10 km (3 000 000 km (6 000 (600 mile) mile) of
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 77
    76 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service OPERATION Fuel hose-replace 5 years (D) Regular Service Every 500 After 50 hrs. Every 250 or 1 000 km hrs. or 5 000 hrs. or 10 km (3 000 000 km (6 000 (600 mile) mile) of
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 78
    MAINTENANCE AND ADJUSTMENT 77 FREQUENCY First Service OPERATION Regular Service Every 500 After 50 hrs. Every 250 or 1 000 km hrs. or 5 000 hrs. or 10 km (3 000 000 km (6 000 (600 mile) mile) of
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 79
    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
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    MAINTENANCE AND ADJUSTMENT 79 ○It is important to insert the dipstick with its chamfered cap edge facing rearwards. NOTE j A. Dipstick B. "H" (High) Line C. "L" (Low) Line A. Dipstick B. Oil Filler Hole out the dipstick and check the oil level. The • Pull oil level should be between the "F" (
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    80 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
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    *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. Although 10W-40 engine oil is the recommended oil for most conditions
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    82 MAINTENANCE AND ADJUSTMENT Engine Oil Capacity when filter is not removed when filter is removed 1.1 L (1.16 US qt) 1.3 L (1.37 US qt) 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 84
    MAINTENANCE AND ADJUSTMENT 83 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
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    84 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
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    • Pull oil level should be between the "H" (High) and "L" (Low) lines on the dipstick. the vehicle on level ground. • Park Lift the cargo bed and support it with the hook. • Unscrew the oil filler plug, and dipstick, wipe its • dipstick dry, and insert it into the filler hole but DO NOT
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    86 MAINTENANCE AND ADJUSTMENT Oil Change NOTE ○Before 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.
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    normal operation and cause serious burns. To avoid a serious burn, never touch a hot muffler or exhaust pipe during oil draining. the cargo bed and support it with the hook. • Lift Remove the filler plug. • Transmission Case Oil Type API GL-5 Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 89
    88 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 90
    MAINTENANCE AND ADJUSTMENT 89 Spark Plug Removal the seat. • Raise pull the spark plug cap from the spark • Carefully plug. j Spark Plug Standard Plug Plug Gap NGK BPR5ES 0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.) A. Spark Plug Cap B. Engine Oil Dipstick Cap Tightening Torque 22 N·m (2.2 kgf·m, 16 ft·lb
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 91
    90 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 92
    MAINTENANCE AND ADJUSTMENT 91 Element Removal the seat. • Raise Release the snaps and remove the air cleaner • housing cover from the housing. NOTICE If dirt gets into the engine, excessive engine wear and possible engine damage may occur. j A. Air Cleaner Housing Cover B. Snaps • • Remove
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 93
    92 MAINTENANCE AND ADJUSTMENT Element Cleaning the element (see Element Removal). • Remove the urethane foam element from the pa• Remove 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 94
    MAINTENANCE AND ADJUSTMENT 93 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 95
    94 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 96
    be• fore the engine begins to pick up speed. Free play should be 2 ∼ 5 mm (0.1 ∼ 0.2 in.). Throttle Pedal Play Adjustment the cargo bed and support it with the hook. • Lift and turn the throttle cable mounting nuts • Loosen located above the transmission case until the proper amount of throttle
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 97
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 98
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 99
    98 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. Carburetor The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 100
    can cause serious brain injury or death. DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area. the cargo bed to support it with the hook. • Lift Remove • screw. the cover plate on the idle adjusting the axel lever stopper screw on the base • Loosen plate above
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 101
    the Periodic Maintenance Chart. j WARNING Gasoline is extremely flammable and can be explosive under certain conditions and cause severe burns. Before performing any service, turn the ignition switch "OFF". Do not smoke. Make sure the area is well-ventilated and free from any source of flame or
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 Dust and/or Water Inspection the cargo bed to 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. a suitable container
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 103
    102 MAINTENANCE AND ADJUSTMENT Fuel Filter The vehicle is equipped the fuel filter at the middle of the fuel line to prevent dirt or other foreign material from entering the carburetor and fuel pump. Have your authorized Kawasaki dealer inspect and clean or replace the fuel filter in accordance with
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 104
    MAINTENANCE AND ADJUSTMENT 103 Belt Drive Torque Converter The vehicle is equipped with a belt drive torque converter type automatic transmission. The belt, driven pulley shoes and drain hose should be checked in accordance with the Periodic Maintenance Chart. The belt and driven pulley shoes
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 105
    104 MAINTENANCE AND ADJUSTMENT 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 106
    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. ○Element installation is performed in the
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 107
    106 MAINTENANCE AND ADJUSTMENT Brakes The vehicle is equipped with hydraulically activated drum brakes on all four wheels. Brake Pedal In accordance with the Periodic Maintenance Chart, check the brake pedal free play. Depress the brake pedal lightly by hand. There should be 2 ∼ 5 mm (0.1 ∼ 0.2 in
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 NOTICE Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immediately. brake fluid reservoir is inside the access hole, • The and using a funnel fill the reservoir to the upper level line. Fluid Level Inspection the vehicle on level ground, check
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 109
    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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 110
    MAINTENANCE AND ADJUSTMENT 109 Adjustment light • Brake pedal. switch is located above the brake j A. Brake Light Switch B. Throttle Pedal A. B. C. D. Brake Light Switch Adjusting Nut Lights sooner. Lights later. adjust the brake light switch, move the switch • To forward or rearward, by
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 111
    110 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. the locknut (upper nut) on the middle of • Loosen the parking brake lever
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 112
    MAINTENANCE AND ADJUSTMENT 111 Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for the specified free play and smooth operation. Wheels Rims The rims are a drop-center, tubeless tire design. Take care not to damage the sealing surfaces of the tire or rim
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 113
    or impair the handling of the vehicle. ○Installation 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. Failure to maintain proper inflation pressures
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 114
    MAINTENANCE AND ADJUSTMENT 113 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 tread depth. Tire
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 115
    114 MAINTENANCE AND ADJUSTMENT Suspension 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. Rear Shock Absorber Spring Force Adjustment j A. Adjusting Sleeve If the spring action feels too
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 Spring Action Position 1 2 3 4 5 Spring Force | | | ↓ Strong Setting Load Soft ↑ | ↓ Hard Light ↑ | ↓ Heavy Surface Good ↑ | ↓ Bad Speed Low ↑ | ↓ High Seat Belts In accordance with the Periodic Maintenance Chart, check that each seat belt functions properly. Push the
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 117
    116 MAINTENANCE AND ADJUSTMENT Headlight Beam Battery The battery is located under the left end of the seat. • The headlight beams can be adjusted vertically. Turn the adjusting screw on each headlight rim to adjust the headlight vertically. DANGER Battery contains sulfuric acid and produce
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 the battery in place, and route the battery vent • Put hose through the hole in the floor board. the capped lead to the (+) terminal, and • Connect then connect the black lead to the (-) terminal. a light coat of grease on the terminals to pre• Put vent corrosion. the
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 119
    118 MAINTENANCE AND ADJUSTMENT charged. If your Mule is only used occasionally or for short periods of time, the battery is more likely to discharge. Due to their internal composition, batteries continually self discharge. The discharge rate depends on the type of battery and ambient temperature. As
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 120
    MAINTENANCE AND ADJUSTMENT 119 Sulfation also occurs when the battery is left in a discharged condition for an extended time. Sulfate is a normal byproduct of the chemical reactions within a battery. But when continuous discharge allows the sulfate to crystallize in the cells, the battery plates
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 121
    120 MAINTENANCE AND ADJUSTMENT quick charger that may overcharge the battery and damage it. ○Leaving the battery connected causes the electri- NOTE j cal components to make the battery discharged, resulting the over discharge of the battery. In this case, the repair or replacement of the battery
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 122
    cause cancer and reproductive harm. 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 123
    122 MAINTENANCE AND ADJUSTMENT Fuse There are two plastic fuse cases next to the parking brake under the left end of the seat, one for the main (30 A) and the other for the accessory connector (10 A). If the electrical systems do not function, inspect the fuse. Before replacing a fuse, check the
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 124
    by an authorized Kawasaki dealer or perform it referring to the Service Manual for this vehicle. Cleaning To prolong the life of your vehicle 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 125
    124 MAINTENANCE AND ADJUSTMENT Avoid spraying water with any great force near the following places. Front and rear brakes - if water gets into the brake drums, they will not work effectively until they have dried out. Under the seat - if water gets into the ignition coils or into the spark plug cap,
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 126
    MAINTENANCE AND ADJUSTMENT 125 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 127
    finished. ○As an alternative to draining the fuel system, a fuel stabilizer, such as STA-BIL, may be used. Follow the manufacturer's instructions for use. NOTE j WARNING Fuel stabilizers may contain poisonous substances. Heed the manufacturer's warnings for use. the spark plug and spray fogging
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 128
    STORAGE 127 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 129
    128 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 130
    Am I Responsible For? You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner's manual. You are responsible for notifying your dealer immediately if there is a problem, and you, as the owner, will need to authorize the dealer to inspect the unit.
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 131
    , be sure to record your service in the Maintenance Record section of this Owner's Manual. Keep all receipts for the service and/or items necessary to perform vehicle if there is a failure, investigating the cause of the problem, and getting any needed authorization from Kawasaki if the repair is
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 132
    YOUR WARRANTY/OWNER SATISFACTION 131 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 133
    ? This owner's manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you. Please send your correspondence to: Consumer Services Kawasaki Motors Corp
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 134
    ENVIRONMENTAL PROTECTION 133 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 135
    134 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
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 136
    MAINTENANCE RECORD 135 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 137
    136 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 138
    MAINTENANCE RECORD 137 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 139
    138 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 140
    MAINTENANCE RECORD 139 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2014 Kawasaki Mule 610 4x4 XC | Owners Manual - Page 141
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