2015 Kawasaki MULE 4000 Owners Manual

2015 Kawasaki MULE 4000 Manual

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  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 1
  • 2015 Kawasaki MULE 4000 | 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 ENVIRONMENTAL PROTECTION j j j j j j j A Table of Contents is included
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 4
    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1), exhaust emission (2) and evaporative emission (3) control systems in compliance with applicable regulations of the United States Environmental Protections Agency and
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | 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 ...Light Switch ...Coolant Temperature Warning Light...Oil Pressure Warning Light...Fuel
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 9
    102 102 103 104 106 106 108 109 111 112 112 112 112 112 114 115 116 117 121 121 122 123 124 125 STORAGE ...TROUBLESHOOTING GUIDE...YOUR WARRANTY/OWNER SATISFACTION ...ENVIRONMENTAL PROTECTION ...MAINTENANCE RECORD ... 126 128 129 133 134
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 11
    10 BASIC SAFE DRIVING Use Proper Riding Gear Proper protective gear can reduce the severity of injury in the event of an accident. Choose a helmet most appropriate for your use of this utility vehicle. A helmet can reduce the risk of head injuries. Wear appropriate eye protection and protective
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 12
    SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio 47
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 13
    12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Viscosity Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio:
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 14
    Light 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 Front & Rear Front & Rear Steel tube, ladder type Assisted with Electric Power Steering (EPS) System (P) Manual (rack and pinion) 7.5° 35 mm (1.4 in.) 23 × 11.00-10 Tubeless 10 × 8.5 AT 24 L (6.3 US gal) 1.821 (High) (M) 3.750 (Low) 4.220, (P) 2.050
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 15
    14 SPECIFICATIONS LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load (M): KAF620M (P): KAF620P MODEL INFORMATION MULE4010 4 × 4...KAF620M MULE4000...KAF620P Specifications are subject to change without notice. 603 kg (1 330 lb) 363 kg (800 lb)
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 17
    16 LOCATION OF PARTS LOCATION OF PARTS 1. Headlights 2. ROPS (Roll Over Protective Structure) 3. Front Cargo Hood 4. Front Cargo Compartment 5. Steering Wheel 6. Seat 7. 8. 9. 10. 11. 12. 13. Seat Belts Cargo Bed Front Bumper Radiator Parking Brake Battery Latch 14. Air Cleaner (Belt Drive
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 18
    LOCATION OF PARTS 17 17. 18. 19. 20. Screen Latch Handle Tail Gate Dashboard 21. 22. 23. 24. Coolant Reserve Tank Tail/Brake Lights Trailer Hitch Bracket Muffler (Spark Arrester) 25. Fuel Tank 26. Fuel Tank Cap 27. Air Cleaner
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 19
    18 LOCATION OF PARTS 28. 29. 30. 31. 32. 33. 34. Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 35. Parking Brake Warning Light 36. Right Glove Compartment 37. FI Warning Light 38. Power Steering Warning
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 21
    20 LOCATION OF LABELS 9. Warning (Hot Surfaces) 10. Warning (Towing Bracket/Trailer) 11. Warning (Refueling)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 22
    LOCATION OF LABELS 21 12. Important Engine Information 15. Important Emission Information 16. Battery Danger/Poison (On the backside)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 23
    22 LOCATION OF LABELS 17. Brake Fluid 18. Radiator Cap Danger
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 24
    LOCATION OF LABELS 23 (1) (3) (2) (4)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 25
    24 LOCATION OF LABELS (5)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 26
    LOCATION OF LABELS 25 (6) (8) (7) (9)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 27
    26 LOCATION OF LABELS (10) (12) (11) (13)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 28
    LOCATION OF LABELS 27 (14) (16) (15) (17)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 29
    28 LOCATION OF LABELS (18)
  • 2015 Kawasaki MULE 4000 | 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.
  • 2015 Kawasaki MULE 4000 | 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 603 kg (1 330 lb). vehicle is not designed
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 32
    GENERAL INFORMATION 31 GENERAL INFORMATION Lighting/Electrical Accessory Connector The lighting/electrical accessory 12 volt connectors are located on the dashboard. An auxiliary light or an accessary may be connected to this connector. j Light Switch Turn on the headlights and taillights by
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 33
    32 GENERAL INFORMATION j Coolant Temperature Warning Light The coolant temperature warning light (TEMP) comes on whenever the coolant temperature rises too high while the vehicle is in operation or when the ignition switch key is turned to ON. If it stays on, stop the engine and check the coolant
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 34
    GENERAL INFORMATION 33 j Oil Pressure Warning Light The oil pressure warning light goes on whenever the oil pressure is dangerously low or the ignition switch key is in the ON position with the engine not running, and goes off when the engine oil pressure is high enough. NOTICE If the engine oil
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 35
    switch key is turned to "ON" and goes off soon after ensuring that its circuit functions properly. The warning light also goes on whenever the troubles occur in digital fuel injection system (DFI). If the warning light comes on, have the DFI system checked by an authorized Kawasaki dealer. Parking
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 36
    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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 37
    36 GENERAL INFORMATION j Brake Pedal The brake pedal is the left pedal on the foot board. Depress the pedal to slow or stop the vehicle. Cargo Bed Tailgate The tailgate can be lowered. Before lowering the tailgate, park on a firm level surface and set the parking brake. Raise the latch handles at
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 38
    the handgrip. Before tilting the cargo bed, park on a firm level surface and set the parking brake. After lifting the bed, support the bed in the tilted position with the supporting rod provided on the bottom of the cargo bed. To lower the bed, check to be sure the area under the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 39
    38 GENERAL INFORMATION j NOTICE Do not carry more than 363 kg (800 lb) in the cargo bed. Fuel Tank The fuel tank is mounted under the right side of the seat. The gasoline octane rating listed is recommended. Use only fresh gasoline with the recommended octane rating from an uncontaminated source
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 40
    . Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended fuel may not be covered under warranty. Fuels Containing Oxygenates Gasoline
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 41
    all fuel from the fuel tank. See the "STORAGE" chapter in this manual. NOTICE Avoid using blends of unleaded gasoline and methanol (wood alcohol) whenever " containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 42
    GENERAL INFORMATION 41 j Glove Compartment A glove compartment is provided at the 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.
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 43
    42 GENERAL INFORMATION j Front Cargo Compartment The front cargo compartment is located under the front cargo hood. Store only light-weight items in it to avoid damage to the inside of the compartment. Do not put items which must not get wet or dirty inside. Hood Opening Push the hood release
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 44
    GENERAL INFORMATION 43 Hood Closing Close the hood until it locks. After the hood is closed, push the two edges of the hood to ensure the hood is latched. Pull up the front ends of the hood to make sure latches are securely locked. j Horn Button Push the horn button to sound the horn. • • A. Horn
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 45
    44 GENERAL INFORMATION j Ignition Switch This is a three-position, key-operated switch. The key can be removed from the switch only when it is in the "OFF" position. OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. Fuel gauge works. Electric starter is engaged
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 46
    GENERAL INFORMATION 45 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. In the event you lose your keys, you
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 47
    46 GENERAL INFORMATION j 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 48
    GENERAL INFORMATION 47 j Shift Levers This vehicle is equipped with three different shift levers: the gear shift lever, the 2WD-4WD shift lever (KAF620M only) 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 49
    48 GENERAL INFORMATION with a The KAF620M is equipped sub-transmission to allow maximum transmission efficiency. Use the low gearing for maximum torque at low speeds, for climbing hills, pulling a trailer, or keeping constant low speeds for agricultural use. The high gearing raises the speed range
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 50
    GENERAL INFORMATION 49 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 white pulling the stopper as indicated on the label next to the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 51
    50 GENERAL INFORMATION j WARNING If the vehicle should move after it is parked, it might be damaged or cause injury. Be sure to apply the parking brake before leaving the vehicle. Seat The seat can be raised for vehicle maintenance and adjustment. Pull up on the rear edge of the seat. • A. Seat
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 52
    GENERAL INFORMATION 51 Seat Belts The vehicle is equipped with lap-style seat belts for both 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 53
    52 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 seat belt slack could reduce its
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 54
    GENERAL INFORMATION 53 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 55
    operation of a winch could cause an accident resulting in serious injury or death. Do not install or operate a winch without reading and understanding the operator's manual supplied with the winch. A. Trailer Hitch Bracket
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 56
    GENERAL INFORMATION 55 Installing procedure for a winch 1. You can see the bracket attached to a cross -member. j A. Winch Bracket B. Bolt Holes 2. 3. Follow a manual to be supplied by the winch maker for installing the winch and other accessory as necessary. After installing the winch, be sure
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 57
    . 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 58
    HOW TO OPERATE 57 Front Final Gear Case ...Transmission Case Oil ...Coolant ...Throttle ...No oil leaks. Oil level between "H" and "L" lines on the dipstick, no leaks. Coolant level between level lines (when engine is cold), no leaks. Throttle pedal free play 5 ∼ 10 mm (0.2 ∼ 0.4 in.). Throttle
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 59
    58 HOW TO OPERATE Starting the Engine j ○The NOTE DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. the seat belts (
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 60
    HOW TO OPERATE 59 Jump Starting If your vehicle's battery is "run down," it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. Connecting Jumper Cables sure the ignition switch key is turned to • Make "OFF". the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 61
    60 HOW TO OPERATE a jumper cable from the positive (+) ter• Connect minal of the booster battery to the positive (+) terminal of the vehicle battery. DANGER Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive. Do not make this last connection at
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 62
    HOW TO OPERATE 61 Moving Off the brake pedal. • Depress Put the gear shift lever into the "H" (High) or "L" • (Low; KAF620M only) position. Release the parking brake. • Gradually increase engine speed by pressing on • the throttle pedal. Braking ○When the throttle pedal is released completely and
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 63
    62 HOW TO OPERATE Stopping the Engine the throttle pedal completely. • Release Put the gear shift lever into the "N" (Neutral) posi• tion. the parking brake to help prevent the vehicle • Apply from rolling. • Turn the ignition switch key to the "OFF" position. Parking the Mule j WARNING
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 64
    HOW TO OPERATE 63 WARNING Gasoline 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. j A. Parking Brake
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 65
    64 HOW TO OPERATE Hi-Lo Shifting (KAF620M) Shifting to Low Range the vehicle completely. • Stop For easy • neutral. Hi-Lo shifting, put the gear shift lever in • Move the shift lever "L" (Low) position. Shifting to High Range j the vehicle completely. • Stop the gear shift lever in neutral. •
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 66
    HOW TO OPERATE 65 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 (KAF620M)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 67
    66 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 68
    HOW TO OPERATE 67 Shifting to Differential (Unlocked-Axle) Model and hold the stopper, then move the shift lever • Pull all the way up (UN-LOCK). ○When the shift lever is moved, the differential may NOTE not immediately lock or unlock until the vehicle has rolled a short distance. j
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 69
    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.
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 70
    SAFE OPERATION 69 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 71
    70 SAFE OPERATION Turning the Vehicle The vehicle will turn in a smaller radius with the differential unlocked (in differential mode). In this mode, the rear wheels can turn at different speeds allowing the vehicle to turn tighter and more smoothly. Even in this mode, however, avoid sharp turns to
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 72
    SAFE OPERATION 71 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 73
    72 SAFE OPERATION Descending Hills Slow down or stop at the top of a hill so you can pick a straight, safe path for descent to avoid any obstacles. Normally you should descend straight down a hill since driving at an angle could cause the vehicle to lean to one side and possibly tip over. Proceed
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 74
    SAFE OPERATION 73 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 75
    74 SAFE OPERATION Driving through Water Avoid driving through water whenever it is possible. When driving across shallow water, choose a location to enter and exit the water where the banks are not too steep or slippery. Check before entering for rocks, holes or other obstacles which may cause you
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 76
    MAINTENANCE AND ADJUSTMENT 75 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 77
    frequently when operated in mud, dust, or other harsh riding conditions. = Emission Related FREQUENCY First Service OPERATION Regular Service After 50 hrs. Every 250 Every 500 hrs. or 1,000 km hrs. or 5,000 or 10,000 km km (3,000 (6,000 miles) (600 miles) miles)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 78
    MAINTENANCE AND ADJUSTMENT 77 FREQUENCY First Service OPERATION Regular Service After 50 hrs. Every 250 Every 500 hrs. or 1,000 km hrs. or 5,000 or 10,000 km km (3,000 (6,000 miles) (600 miles) miles)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 79
    78 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service OPERATION Regular Service After 50 hrs. Every 250 Every 500 hrs. or 1,000 km hrs. or 5,000 or 10,000 km km (3,000 (6,000 miles) (600 miles) miles)
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 80
    , accident, 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. is necessary to match indent of the dipstick with the mark on the tube to measure the correct amount of oil. j Oil Level Inspection the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 81
    80 MAINTENANCE AND ADJUSTMENT out the dipstick and check the oil level. The • Pull oil level should be between the "F" (Full) and "L" (Low) lines on the dipstick. Oil and/or Oil Filter Change up the engine thoroughly, and then stop the • Warm engine. • Pull up on the rear edge of the seat. j A.
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 82
    MAINTENANCE AND ADJUSTMENT 81 the oil filter is to be changed, first lift the cargo • If bed to support it with the rod, and then remove the oil filter cartridge and replace it with a new one. j A. Drain Plug the vehicle held level, let the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 83
    . NOTE *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. the engine up to the "F" (Full) line on the dip• Fill stick
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 84
    the front and rear tires, with consequent loss of control, accident, and injury. Check the oil level and change the oil according to the owner's manual. j Oil Level Inspection the front final gear case guard by remov• Remove ing the mounting bolts and nuts.
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 85
    84 MAINTENANCE AND ADJUSTMENT the vehicle level front-to-rear and side-to • With -side, remove the filler cap from the front final gear case. j A. Guard B. Nuts (Front Side) A. Front Final Gear Case B. Filler Cap NOTICE Be careful not to allow any dirt or foreign materials to enter the gear case.
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 86
    MAINTENANCE AND ADJUSTMENT 85 Oil Change ○Before draining the oil, warm it up by running the vehicle. Warm oil drains easily and picks up any sediment. the front final gear case guard. • Remove With the vehicle • gear case. level, place an oil pan beneath the • Remove the filler cap and drain plug
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 87
    , and injury. Check the oil level and change the oil according to the owner's manual. • Install the filler cap and gear case guard. Oil Level Inspection the vehicle on level ground. • Park Lift the cargo bed and support it with the rod. • Unscrew the oil filler plug, wipe its dipstick dry, and
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 88
    MAINTENANCE AND ADJUSTMENT 87 out the dipstick and check the oil level. The • Pull oil level should be between the "H" (High) and "L" (Low) lines on the dipstick. j A. Transmission Case B. Oil Filler Plug NOTICE Be careful not to allow any dirt or foreign materials to enter the transmission case.
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 89
    during 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. • ○Before draining the oil, warm it up by running the vehicle. Warm oil drains easily
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 90
    MAINTENANCE AND ADJUSTMENT 89 Transmission Case Oil Type API "GL-5" Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Transmission Case Oil Capacity KAF620M: 2.5 L (2.6 US qt) KAF620P: 2.2 L (2.3 US qt) Cooling System WARNING The cooling system can get extremely hot during normal
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 91
    90 MAINTENANCE AND ADJUSTMENT Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer damage. Check the coolant level each day before operating the vehicle, and replenish coolant if the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 92
    MAINTENANCE AND ADJUSTMENT 91 ○In an emergency you can add water alone to the NOTE coolant reserve tank, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible. NOTICE If coolant must be added often, or the reserve tank completely
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 93
    92 MAINTENANCE AND ADJUSTMENT Spark Plugs The standard spark plug is shown in the table. The spark plug should be taken out periodically in accordance with the Periodic Maintenance Chart for cleaning, inspection, and resetting of the plug gap. If the plugs are oily or have carbon built up on them,
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 94
    MAINTENANCE AND ADJUSTMENT 93 Spark Plug Removal the cargo bed to support it with the rod. • Lift pull the spark plug caps from the spark • Carefully plugs. Valve Clearance Valve and valve seat wear decrease valve clearance,
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 95
    gauge show whether the air cleaner is clogged. Whenever the red band shows in the gauge window, the air filter element should be cleaned. After servicing the air filter element, the restriction gauge should be reset by pushing the button at the end of the gauge. NOTICE A clogged air cleaner may
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 96
    MAINTENANCE AND ADJUSTMENT 95 Element Removal up the snaps and remove the air cleaner hous• Pull ing cap from the housing. NOTICE If dirt gets into the engine, excessive engine and possible engine damage may occur. j A. Air Cleaner Housing B. Cap C. Snaps A. Paper Element the air cleaner
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 97
    96 MAINTENANCE AND ADJUSTMENT 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 pressed air from the inside to the outside (from the Evaporative Emission Control System This
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 98
    MAINTENANCE AND ADJUSTMENT 97 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. • Remove the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 99
    98 MAINTENANCE AND ADJUSTMENT DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. the engine. • Stop Install the drain
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 100
    MAINTENANCE AND ADJUSTMENT 99 Throttle Pedal Play Adjustment the cargo bed and support it with the rod. • Lift and turn the throttle cable mounting nuts • Loosen at the end of the throttle cable. the adjuster until the proper
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 101
    100 MAINTENANCE AND ADJUSTMENT The full throttle pedal stop position can be adjusted to prevent pulling the throttle cable more than required. Remove the cover by unscrewing the bolt. Throttle Pedal Stop Position Adjustment • the locknut. • Loosen in the throttle pedal stop bolt. • Screw the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 the throttle pedal stop bolt until the bolt head • Turn lightly touches the bottom of the throttle pedal. the locknut securely. • Tighten Be sure • smoothly. to check the throttle cable moves Idle Adjustment Idle adjustment is controlled by the ECU and cannot be
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 103
    102 MAINTENANCE AND ADJUSTMENT Fuel Pump Filter The fuel pump filter can become blocked causing fuel pump damage if dirt/mud/debris or contaminated fuel enters the fuel tank. The engine may hesitate or lose power if the fuel pump filter becomes blocked. If you suspect that the fuel filter has
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 105
    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
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | 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 ∼ 10 mm (0.1 ∼ 0.4 in
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 NOTICE Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immediately. Fluid Level Inspection the vehicle on level ground, check that, • With through the inspection hole in the dashboard, the fluid level in the reservoir is between the upper (
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 109
    108 MAINTENANCE AND ADJUSTMENT WARNING Mixing two types and brands of fluid for use in the brake lowers the brake fluid boiling point and could reduce brake effectiveness. Change the fluid in the brake system completely if the fluid level is low but the type and brand of the fluid already in the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 110
    MAINTENANCE AND ADJUSTMENT 109 Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is hard to adjust. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. In accordance with the Periodic Maintenance Chart,
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 111
    110 MAINTENANCE AND ADJUSTMENT the parking brake lever up and to the rear. • Pull 8 to 12 clicks of lever travel, the vehicle • After should not roll while parked. j A. Locknut B. Nut A. 8 ∼ 12 clicks • If it does, adjust the parking brake lever. Adjustment the locknut (upper nut) on the middle
  • 2015 Kawasaki MULE 4000 | 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. The steering wheel position can be adjusted to suit the operator. Loosen the upper and lower nuts on the steering column
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 113
    drop can happen when the engine starts; inspect the battery voltage. Cable harness or connectors may have been disconnected. See an authorized dealer for service. Wheels Rims The rims are a drop-center, tubeless tire design. Take care not to damage the sealing surfaces of the tire or rim when
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 114
    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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 115
    114 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 Seat Belts In accordance with the Periodic Maintenance Chart, check that each seat belt functions properly. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. The click sound shows it is securely latched. Push
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 117
    116 MAINTENANCE AND ADJUSTMENT Headlight Beam the adjusting screw on each headlight rim in • Turn or out to adjust the headlight vertically. • The headlight beams can be adjusted vertically. Remove the holder. j A. Adjusting Screws A. Holder
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 Battery The battery is located under the left end of the seat. • Remove the battery holder. DANGER Battery contains sulfuric acid and produces hydrogen gas. Sulfuric acid can cause burns and hydrogen gas can cause an explosion. Read and heed the battery safety label
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 119
    the three positive cables to the (+) termi• nal, and then connect the negative cable to the (-) terminal. installed in the battery for initial service. It is not necessary to check the battery electrolyte level or add distilled water. However, in order to maximize battery life and ensure that it
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 120
    MAINTENANCE AND ADJUSTMENT 119 Current Drain Days from 100% DischargCharged to 50% ing Ampere Discharged 7 mA 10 mA 15 mA 20 mA 30 mA 60 Days 42 Days 28 Days 21 Days 14 Days Days from 100% Charged to 100% Discharged 119 Days 83 Days 56 Days 42 Days 28 Days Battery Maintenance It is the owner's
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 121
    vehicle, or the electrical system cannot work properly. Make Type East Penn Manufacturing 8U1L ○If you charge the sealed battery, never fail to observe the instructions shown on the label on the battery and charger. NOTE
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 122
    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. A. Fuse Box
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 123
    122 MAINTENANCE AND ADJUSTMENT can check the 40 A fuse if it is blown at the • You top of the fuse. When replacing the fuse, release the bolted leads first. 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 124
    General Lubrication 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. j
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 125
    Where to be Careful j 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 the
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 126
    MAINTENANCE AND ADJUSTMENT 125 Semi-gloss Finish • • • To clean the semi-gloss finish; When washing the vehicle, always use a mild neutral detergent and water. The semi-gloss finish effect may be lost when the finish is excessively rubbed. If any doubt, consult an authorized Kawasaki dealer.
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 127
    oil. • • ○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. WARNING Fuel stabilizers may contain poisonous substances. Heed the manufacturer's warnings for use. the spark plugs and spray fogging oil
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 128
    STORAGE 127 oil on all unpainted metal surfaces to pre• Spray vent rusting. Avoid getting oil on rubber parts or in a cover over the vehicle to keep dust and dirt • Put from collecting on it. Removal from Storage: • • the brakes. Lubricate all the cables as indicated in the General Lubrication
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | 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.
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | 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
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 136
    MAINTENANCE RECORD 135 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 137
    136 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 138
    MAINTENANCE RECORD 137 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 139
    138 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 140
    MAINTENANCE RECORD 139 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki MULE 4000 | Owners Manual - Page 141
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