Owners Manual
Page 8
... to do their Mule, a Service Manual is the result of Kawasaki's engineering expertise and a tradition of course, be competent mechanics and possess the special tools described in the Service Manual. Consumer Products & Machinery Company © 2010 Kawasaki Heavy Industries, Ltd. Jan. 2010. (1). (D, Ke) Keep this Owner's Manual aboard your Mule at the time of a new Kawasaki Mule. FOREWORD Congratulations on their own work should be...
... to do their Mule, a Service Manual is the result of Kawasaki's engineering expertise and a tradition of course, be competent mechanics and possess the special tools described in the Service Manual. Consumer Products & Machinery Company © 2010 Kawasaki Heavy Industries, Ltd. Jan. 2010. (1). (D, Ke) Keep this Owner's Manual aboard your Mule at the time of a new Kawasaki Mule. FOREWORD Congratulations on their own work should be...
Owners Manual
Page 9
... Warning Light ...Parking Brake Warning Light...Power Steering Warning Light...Steering Wheel...Brake Pedal...Cargo Bed ...Fuel Tank ...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Hour Meter ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever ...Differential Shift Lever ...Parking Brake Lever...Seats ...9 11 15 16 19 29 31 31 31 32 33 34 34 35 35 36 36 38 41 41 42 44 44 45 46 47 47 48 48 49 50 Seat Belts ...Throttle...
... Warning Light ...Parking Brake Warning Light...Power Steering Warning Light...Steering Wheel...Brake Pedal...Cargo Bed ...Fuel Tank ...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Hour Meter ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever ...Differential Shift Lever ...Parking Brake Lever...Seats ...9 11 15 16 19 29 31 31 31 32 33 34 34 35 35 36 36 38 41 41 42 44 44 45 46 47 47 48 48 49 50 Seat Belts ...Throttle...
Owners Manual
Page 10
... ...Periodic Maintenance Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Tank Vent...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Power Steering System...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam ...Battery ... 79...
... ...Periodic Maintenance Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Tank Vent...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Power Steering System...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam ...Battery ... 79...
Owners Manual
Page 12
... "N" (neutral) position, 3. In these conditions, Kawasaki recommends that operators and passengers wear a properly fitting D.O.T. This will help prevent injury in the event of your area. Before Starting the Engine Three "musts" before getting out of an accident. Wearing proper protective gear can affect the vehicle's handling characteristics. Respect private property. Operating in motion. Tire Air Pressure Tire inflation and type can make...
... "N" (neutral) position, 3. In these conditions, Kawasaki recommends that operators and passengers wear a properly fitting D.O.T. This will help prevent injury in the event of your area. Before Starting the Engine Three "musts" before getting out of an accident. Wearing proper protective gear can affect the vehicle's handling characteristics. Respect private property. Operating in motion. Tire Air Pressure Tire inflation and type can make...
Owners Manual
Page 13
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) Front Rear 3 305 mm (130.12 in.) 1 486 mm (58.50 in.) 1 925 mm (75.79 in.) 2 165 mm (85.24....39 × 47.72 × 11.30 in.) Short bed mode 770 × 1 212 × 287 (30.31 × 47.72 × 11.30 in.) ENGINE Type Displacement Bore × Stroke Compression Ratio OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 × ...
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) Front Rear 3 305 mm (130.12 in.) 1 486 mm (58.50 in.) 1 925 mm (75.79 in.) 2 165 mm (85.24....39 × 47.72 × 11.30 in.) Short bed mode 770 × 1 212 × 287 (30.31 × 47.72 × 11.30 in.) ENGINE Type Displacement Bore × Stroke Compression Ratio OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 × ...
Owners Manual
Page 14
12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Grade Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5°/750 ∼ 22°/4 000 (BTDC /rpm) NGK BPR2ES Forced lubrication (wet sump) Kawasaki Performance 4-Stroke ATV/UTV Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with API SG, SH, SJ, SL, SM...
12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Grade Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5°/750 ∼ 22°/4 000 (BTDC /rpm) NGK BPR2ES Forced lubrication (wet sump) Kawasaki Performance 4-Stroke ATV/UTV Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with API SG, SH, SJ, SL, SM...
Owners Manual
Page 16
... products meets or exceeds warranty and service requirements and can help to extend the life of your vehicle. Specifications subject to change without notice. 14 SPECIFICATIONS Headlight Tail/Brake Light LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load 603 kg (1 330 lb) Short Bed Mode: 182 kg (400 lb) Long Bed Mode: 363 kg (800 lb) MODEL INFORMATION MULE 4010 TRANS 4 × 4...KAF620R/S 12...
... products meets or exceeds warranty and service requirements and can help to extend the life of your vehicle. Specifications subject to change without notice. 14 SPECIFICATIONS Headlight Tail/Brake Light LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load 603 kg (1 330 lb) Short Bed Mode: 182 kg (400 lb) Long Bed Mode: 363 kg (800 lb) MODEL INFORMATION MULE 4010 TRANS 4 × 4...KAF620R/S 12...
Owners Manual
Page 18
Air Cleaner (Belt Drive Torque Converter) 16. Latch 15. Battery 14. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. 16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6. Handgrip Belt Drive Torque Converter 17.
Air Cleaner (Belt Drive Torque Converter) 16. Latch 15. Battery 14. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. 16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6. Handgrip Belt Drive Torque Converter 17.
Owners Manual
Page 20
Right Glove Compartment 39. Brake Fluid Reserve Tank 43. 44. 45. 46. 47. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light Parking Brake Warning Light 38. Power Steering Warning Light 41. Differential Shift Lever 42. 18 LOCATION OF PARTS 30. 31. 32. 33. 34. 35. 36. FI Warning Light 40. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 37.
Right Glove Compartment 39. Brake Fluid Reserve Tank 43. 44. 45. 46. 47. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light Parking Brake Warning Light 38. Power Steering Warning Light 41. Differential Shift Lever 42. 18 LOCATION OF PARTS 30. 31. 32. 33. 34. 35. 36. FI Warning Light 40. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 37.
Owners Manual
Page 21
LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Load) Warning (Cargo Bed) Warning (Refueling) Warning (Rear Seat Capacity) Warning (Cargo Bed) Warning (Trailer-Towing Bracket) Warning (Hot Surfaces) Important Engine Information Specification Information (Front Hood) Important Emission Information Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Warning (Pinching Fingers: both sides) Important Information (Tires/Max.
LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Load) Warning (Cargo Bed) Warning (Refueling) Warning (Rear Seat Capacity) Warning (Cargo Bed) Warning (Trailer-Towing Bracket) Warning (Hot Surfaces) Important Engine Information Specification Information (Front Hood) Important Emission Information Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Warning (Pinching Fingers: both sides) Important Information (Tires/Max.
Owners Manual
Page 31
... The front body work and fenders are personally responsible for your vehicle be securely anchored. LOADING INFORMATION 29 LOADING INFORMATION WARNING Incorrect loading, improper installation or use on Kawasaki utility vehicles. Before you operate it, make the vehicle difficult to your own safety and the safety of gravity. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design...
... The front body work and fenders are personally responsible for your vehicle be securely anchored. LOADING INFORMATION 29 LOADING INFORMATION WARNING Incorrect loading, improper installation or use on Kawasaki utility vehicles. Before you operate it, make the vehicle difficult to your own safety and the safety of gravity. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design...
Owners Manual
Page 37
.... Do not tamper with an electrical power steering system. Power Steering Warning Light NOTE żIf the warning light does not go on board, contact an authorized dealer. See a dealer for inspection. Steering Wheel This vehicle is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected. A. The steering wheel position can be adversely affected and...
.... Do not tamper with an electrical power steering system. Power Steering Warning Light NOTE żIf the warning light does not go on board, contact an authorized dealer. See a dealer for inspection. Steering Wheel This vehicle is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected. A. The steering wheel position can be adversely affected and...
Owners Manual
Page 41
... securely. Do not smoke. Operating problems that result from any appliance with a minimum Antiknock Index of low quality or not meeting standard industry specifications may not be explosive under warranty. After refueling, make sure the tank cap is important. Fuel Requirements: Fuel Type This vehicle is certified to the top. Turn the ignition switch to reduce exhaust emissions. Use clean, fresh unleaded...
... securely. Do not smoke. Operating problems that result from any appliance with a minimum Antiknock Index of low quality or not meeting standard industry specifications may not be explosive under warranty. After refueling, make sure the tank cap is important. Fuel Requirements: Fuel Type This vehicle is certified to the top. Turn the ignition switch to reduce exhaust emissions. Use clean, fresh unleaded...
Owners Manual
Page 47
... starter will overheat and the battery power will need the key number to recover power. NOTE żThe vehicle is equipped with the key is a key number, which is stamped on the key itself. It's possible the Upon release, key will return to the starter can be used for the battery to have a duplicate made. Do not turn the ignition switch key to the "START" position with the engine running...
... starter will overheat and the battery power will need the key number to recover power. NOTE żThe vehicle is equipped with the key is a key number, which is stamped on the key itself. It's possible the Upon release, key will return to the starter can be used for the battery to have a duplicate made. Do not turn the ignition switch key to the "START" position with the engine running...
Owners Manual
Page 58
... engine is minimal, and habitual performance of these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for cuts, cracks, damage, or excessive wear. Always perform daily safety checks before operation. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. j WARNING Failure to a safe operating condition. Fuel ...Enough fuel in the window. Air Cleaner ...Check the restriction gauge...
... engine is minimal, and habitual performance of these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for cuts, cracks, damage, or excessive wear. Always perform daily safety checks before operation. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. j WARNING Failure to a safe operating condition. Fuel ...Enough fuel in the window. Air Cleaner ...Check the restriction gauge...
Owners Manual
Page 86
... 5,000 km (3,000 (600 miles) miles) of use of use j CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect Front final gear case oil and transmission case oil-change* 1 year D • D • D •...
... 5,000 km (3,000 (600 miles) miles) of use of use j CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect Front final gear case oil and transmission case oil-change* 1 year D • D • D •...
Owners Manual
Page 98
... burns. Dispose of used oil properly. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) 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 2.5 L (2.6 US qt) j WARNING Oil on tires can make them with its gasket. 96 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an...
... burns. Dispose of used oil properly. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) 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 2.5 L (2.6 US qt) j WARNING Oil on tires can make them with its gasket. 96 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an...
Owners Manual
Page 118
...; Turn the ignition switch to adjust. NOTICE To avoid damaging the electrical connections inside the switch, be inspected in .) of pedal travel. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is depressed, the brake light goes on after about 10 mm (0.4 in accordance with the Periodic Maintenance Chart. The brake light should be sure that the switch body does...
...; Turn the ignition switch to adjust. NOTICE To avoid damaging the electrical connections inside the switch, be inspected in .) of pedal travel. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is depressed, the brake light goes on after about 10 mm (0.4 in accordance with the Periodic Maintenance Chart. The brake light should be sure that the switch body does...
Owners Manual
Page 135
... rear seat - if water gets into the spark plug caps, it has been splashed with sea water or exposed to keep water off the following places. j Where to be wiped dry. Muffler rear opening with tape. Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the spark. When this vehicle. Power Steering System - Ignition switch - cover with the Periodic Maintenance Chart, have dried out. if water...
... rear seat - if water gets into the spark plug caps, it has been splashed with sea water or exposed to keep water off the following places. j Where to be wiped dry. Muffler rear opening with tape. Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the spark. When this vehicle. Power Steering System - Ignition switch - cover with the Periodic Maintenance Chart, have dried out. if water...
Owners Manual
Page 139
...;Engine oil low No Power Engine overheated żToo much idling or low speed running (not enough air flow) żOverloaded żWrong spark plug żRadiator clogged żCoolant level too low żCoolant deteriorated żCooling fan breaker functioned żEngine oil low Compression leakage żValve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel • j running (not Power Steering Won't Work functioned to prevent overheating. • ECU Fuse failed • Battery...
...;Engine oil low No Power Engine overheated żToo much idling or low speed running (not enough air flow) żOverloaded żWrong spark plug żRadiator clogged żCoolant level too low żCoolant deteriorated żCooling fan breaker functioned żEngine oil low Compression leakage żValve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel • j running (not Power Steering Won't Work functioned to prevent overheating. • ECU Fuse failed • Battery...