Owners Manual
Page 8
... part of printing. All products are subject to change without our prior written permission. This publication includes the latest information available at all times so that you can refer to do their Mule, a Service Manual is the result of Kawasaki's engineering expertise and a tradition of a new Kawasaki Mule. Motorcycle & Engine Company © 2011 Kawasaki Heavy Industries, Ltd. It is available for...
... part of printing. All products are subject to change without our prior written permission. This publication includes the latest information available at all times so that you can refer to do their Mule, a Service Manual is the result of Kawasaki's engineering expertise and a tradition of a new Kawasaki Mule. Motorcycle & Engine Company © 2011 Kawasaki Heavy Industries, Ltd. It is available for...
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
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... ...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
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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 a 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 and...
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 a 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 and...
Owners Manual
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Specifications subject to change without notice. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your vehicle. 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...
Specifications subject to change without notice. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your vehicle. 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...
Owners Manual
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Belt Drive Torque Converter 17. Latch 15. Battery 14. 16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Handgrip Air Cleaner (Belt Drive Torque Converter) 16. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12.
Belt Drive Torque Converter 17. Latch 15. Battery 14. 16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Handgrip Air Cleaner (Belt Drive Torque Converter) 16. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12.
Owners Manual
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FI Warning Light 40. 18 LOCATION OF PARTS 30. 31. 32. 33. 34. 35. 36. Right Glove Compartment 39. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light Differential Shift Lever 42. Brake Fluid Reserve Tank 43. 44. 45. 46. 47. Parking Brake Warning Light 38. Power Steering Warning Light 41. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 37.
FI Warning Light 40. 18 LOCATION OF PARTS 30. 31. 32. 33. 34. 35. 36. Right Glove Compartment 39. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light Differential Shift Lever 42. Brake Fluid Reserve Tank 43. 44. 45. 46. 47. Parking Brake Warning Light 38. Power Steering Warning Light 41. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 37.
Owners Manual
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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 LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Warning (Pinching Fingers: both sides) Important Information (Tires/Max.
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 LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 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
...; • NOTE żKawasaki Parts and Accessories have followed these instructions. Do not carry cargo on the vehicle's center of gravity. NOTICE The front body work and fenders are personally responsible for your own safety and the safety of others. Cargo should be securely anchored. Cargo weight should be equally distributed from side to steer and may affect vehicle handling in carrying cargo...
...; • NOTE żKawasaki Parts and Accessories have followed these instructions. Do not carry cargo on the vehicle's center of gravity. NOTICE The front body work and fenders are personally responsible for your own safety and the safety of others. Cargo should be securely anchored. Cargo weight should be equally distributed from side to steer and may affect vehicle handling in carrying cargo...
Owners Manual
Page 37
.... Steering Wheel This vehicle is in one second if the system is equipped with an electric power steering system. GENERAL INFORMATION 35 j Power Steering Warning Light The power steering warning light will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer to have the system checked. The system does not require regular maintenance by users. NOTE żThe power steering system functions only when engine is running. ż...
.... Steering Wheel This vehicle is in one second if the system is equipped with an electric power steering system. GENERAL INFORMATION 35 j Power Steering Warning Light The power steering warning light will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer to have the system checked. The system does not require regular maintenance by users. NOTE żThe power steering system functions only when engine is running. ż...
Owners Manual
Page 41
... of a higher octane rating. Operating problems that result from any appliance with a minimum Antiknock Index of fuel oxygenates approved for serious burns. Fuel Requirements: Fuel Type This vehicle is certified to operate on the fuel tank, wipe it can be covered under certain conditions, creating the potential for use in unleaded gasoline by the U.S. GENERAL INFORMATION 39 WARNING Gasoline is extremely flammable...
... of a higher octane rating. Operating problems that result from any appliance with a minimum Antiknock Index of fuel oxygenates approved for serious burns. Fuel Requirements: Fuel Type This vehicle is certified to operate on the fuel tank, wipe it can be covered under certain conditions, creating the potential for use in unleaded gasoline by the U.S. GENERAL INFORMATION 39 WARNING Gasoline is extremely flammable...
Owners Manual
Page 47
... your key number here. START NOTICE Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will return to let it cool and for the ignition switch, and one spare key. It's possible the All electrical circuits off . Upon release, key will drop temporarily. Included with the key is a key number, which is equipped with the engine running...
... your key number here. START NOTICE Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will return to let it cool and for the ignition switch, and one spare key. It's possible the All electrical circuits off . Upon release, key will drop temporarily. Included with the key is a key number, which is equipped with the engine running...
Owners Manual
Page 58
... time required is cold), no leaks. j WARNING Failure to a safe operating condition. Check for the red band in serious damage or an accident. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Tires ...Air pressure (when cold): Front Rear 69 kPa (0.7 kgf/cm², 10 psi) 167 kPa (1.7 kgf/cm², 24 psi) Check for the action required to return the vehicle to perform...
... time required is cold), no leaks. j WARNING Failure to a safe operating condition. Check for the red band in serious damage or an accident. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Tires ...Air pressure (when cold): Front Rear 69 kPa (0.7 kgf/cm², 10 psi) 167 kPa (1.7 kgf/cm², 24 psi) Check for the action required to return the vehicle to perform...
Owners Manual
Page 60
the seat belts (both operator and passen• Wear ger). the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in enclosed areas. vehicle is in a well-ventilated area. 58 HOW TO OPERATE Starting the Engine NOTE żThe j DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Operate only in the "H" (High) , "L" (Low...
the seat belts (both operator and passen• Wear ger). the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in enclosed areas. vehicle is in a well-ventilated area. 58 HOW TO OPERATE Starting the Engine NOTE żThe j DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Operate only in the "H" (High) , "L" (Low...
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
... tires or rims. Clean off any oil that inadvertently gets on the dipstick with a new one. Tighten it with its gasket. To avoid a serious burn, never touch a hot muffler or exhaust pipe during normal operation and cause serious burns. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. 96 MAINTENANCE AND ADJUSTMENT WARNING The exhaust...
... tires or rims. Clean off any oil that inadvertently gets on the dipstick with a new one. Tighten it with its gasket. To avoid a serious burn, never touch a hot muffler or exhaust pipe during normal operation and cause serious burns. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. 96 MAINTENANCE AND ADJUSTMENT WARNING The exhaust...
Owners Manual
Page 118
... 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.) of pedal travel. NOTICE To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. A. Inspection j • • Turn the ignition switch to adjust. Brake...
... 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.) of pedal travel. NOTICE To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. A. Inspection j • • Turn the ignition switch to adjust. Brake...
Owners Manual
Page 135
... the general lubrication performed by an authorized Kawasaki dealer or perform it referring to the Service Manual for Washing Before washing, precautions must be wiped dry. Air cleaner intake (middle of your vehicle, wash it down immediately after it has been splashed with a plastic bag. Horn button - Under the rear seat - if water gets into the ignition coils or into the brake drums, they may...
... the general lubrication performed by an authorized Kawasaki dealer or perform it referring to the Service Manual for Washing Before washing, precautions must be wiped dry. Air cleaner intake (middle of your vehicle, wash it down immediately after it has been splashed with a plastic bag. Horn button - Under the rear seat - if water gets into the ignition coils or into the brake drums, they may...
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...