2009 Kawasaki MULE 4010 4x4 Owners Manual

2009 Kawasaki MULE 4010 4x4 Manual

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  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 1
  • 2009 Kawasaki MULE 4010 4x4 | 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.
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 3
    or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. żThe KAF620N is identical to the
  • 2009 Kawasaki MULE 4010 4x4 | 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. 1.
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 5
    the owner of this vehicle, you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have provided
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 6
    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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 7
    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...
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 8
    Nuts...Tires ...Joint Boots...Seat Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System...Breaker...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE... 87 89 91 91 94 94 96 99 99 100 101 103 103 106 107 108 109 110 110 110 110 112 113 113
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 9
    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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 10
    BASIC SAFE DRIVING 9 Wearing Seat Belt Both the operator and passenger should wear the seat belts whenever the vehicle is operated. This will reduce the severity of injury in case of a sudden stop or collision. Also, to reduce chance of injury, always keep arms and legs inside the cab frame while
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 11
    10 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance 47 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2 ft) 2 persons 3 005
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    SPECIFICATIONS 11 Compression Ratio Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil 10.3 : 1 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5°/750 ∼ 22°/4 000 (BTDC
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 13
    12 SPECIFICATIONS Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Castor Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light LOAD
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 14
    SPECIFICATIONS 13 Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load (M): KAF620M : California model only Specifications subject to change without notice. 603 kg (1 330 lb) 363 kg (800 lb) (N): KAF620N (P): KAF620P
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 15
    14 SERIAL NUMBER LOCATIONS 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 16
    LOCATION OF PARTS 15 LOCATION OF PARTS 1. 2. 3. 4. 5. 6. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Seat 7. 8. 9. 10. 11. 12. Seat Belts Cargo Bed Front Bumper Radiator Parking Brake Battery 13. Latch 14. Air Cleaner (Belt Drive Torque Converter) 15. Belt
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    16 LOCATION OF PARTS 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. 26. 27. 28. Fuel Tank Fuel Tank Cap Fuel Gauge Air Cleaner
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    LOCATION OF PARTS 17 29. 30. 31. 32. 33. 34. 35. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Parking Brake Warning Light 37. Right Glove Compartment 38. FI Warning Light 39. Power Steering Warning Light 40.
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    18 LOCATION OF LABELS LOCATION OF LABELS 1. Warning (Off-Highway Utility Vehicle) 2. Warning (Front Cargo Hood) 3. Caution (Shifting) 4. Specification 5. Warning (General) 6. Important Information (Tires/Max. Load) 7. Warning (Cargo Bed) 8. Cargo Bed Information 9. Warning (Hot Surfaces) 10.
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    LOCATION OF LABELS 19
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    20 LOCATION OF LABELS (1) (2) (3) (4) (KAF620M) (4) (KAF620N)
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    LOCATION OF LABELS 21 (4) (KAF620P)
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    22 LOCATION OF LABELS (5)
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    LOCATION OF LABELS 23 (6) (KAF620M/N/P) (8) (9) (7)
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    24 LOCATION OF LABELS (10)
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    LOCATION OF LABELS 25 (11) (12) (13)
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    26 LOCATION OF LABELS (14) (16) California model only (15)
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    the vehicle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has front body work and fenders are not designed to carry cargo or to support your weight. They may break. Because any vehicle is sensitive to
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 29
    28 LOADING INFORMATION Always subtract trailer tongue weight from the • Maximum Load capacity. Refer to the "Trailer Hitch Bracket" section in the "General Information" chapter. Maximum Load Weight of operator, passenger, and cargo must not exceed 603 kg (1 330 lb). vehicle is not designed to carry
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 30
    GENERAL INFORMATION 29 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 31
    30 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 32
    GENERAL INFORMATION 31 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. CAUTION If the engine oil
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 33
    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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 34
    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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 35
    34 GENERAL INFORMATION j Brake Pedal The brake pedal is the left pedal on the foot board. Depress the pedal to slow or stop the vehicle. Cargo Bed For loading and unloading, the tail gate of the cargo bed can be opened. Raise the latch handles at each end of the tail gate and slide both latches
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 36
    GENERAL INFORMATION 35 the handgrips. Support the bed in the tilted position with the rod. j A. Supporting Rod A. Latch B. Handgrip CAUTION Do not carry more than the maximum load stated here in the cargo bed. Maximum Load: 363 kg (800 lb)
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 37
    36 GENERAL INFORMATION j WARNING Overloading or improper use of the cargo bed can cause changes in handling which can lead to an accident. Follow guidelines provided in the "LOADING INFORMATION" chapter. Passengers riding in the cargo bed can be tossed about or even thrown out causing serious
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 38
    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 standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 39
    the fuel tank and carburetors. See the "STORAGE" chapter in this manual. CAUTION Avoid using blends of unleaded gasoline and methanol (wood alcohol) gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 40
    GENERAL INFORMATION 39 j 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 the empty mark (red line) , refuel at the earliest opportunity. Glove Compartment A glove compartment is provided at the each end of the dashboard
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 41
    40 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. A. Right Glove Compartment A. Front
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 42
    GENERAL INFORMATION 41 j A. Latch Release Knob A. Push here B. Latches żWhen the hood is hard to open, pull and lift up the front hood center portion with pulling the knob to open the front hood. NOTE WARNING An open front cargo hood can distract or impair visibility of the operator, causing
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 43
    42 GENERAL INFORMATION j Horn Button A car type horn button is provided on the center of the steering wheel. Push the horn button to sound the horn. 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. Horn
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 44
    GENERAL INFORMATION 43 OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. 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" position. you need,
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 45
    44 GENERAL INFORMATION j Hour Meter The hour meter shows the total hours that the vehicle has been operated. This meter cannot be reset. Shift Levers This vehicle is equipped with three different shift levers: the gear shift lever, the 2WD-4WD shift lever (KAF620M/N only) and the differential
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 46
    GENERAL INFORMATION 45 at low speeds, for climbing hills, pulling a trailer, or keeping constant low speeds for agricultural use. The high gearing raises the speed range for ordinary off-highway use. Stop the vehicle before moving the Hi-Lo shift lever. j CAUTION Use of the high range for heavy
  • 2009 Kawasaki MULE 4010 4x4 | 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
  • 2009 Kawasaki MULE 4010 4x4 | 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 49
    48 GENERAL INFORMATION j Seat The seat can be raised for vehicle maintenance and adjustment. Pull up on the rear edge of the seat. Seat Belts The vehicle is equipped with lap-style seat belts both for the operator and passenger. Always wear the seat belts when operating and riding in the vehicle.
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 50
    GENERAL INFORMATION 49 To wear the seat belt properly, follow this procedure: 1. Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted. 2. Push the latch plate into the buckle until it clicks. 3. Adjust the seat belt for a SNUG FIT. j WARNING
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    50 GENERAL INFORMATION To unfasten the belt, press the red button in the buckle. 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 52
    GENERAL INFORMATION 51 j Trailer Hitch Bracket This vehicle is equipped with a bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, observe the following precautions: WARNING Never carry a passenger in a trailer. Never load
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 53
    for a winch 1. Remove the front bumper cover screws, and front bumper cover. WARNING Do not operate or install winch without reading and understanding the operators manual supplied with the winch. A. Front Bumper Cover B. Screws
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    four bolts. 3. You can see the bracket attached to a cross -member. j A. Front Bumper B. Bolts C. Winch Bracket A. Winch Bracket B. Bolt Holes 4. 5. 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
  • 2009 Kawasaki MULE 4010 4x4 | 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 every day before operation
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 56
    HOW TO OPERATE 55 Throttle ...Throttle pedal free play 5 ∼ 10 mm (0.2 ∼ 0.4 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 57
    56 HOW TO OPERATE Starting the Engine j WARNING Never run the vehicle in a closed area, such as a garage. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. the seat belts (both operator
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 58
    HOW TO OPERATE 57 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. the cover under the left end of the front • Remove seat. j WARNING Battery acid
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    58 HOW TO OPERATE WARNING 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 making this last connection. Do not connect to a frozen battery. It could explode. Do not reverse polarity
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 60
    HOW TO OPERATE 59 Moving Off Depress the brake pedal. • Put the gear shift lever into the "H" (High) or "L" • (Low; KAF620M/N only) position. the parking brake. • Release Gradually engine speed by pressing on • the throttleincrease pedal. Braking j żWhen the throttle pedal is released completely
  • 2009 Kawasaki MULE 4010 4x4 | 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 • Stop the
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 62
    HOW TO OPERATE 61 the ignition switch key to prevent unau• Remove thorized use. parking inside a garage or other structure, • When be sure the structure is well ventilated and the vehicle is not close to any source of flame or sparks. This includes any appliance with a pilot light. Hi-Lo Shifting (
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 63
    62 HOW TO OPERATE Shifting to High Range the vehicle completely. • Stop the gear shift lever in neutral. • Put • Move the shift lever "H" (High) position. Reversing Gears the throttle pedal, and stop the vehicle. • Release When you want to operate the vehicle in reverse, • stop the vehicle
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 64
    HOW TO OPERATE 63 2WD-4WD Shifting (KAF620M/N) the stopper under the 2WD-4WD shift lever • Pull knob and while holding it against the knob, move shift back into "2WD" position, pull and hold the • To stopper, then move the shift lever all the way up "2WD". the shift lever to the all way down "4WD".
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 65
    64 HOW TO OPERATE Shifting the Differential j żDo 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
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    your vehicle may result in an unsafe operating condition. Before operation, make sure that the vehicle is not overloaded and that you have followed the instructions in the "Loading Information" chapter.
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 67
    66 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 68
    SAFE OPERATION 67 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 69
    68 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 70
    SAFE OPERATION 69 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 71
    70 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 72
    SAFE OPERATION 71 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 73
    72 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the Mule in good running condition. The initial maintenance is vitally important and
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    more frequently when operated in mud, dust, or other harsh riding conditions. = Emission Related FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use j OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    74 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use D OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    MAINTENANCE AND ADJUSTMENT 75 FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
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    76 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 500 hrs. or 10,000 km (6,000 miles) of use OPERATION After 50 hrs. Every 250 or 1,000 km hrs. or 5,000 km (3,000 (
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 78
    MAINTENANCE AND ADJUSTMENT 77 Engine Oil In order for the engine to function properly, maintain the engine oil at the proper level, and change the oil and oil filter in accordance with the Periodic Maintenance Chart. Not only do dirt and metal particles collect in the oil, but the oil itself loses
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    . Contact your local authorities for approved disposal methods or possible recycling. 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. • Install the filler cap. Oil and/or Oil
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    MAINTENANCE AND ADJUSTMENT 79 j A. Cartridge A. Packing a thin film of oil to the packing and screw the • Apply cartridge in until the packing touches the engine, then turn it 3/4 turn. the drain plug with its gasket. Tighten it to • Install the specified torque. Tightening Torque Drain Plug:
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    80 MAINTENANCE AND ADJUSTMENT Recommended Engine Oil Capacity Grade: API SF or SG class API SH, SJ or SL with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 j żDo not add any chemical additive to the oil. NOTE Oils fulfilling the above requirements are fully formulated and provide adequate
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 82
    MAINTENANCE AND ADJUSTMENT 81 Front Final Gear Case Oil (KAF620M/N) In order for the differential, pinion, and ring gears to function properly, check the oil level and change the oil in accordance with the Periodic Maintenance Chart. WARNING Vehicle operation with insufficient, deteriorated, or
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    82 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. B. C. D. A. Front Final Gear Case B. Filler Cap Front Final Gear Case Filler Opening Bottom Thread Drain Plug CAUTION Be careful not to allow any
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 84
    MAINTENANCE AND ADJUSTMENT 83 Oil Change WARNING NOTE When draining or filling the gear case, be careful that no oil gets on the tires or rims. Oil on tires can make them slippery which can cause an accident and injury. Clean off any oil that inadvertently gets on them with soap and water. the oil
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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 rod. • Unscrew the oil filler plug, wipe its dipstick dry, and • insert it into the filler hole but DO NOT SCREW IT
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    . NOTE A. Transmission Case B. Drain Plug WARNING To avoid a serious burn, never touch a hot muffler or exhaust pipe during oil draining. • Lift the cargo bed and support it with the rod.
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    86 MAINTENANCE AND ADJUSTMENT • Remove the filler plug. WARNING When draining or filling the transmission case, be careful that no oil gets on the tires or rims. Oil on tires can make them slippery which can cause an accident and injury. Clean off any oil that inadvertently gets on them with soap
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 88
    MAINTENANCE AND ADJUSTMENT 87 Cooling System WARNING Do not touch the radiators when they are hot, nor open the radiator caps. Hot coolant inside will cause you severe burns. Radiator and Cooling Fan Check and clean the screen and radiator fins for obstruction by insects or mud in accordance with
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 89
    88 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 90
    MAINTENANCE AND ADJUSTMENT 89 żIn an emergency you can add water alone to the coolant reserve tank, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible. CAUTION If coolant must be added often, or the reserve tank completely runs dry
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 91
    90 MAINTENANCE AND ADJUSTMENT Spark Plug Removal the cargo bed to support it with the rod. • Lift pull the spark plug caps from the spark • Carefully plugs. j Spark Plug Standard Plug Plug Gap NGK BPR2ES 0.7 ∼ 0.8 mm (0.028 ∼ 0.
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 92
    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.
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 93
    92 MAINTENANCE AND ADJUSTMENT j A. Air Filter Restriction Gauge Element Removal A. Air Cleaner Housing B. Cap C. Snaps up the snaps and remove the air cleaner hous• Pull ing cap from the housing. the air cleaner element out of the housing. • Pull a clean, lint-free towel into the air cleaner •
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    MAINTENANCE AND ADJUSTMENT 93 CAUTION If dirt gets into the engine, excessive engine and possible engine damage may occur. away the remaining dust by applying com• Blow pressed air from the inside to the outside (from the • • clean side to the dirty side). Inspect the element material for damage
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 95
    the "Periodic Maintenance Chart". Spark Arrester This vehicle is equipped with a spark arrester approved for off-highway use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. Clean the spark arrester in accordance with the Periodic Maintenance Chart. j CAUTION
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 96
    MAINTENANCE AND ADJUSTMENT 95 WARNING Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. the engine. • Stop • Install the drain plug. j A. Spark
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 97
    pedal does not return properly, check the throttle cable routing, pedal free play, and cable damage. Then lubricate the throttle cable. the cargo bed and support it with the rod. • Lift Loosen and turn the throttle cable mounting nuts • at the end of the throttle cable. Slide the adjuster until the
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 98
    MAINTENANCE AND ADJUSTMENT 97 • Remove the cover by unscrewing the bolt. j A. Throttle Cable B. Mounting Nuts • Tighten the mounting nuts securely. Throttle Pedal Stop Position Adjustment The full throttle pedal stop position can be adjusted to prevent pulling the throttle cable more than
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 99
    98 MAINTENANCE AND ADJUSTMENT j A. Pully (Fully Opened Position) B. Stopper the throttle pedal stop bolt until the bolt head • Turn lightly touches the bottom of the throttle pedal. the locknut securely. • Tighten sure to check the throttle cable moves • Be smoothly. A. Throttle Pedal B. Locknut
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 100
    MAINTENANCE AND ADJUSTMENT 99 Idle Adjustment Idle adjustment is controlled by the ECU and cannot be adjusted. If the idle speed is unstable, have your dealer inspect the throttle body. Specified Idle Speed: 950 ±50 rpm Fuel Tank Vent The fuel tank vent hoses must be routed as specified. The
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 101
    100 MAINTENANCE AND ADJUSTMENT 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 Belt Drive Torque Converter Air Cleaner A clogged belt drive torque converter air cleaner may cause the torque converter to malfunction. CAUTION A clogged air cleaner may allow dirt and dust to enter the belt drive torque converter causing excessive wear of the inner
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 103
    102 MAINTENANCE AND ADJUSTMENT CAUTION If dirt gets into the belt drive torque converter, excessive wear and loss of driving power may result. away the remaining dust by applying com• Blow pressed air from the inside to the outside (from the • clean side to the dirty side). Inspect the element
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 104
    MAINTENANCE AND ADJUSTMENT 103 Brakes The vehicle is equipped with hydraulically activated drum brakes on all four wheels. Brake Pedal the brake pedal has more or less free play • If than specified or the pedal action feels rough or "catchy," have the brake system inspected immediately by an
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 105
    104 MAINTENANCE AND ADJUSTMENT WARNING Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not mix two types and brands of fluid for use in the brakes. This lowers the brake fluid boiling point and could reduce brake
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 106
    lines or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, have the brake system serviced immediately. j A. Cap Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. A. Brake Fluid Reservoir B. Upper Level Line (MAX) C. Lower
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 107
    106 MAINTENANCE AND ADJUSTMENT Brake Light Switch When the brake pedal is depressed, the brake light goes on. The brake light switch should be inspected in accordance with the Periodic Maintenance Chart. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 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. 8 to 12 clicks of lever travel, the vehicle • After should not roll while
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 109
    108 MAINTENANCE AND ADJUSTMENT Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for the specified free play and smooth operation. Free Play Inspection j A. Locknut B. Nut the vehicle on level ground. • Park Lightly turn the steering wheel left and right
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 110
    happen when the engine starts; inspect the battery voltage. Cable harness or connectors may have been disconnected. See an authorized dealer for service. j żIf the steering becomes irregular or unusual for NOTE A. Steering Column Bracket B. Nuts any reason other than above, have an authorized
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 111
    change or impair the handling of the vehicle. żInstallation of tubeless tires on rims requires compressed air and is normally recommended as a dealer service operation. Nevertheless, a tube can be inserted into the tire by the operator as an emergency repair. Maximum Tire Air Pressure for Seating
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 112
    MAINTENANCE AND ADJUSTMENT 111 WARNING Inflate both front tires to the same pressure and both rear tires to the same pressure. Operating with unequally or improperly pressurized tires can adversely affect steering or handling. Minimum Tread Depth: 3 mm (0.12 in.) inspect the tire for cracks and
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 113
    112 MAINTENANCE AND ADJUSTMENT Joint Boots In accordance with the Periodic Maintenance Chart, inspect the joint boots on the front axles, tie rod ends, steering knuckles, and rear axle shafts for cracks, holes, damage or deterioration. If there is any one of them, have the joint boot replaced by an
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 114
    MAINTENANCE AND ADJUSTMENT 113 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 115
    114 MAINTENANCE AND ADJUSTMENT Battery The battery is located under the left end of the seat. WARNING Heed the battery safety label shown here. j A. Adjusting Screws Battery Removal • Remove the cover under the front seat left end.
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 j A. Cover • Remove the battery holder. A. Holder B. (+) Terminal C. (-) Terminal the cables from the battery, first from • Disconnect the (-) terminal and then the (+) terminal. żThere is no need to separate the smaller cables clamped with the main battery
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 117
    a sealed type, and the sealing strip should not be removed at any time after the specified electrolyte has been 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 Current Drain (Y50-N18L-A) 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
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 119
    the wiring harness and electrical equipment for bare wires or other possible causes. j żIf you charge the sealed battery, never fail to observe the instructions shown on the label on the battery and charger. NOTE CAUTION Do not use a fuse of a higher capacity than the specified fuse rating, or
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 120
    blown, steering becomes heavy. Replace the blown fuse with a fuse of the same specific amperage and type. If a replaced fuse blows again, there can be trouble with the ECU or harness/connectors. See an authorized dealer for inspection. You can check the 40 A fuse if it is blown at the top
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 121
    120 MAINTENANCE AND ADJUSTMENT Breaker The breaker for the radiator fan is located under the seat near the fuse box. If the fan does not function, inspect the breaker. In order to reset the breaker, push the button at the side of the breaker case. Before resetting, however, check that the radiator
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 122
    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. Cleaning To prolong the life of your vehicle, wash it down immediately after it has been splashed with sea water
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 123
    122 MAINTENANCE AND ADJUSTMENT CAUTION Coin operated, high pressure spray washers are not recommended. Water may be forced into bearings and other components causing eventual failure from rust and corrosion. Some soaps are highly alkaline and may leave a residue or cause spotting. Bolt and Nut
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 124
    engine oil. • • żAs 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 WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 125
    124 STORAGE oil on all unpainted metal surfaces to pre• Spray vent rusting. Avoid getting oil on rubber parts or in all the cables as indicated in the General • Lubricate Lubrication section. the battery, and store it where it will not • Remove be exposed to direct sunlight, moisture, or freezing
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 126
    TROUBLESHOOTING GUIDE 125 TROUBLESHOOTING GUIDE • • • Engine Cranks, But Won't Start fuel in tank • No Water in fuel • Air filter clogged or inlet blocked • Engine flooded • Fuel tank vent clogged • Spark
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 127
    receipt of your correspondence we will contact the dealership and work with them in resolving your problem. In order to provide a permanent record, all warranty and service resolutions take place only through written correspondence. Please send your correspondence to: CONSUMER RELATIONS KAWASAKI
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 128
    ENVIRONMENTAL PROTECTION 127 ENVIRONMENTAL PROTECTION To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 129
    128 MAINTENANCE RECORD MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Traveled Distance Maintenance Performed
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 130
    MAINTENANCE RECORD 129 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 131
    130 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 132
    MAINTENANCE RECORD 131 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 133
    132 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 134
    MAINTENANCE RECORD 133 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 | Owners Manual - Page 135
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