Home

Mule4010Trans4x4CAMO..

1. FREQUENCY Whichever First Service Regular Service comes first After 50 hrs Every 250 Every 500 or 1 000 km hrs or 5 000 OPERATION i 600 miles km 3 000 nies Every of use miles of use Bt URE Brake fluid change 2 years D Brake master cylinder cup and dust seal 2 years D replace Brake wheel cylinder assembly replace 2 years D Brake hose replace 4 years D Engine Oil In order for the engine to function properly main tain the engine oil atthe proper level and change the oil and oil filter in accordance with the Periodic Main tenance Chart Not only do dirt and metal particles collect in the oil but the oil itself loses its lubricative quality if used too long A WARNING Vehicle operation with insufficient deterio rated or contaminated engine oil will cause accelerated wear and may result in engine seizure 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 Oil Level Inspection e If the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil reaches ev ery part can cause engine damage e If the vehicle has just been used wait several min utes for all the oil to drain do
2. 9 11 SERIAL NUMBER 15 LOCATION OF PARTS 16 LOCATION OF LABELS 19 LOADING 30 GENERAL INFORMATION 32 Lighting Electrical Accessory Connector 32 Liglit SWItCI 32 Coolant Temperature Warning Light 33 Oil Pressure Warning Light 34 Fuel Injection Warning Light 35 Parking Brake Warning Light 35 Power Steering Warning Light 36 Steering Wheel sss 36 Brake Pedal esses 37 Converting Rear Seat and Cargo Bed 37 From 4 person to 2 37 From 2 person to 4 person Mode 40 Cargo Bed ciel uie sedes 41 rend 41 Loading Cargo 41 Raising amp Lowering the Cargo Bed 42 Fuel Tank ose ere ebbe 46 Glove 49 Front Cargo Compartment 50 Horn Button sneis a ia 51 Ignition Switch 52 KEYS PM 53 Fuel Gauge Hour 54
3. 119 Power Steering 120 Wheels neget eines 121 RIMS sionem NR RTI 121 Wheel Nuts sssssseemmm 121 Ne PIX E 121 JOINT BOOS eene De se aac teda 123 6 80 124 Seat uie EE ts 125 Cargo Bed 126 Headlight 126 Battery sese e ee aded 127 FUSE fii Ee eid 131 Power Steering 131 Breaker tle ttd et RARE 132 General Lubrication 133 nite eere Et 134 Bolt and Nut Tightening 135 STORAGE oet sete ipe tee M ht cte 136 TROUBLESHOOTING GUIDE 138 YOUR WARRANTY OWNER SATISFACTION dete peau de e 139 ENVIRONMENTAL PROTECTION 143 MAINTENANCE RECORD 144 BASIC SAFE DRIVING 9 BASIC SAFE DRIVING Knowing and following these rules for safe oper ation will increase your satisfaction with your new Kawasaki vehicle Perform the Daily Checks Refer to the Daily Checks section for a list of items to check each day before use Habitual performance of these checks will help to insure safer more re liable usage Be sure that any irregularities found during these checks are correct
4. 77 Climbing 5 78 Descending Hills sees 79 Traversing Hillsides 80 Sliding and 80 Driving through 81 MAINTENANCE AND ADJUSTMENT 82 Periodic Maintenance 83 Engine 87 Front Final Gear Case 92 Transmission Case 95 Cooling System 98 Spark Plugs 2nd 100 Valve Clearance 102 Engine Air 102 Evaporative Emission Control System 105 Spark 105 Throttle 107 ldieAdjustme t i 110 Fuel Pump Filter 110 Fuel Tank 111 Belt Drive Torque Converter 111 Belt Drive Torque Converter Air Cleaner 112 Brak68S eee RO 114 Brake 114 Brake Light Switch 117 Parking Brake Lever 118 Steering
5. 14 56070 0051 CF03347BN2 C IMPORTANT EMISSION CONTROL INFORMATION THIS ENGINE MEETS U S EPA AND CALIFORNIA EXH REGULATIONS FORPSCSIMODEL YEAR SHALL OFF ROAD ENGINES L EMISSION FAMILY DISPLACEMENT n EMISSION CONTROL SYSTEM DATE OF MANUFAGTURE EMISSION CONPLIANCE PERIOD LXOSHOURS REFER TO ONNER S WANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTHENTS E E Kawasaki KAWASAKI HEAVY INDUSTRIES LTD CF03929BM2 15 MED BY KAWASAKI MOTORS CORP U S A LINCOLN NE This s unde tru r SAE J11 FMVSS 216 ED cture meets RO PS requiremenls for wheeled tractors 1 7 2 and 7 4 This structure also meets J sal ila Roof Crush resistance requirement 16 FYD LIFT Pull and lift up the front hood center fortron while pulling the knob to open the front hood 56030 0267 CFO3959B 5 CF03377BN6 C 17 CONTROL INFORMATION THIS EQUIPMENT MEETS U S EPA EYP STANDARDS AND CALIFORNIA EVP EMISSION REGULATIONS FOR SMALL OFF ROAD ENGINES EQUIPMENT FAMILY 66666599 CARB EVP FAMILY 1 0 DATE OF MEG WOTORS WANUFACTURING CF03856BM2 C 18 MAINTENANCE FREE SANS ENTRETIEN LIBRE DE MANTENIMIENTO DANGER POISON iPELIGRO VENENO Ni CAUSE INJUR
6. 1 7 kgf cm 24 psi NOTE O Tires are an important part of the suspension of the vehicle Tire construction characteristics and tire inflation pressure can greatly influence vehicle handling Kawasaki recommends that you always replace tires with standard replacement tires as shown above It is also very important to have tires of the same type and size on all axles and at the same inflation pressure on each axle O Installation of non standard tires or use of differ ent tires on one axle can change or impair the handling of the vehicle OInstallation of tubeless tires on rims requires com pressed 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 Beads 250 kPa Front and Rear 2 5 kgf cm 36 psi 122 MAINTENANCE AND ADJUSTMENT Payload and Tire Pressure Failure to maintain proper inflation pressures or observe payload limits for your tires can change or impair handling and performance ofthe vehicle The maximum recommended load carrying capacity is 603 kg 1 330 Ib Use a tire pressure gauge to accurately set tire pressure A WARNING Operating with unequally or improperly pres surized tires can adversely affect steering or handling Inflate both front tires to the same pressure and both rear tires to the same pressure Tire Wear Damage As tire tread
7. Support the bed in the tilted position with the sup porting rod provided on the bottom of the cargo bed Do not drive the vehicle with the front end of the cargo bed raised or unlatched To lower the bed check to be sure the area un der the front of the cargo bed is clear then carefully lower the bed into position Check that the both latches have locked the bed into place Do not leave the cargo bed unlatched A WARNING Reduced clearance between cargo bed and ROPS can cause hand injury Do not hold ROPS in the location of the label when rais ing or lowering the cargo bed With the Cargo Bed Shortened Condition 1 Pull the rear seat stopper pin on the left side A Stopper pin B Rear Seat 2 Push the rear seat back forward 3 Release the latches on both sides GENERAL INFORMATION 43 Latch gt Rear Seat Stored position Rear Seat Back lowered position B Front Seat Back Push the rear seat assembly forward into the 5 Holding the hand grip and cargo bed top raise stored position the cargo bed 44 GENERAL INFORMATION A Handgrip A Supporting Rod B Hold here B Cargo Bed Raised Position 6 Support the bed in the tilted position with the NOTE supporting rod O To lower the cargo bed follow the reverse proce dure for raising Be sure to restore the seat as be fore and put the latches on Never drive the Mule without putting the latches to the
8. DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio Forward Reverse Electric starter Front to rear 1 2 1 2 FI Fuel Injection Magneto and transistor 5 BTDC 3750 r min rpm 22 BTDC 4 000 r min rpm NGK BPR2ES Forced lubrication wet sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 1 8 L 1 9 US qt 4 6 L 4 9 US qt 4WD gear 2 speed amp reverse automatic 3 9 0 85 Belt drive torque converter 5 200 5 429 8 404 High 17 303 Low 19 475 Transmission Gear Ratio Front Final Gear Case Oil Forward Reverse Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Steering Caster Trail Tire Size Rim Size Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail Brake Light Front amp Rear Front amp Rear SPECIFICATIONS 13 1 821 High 3 750 Low 4 220 API GL 5 or API GL 6 Hypoid gear oil for Limited Slip Differentials SAE90 or SAE140 0 4 L 0 4 US qt API GL 5 Hypoid gear oil SAE 90 above 5 C 41 F SAE 80 below 5 C 41 F 2 5 L 2 6 US qt Steel tube ladder type Assisted with Electric Power Steering EPS System 7 5 35 mm 1 4 in 23 x 11 00 10 Tubeless 10 x 8 5 AT 24 L 6 3 US gal 12 V 14 Ah 12V 35 W x 2 12V 5 21 W x 2 14 SPECIFICATIONS LOAD CAPACITY Maximum Vehic
9. An air oil mist may be forcibly ejected from the spark plug holes and could get into your eyes Do not lean over the engine when per forming this procedure If you do get oil in your eyes wash them immediately with lib eral amounts of clean fresh water and con sult a physician as soon as possible e Put boards under the front and rear wheels to keep dampness away from the tire rubber e Spray oil on all unpainted metal surfaces to pre vent rusting Avoid getting oil on rubber parts or in the brakes e Lubricate all the cables as indicated in the General Lubrication section e Remove the battery and store it where it will not be exposed to direct sunlight moisture or freezing temperatures During storage it should be given a slow charge one ampere or less about once a month NOTICE Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery The more discharged a battery becomes the more easily it freezes Never remove the sealing strip or the battery can be damaged e Tie a plastic bag over the exhaust pipe and air cleaner intake rear ROPS top to prevent mois ture or small animals from entering e Put a cover over the vehicle to keep dust and dirt from collecting on it STORAGE 137 Removal from Storage A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon monoxide can cause
10. and evaporative emission 3 control systems in compliance with applicable regulations of the United States Environmental Protections Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the intake manifold Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of the crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a fuel injection system and ignition system having optimum ignition timing characteristics The fuel injection system has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thor ough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere 3 Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and fuel tank Also vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere Instead fuel vapors
11. 130 MAINTENANCE AND ADJUSTMENT Battery Maintenance It is the owner s responsibility to keep the battery fully charged Failure to do so can lead to battery failure and leave you stranded If you are riding your vehicle infrequently inspect the battery voltage weekly using a voltmeter If it drops below 12 6 volts the battery should be charged using an appropriate charger check with your kawasaki dealer or visit by kawasaki com If you will not be using your vehicle for longer than two weeks the battery should be charged using an appropriate charger Do not use an automotive type quick charger that may overcharge the battery and damage it NOTE O Leaving the battery connected causes the electri cal components to make the battery discharged resulting the over discharge of the battery In this case the repair or replacement of the battery is not included in the warranty If you do not drive for four weeks or more disconnect the battery from the vehicle Kawasaki recommended chargers are Battery Mate 150 9 OptiMate 4 Yuasa MB 2040 2060 Christie C10122S If the above chargers are not available use equiv alent one For more details ask your Kawasaki dealer Battery Charging e Remove the battery from the vehicle see Battery Removal e Attach the leads from the charger and charge the battery at a rate amperage x hours that is indi cated on the battery If it is not possible to read the rate charge the battery at an
12. Be sure to release the parking brake before driving off Failure to do so may result in poor performance and premature wearing of the rear brakes and belt converter system A Parking Brake Lever 58 GENERAL INFORMATION A 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 Seats There are front and rear seats on this vehi cle It can be transformed from 2 passenger to 4 passenger by unfolding the rear seat 2 passenger mode 01258010 P 4 passenger mode NOTE O Converting the rear seat must be made in combi nation with cargo bed conversion See the Con verting Rear Seat and Cargo Bed section in the HOW TO OPERATE chapter GENERAL INFORMATION 59 Seat Belts The vehicle is equipped with retractable lap style seat belts for all occupants operator and passenger for the front seat and two passengers for the rear seat Always wearthe seat belts when operating and riding in the vehicle E A Seat Belt B Buckle C Red Button 60 GENERAL INFORMATION A WARNING Not wearing a seat belt or wearing one im properly can result in serious injury or death in the event of an accident Make certain the operator and all passengers always wear their seat belts properly A WARNING Operator and all passengers must be able to place both feet flat on the floorboa
13. Chart to keep the Mule in good running condition The initial mainte nance is vitally important and must not be neglected If you are in doubt as to any adjustment or vehicle operation please ask your authorized Kawasaki dealer to check the Mule Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect mainte nance or improper adjustment done by the owner MAINTENANCE AND ADJUSTMENT 83 Periodic Maintenance Chart In addition to the following items always perform the Daily Checks listed in the HOW TO OPERATE chapter e Clean adjust lubricate replace parts as necessary D Service to be performed by an authorized Kawasaki Dealer or someone equally competent Service more frequently when operated mud dust or other harsh riding conditions Q Emission Related FREQUENCY Whichever First Service Regular Service comes first After 50 hrs Every 250 Every 500 OPERATION J or APO or s000 600 miles km 3 000 6 000 miles Every of use miles of use ot use Converter drive belt inspect EL h DS Converter drive belt deflection inspect are NE Converter driven pulley shoe inspect e D Converter air cleaner element clean o Converter dust or water drain e Fuel hoses or pipe and connections inspect Air cleaner element clean o O Air cleaner housing dust or water drain 84 MAINTENANCE AND ADJUSTMENT OPERAT
14. amperage that is about 1 10th of the battery capacity e The charger will keep the battery fully charged un til you are ready to reinstall the battery in the vehi cle see Battery Installation NOTICE Never remove the sealing strip or the battery can be damaged Do not install a conventional battery in this vehicle or the electrical system cannot work properly NOTE Olf you charge the sealed battery never fail to ob serve the instructions shown on the label on the battery and charger A WARNING Battery posts terminals and related acces sories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Fuse There are eight fuses in the fuse box under the seat If the electrical systems do not function in spect the fuse Before replacing a fuse check the wiring harness and electrical equipment for bare wires or other possible causes NOTICE Do not use a fuse of a higher capacity than the specified fuse rating or damage to the electrical system could result Refer to the Fuse Location label on the other side fuse case lid A Fuse Box B Front Seat MAINTENANCE AND ADJUSTMENT 131 Power Steering System There are 40 A and 7 5 A fuses forthe power steer ing system under the front seat Ue 40 A Fuse Cover removed B 7 5 A Fuse If the fuse is blown steering becom
15. cargo bed With the Cargo Bed Extended Condition 1 Release the side latches A Latch B Rear Seat Stored position 2 Holding the handgrip and cargo bed on the top edge raise the cargo bed 3 Support the bed in the tilted position with the supporting rod NOTE O To lower the cargo bed follow the reverse proce dure for raising Be sure to attach the latches to the cargo bed GENERAL INFORMATION 45 A WARNING Cargo bed becomes heavier in the extended mode Pay attention when raising or lower ing the cargo bed not to injure your hand 46 GENERAL INFORMATION 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 uncontam inated source to insure proper running of your vehicle Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated B Filling Cap NOTICE Always clean dirt mud debris water from the fuel tank cap and surrounding area prior to filling the tank to prevent dirt mud debris wa ter from entering the fuel tank Accumulation of moisture or sediment in the fuel system can restrict the flow of fuel and cause fuel pump and or engine damage A WARNING Gasoline is extremely flammable and can be explosive under certain conditions creating the potential for serious burns Turn th
16. control the vehicle s speed 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 ob stacles Normally you should descend straight down a hill since driving at an angle could cause the vehi cle to lean to one side and possibly tip over Proceed slowly and cautiously Apply the brake as necessary Be careful if the surface is loose because the tires are more likely to skid and braking effectiveness will be reduced Turning while descending a slope must be done very carefully and gradually to avoid tipping the ve hicle over A WARNING Riding sideways across a hill may cause the vehicle to overturn causing severe injury or death Do not turn sideways to the hill Remember e Stop and look for obstacles before descending a hill e Go straight downhill e Go slowly e If you must turn do so carefully and gradually SAFE OPERATION 79 NOTE OWhen the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking This is caused by the ve hicle s automatic transmission which releases the engine at very low speed to prevent it from stalling Use the brakes to control the vehicle s speed 80 SAFE OPERATION Traversing Hillsides Sliding and Skidding When driving across the side of a hill reduce vehi cle speed and exercise extreme caution to prevent tipping or loss of control Av
17. hills with slippery sides that will cause you to lose traction Do not climb hills where you cannot see far enough ahead If you cannot see what is on the other side of the crest of a hill slow down until you can get a clear view Don t apply power suddenly while climbing or the front wheels might rise off the ground If the vehicle does not have enough power to reach the top of the hill and stalls allow the vehicle to roll slowly straight back down the hill controlling its descent with the brakes Leave the gear shift lever in the H High or L Low position until you stop at the bottom of the hill A WARNING Riding sideways across a hill may cause the vehicle to overturn causing severe injury or death Do not turn sideways to the hill Remember e Some hills are too steep Use common sense e Never drive past your limit of visibility If you can t see what is on the other side of the crest of a hill slow down until you can get a clear view e Don t turn sideways to the hill e If you get stuck on a hill roll slowly straight back down using the brake with the gear shift lever left in the High or L Low position NOTE O When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking This is caused by the ve hicle s automatic transmission which releases the engine at very low speed to prevent it from stalling Use the brakes to
18. lowers performance burns the valves and valve seats and may cause seri ous engine damage Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Main tenance Chart Inspection and adjustment should be done by an authorized Kawasaki dealer Valve Clearance EX amp IN 0 25 mm 0 010 in A clogged engine air cleaner restricts the engine s air intake increasing fuel consumption reducing en gine power and causing spark plug fouling A WARNING A clogged air cleaner may allow dirt and dust to enter the fuel injection system and the throttle may stick resulting in a haz ardous operating condition Clean the air filter according to the periodic maintenance chart more often if the vehicle is used in extremely dusty conditions NOTICE A clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and possible engine damage The air filter element should be cleaned in accor dance with the Periodic Maintenance Chart In dusty areas the elements should be cleaned more fre quently than the recommended interval The engine air filter restriction gauge shows 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 top of the gauge Air Filter
19. mode raise the cargo bed and support it with the rod e Remove the oil filler cap A Drain Plug e With the vehicle held level let the oil drain com pletely A WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local author A Oil Filler Cap ities for approved disposal methods or pos B Dipstick sible recycling e Place an oil pan beneath the engine e If the oil filter is to be changed remove the oil filter e Remove the drain plug cartridge and replace it with a new one 90 MAINTENANCE AND ADJUSTMENT e Apply a thin film of oil to the gasket and screw the cartridge in until the gasket touches the engine then turn it 3 4 turn BL03004BM2 C A Gasket e Install the drain plug with its gasket Tighten it to the specified torque Tightening Torque Drain Plug 22 N m 2 2 kgf m 16 0 ft lb NOTE O Replace any damaged gaskets with new ones e Fill the engine up to the F Full line on the dip stick with high quality engine oil as specified in the table e Start the engine and check for oil leakage MAINTENANCE AND ADJUSTMENT 91 Engine Oil Grade Kawasaki Performance 4 Stroke Although 10W 40 engine oil is the recommended ATV UTV Oil oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric condi Kawasaki Performance 4 Stroke tions in your riding area Semi Synthetic Oil Kawasaki Performance 4 Str
20. off when the switch is pushed again A Light Switch 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 level in the reserve tank after the engine cools down Refer to the Cooling System section in the Main tenance and Adjustment chapter Also check the breaker of the radiator fan and if it has functioned reset the breaker Be sure to check that the radiator fan is free from mud and other obstacles See Breaker section of MAINTENANCE AND ADJUSTMENT chapter A Coolant Temperature Warning Light GENERAL INFORMATION 33 NOTICE Do not let the engine continue running with a warning light on Prolonged engine opera tion can result in engine damage from over heating 34 GENERAL INFORMATION 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 gets extremely low or if the oil pump does not function properly or oil passages are clogged or otherwise do not function properly the oil pressure warning light will light If this light stays on when the e
21. rate Electrical accessories such as digital clocks and computer memory also draw current from the bat tery even when the key is switched off Combine such key off draws with hot temperature and a battery can go from fully charged to completely dis charged in a matter of days Self discharge Approx Number of Days From 100 Charged to 100 discharged Temperature Lead Antimony Lead Calcium Battery Battery 40 C 104 F 100 Days 300 Days 25 C 77 F 200 Days 600 Days 0 32 F 550 Days 950 Days MAINTENANCE AND ADJUSTMENT 129 Current Drain Y50 N18L A Days from 100 Days from 100 Charged to 50 Discharged Discharg ing Ampere Charged to 100 Discharged 119 Days 83 Days 56 Days 42 Days 28 Days In extremely cold weather the fluid in an inade quately charged battery can easily freeze which can crack the case and buckle the plates A fully charged battery can withstand sub freezing temper atures with no damage Battery Sulfation common cause of battery failure is sulfation Sulfation occurs when the battery is left in a dis charged condition for an extended time Sulfate is a normal by product of the chemical reactions within a battery But when continuous discharge allows the sulfate to crystallize in the cells the battery plates become permanently damaged and will not hold a charge Battery failure due to sulfation is not war rantable
22. serious brain injury or death Do not run the engine in enclosed areas Op erate only in a well ventilated area e Remove the plastic bags from the exhaust pipe and air cleaner intake e Clean the terminals of the battery charge the bat tery if necessary and install it in the vehicle e Make sure the spark plugs are tight e Fill the fuel tank with fuel e Check all the points listed in the Daily Checks section e Lubricate as indicated in the General Lubrication section 138 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Starter Motor Won t Turn e Fuse failed be sure to check for cause of failure e Battery cables do not make good electrical contact with battery terminals e Battery discharged Engine Cranks But Won t Start e No fuel in tank e Water in fuel e Air filter clogged or intake blocked e Engine flooded e Fuel tank vent clogged e Spark plug wire not on spark plug e Spark plug dirty Engine Stops e No fuel in tank e Water in fuel e Air filter clogged or intake blocked e Fuel tank vent clogged e Engine overheated e Too much idling or low speed running not enough air flow e Overloaded e Wrong spark plug e Radiator clogged e Coolant level too low e Coolant deteriorated e Cooling fan breaker functioned e Engine oil low No Power e Engine overheated e much idling or low speed running not enough air flow e Overloaded e Wrong spark plug e Radiator clogged e Coolant level
23. the towing bracket Do not operate the vehicle faster than 16 km h 10 mph when towing Remember that towing a trailer in creases braking distance Do not tow more than 545 kg 1 200 Ib trailer weight trailer plus cargo weight Attach the trailer to the trailer hitch bracket only do not attach a trailer to any other location A Trailer Hitch Bracket 62 GENERAL INFORMATION Winch Installation This vehicle is equipped with a bracket for a winch below the radiator The winch is not supplied with this vehicle To avoid injury and property damage observe the following precautions A WARNING Improper installation or 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 Installing procedure for a winch You can see the bracket attached to a cross member A Winch Bracket B Bolt Holes Follow a manual to be supplied by the winch maker for installing the winch and other acces Sory as necessary After installing the winch be sure to re install the bumper and bumper cover HOW TO OPERATE 63 HOW TO OPERATE Daily Checks Check the following items each day before operation The time required is minimal and habitual performance of these checks will help ensure safe reliable operation If any irregularities are found during these checks re
24. too low e Coolant deteriorated e Cooling fan breaker functioned e Engine oil low e Compression leakage e Valve clearance insufficient e Air filter clogged or intake blocked e Spark plug dirty or worm e Engine oil incorrect e Water in fuel Power Steering Won t Work e ECU functioned to prevent overheating e Fuse failed e Battery discharged e Cable harness connectors disconnected YOUR WARRANTY OWNER SATISFACTION 139 YOUR WARRANTY OWNER SATISFACTION Welcome to the Kawasaki family Congratulations on buying your Kawasaki vehicle You ve chosen a great high quality product with state of the art features and built to Kawasaki s high standards Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki Motors Corp U S A Here is some important information regarding your vehicle s lim ited warranty Frequently Asked Questions What is a Limited Warranty The most important thing to know about your warranty is that it protects you from manufacturing defects in material or workmanship during the warranty period You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale The warranty does not cover the cost of regularly scheduled maintenance The warranty also does not apply to the normal wear of items such as tires brake pads transmission drive belts chains sprockets etc What is the Good Times Protection Plan Much of the warran
25. touch a hot engine exhaust pipe or muffler during operation or after stopping the engine e Stop the vehicle on a level surface NOTICE Avoid parking on steeply inclined surfaces e When the engine has stopped apply the parking brake to help prevent the vehicle from rolling 70 HOW TO OPERATE A Parking Brake Lever A 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 e Remove the ignition switch key to prevent unau thorized use e When parking inside a garage or other structure be sure the structure is well ventilated and the ve hicle is not close to any source of flame or sparks This includes any appliance with a pilot light A 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 HOW TO OPERATE 71 Shifting to High Range Hi Lo Shifting e Stop the vehicle completely e Put the gear shift lever in neutral Shifting to Low Range e Move the shift lever to the High position e Stop the vehicle completely NOTE e For easy Hi Lo shifting put the gear shift lever in Before shifting make certain that the vehicle is neutral completely stopped The Hi Lo shif
26. B Drain Cap Dust and or Water Inspection e Unscrew the clamp screw and remove the drain cap on the bottom of the converter housing to ex pel dust and or water accumulated inside 112 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 caus ing excessive wear of the inner parts and loss of driving power The air cleaner elements must be cleaned in ac cordance with the Periodic Maintenance Chart In dusty areas the elements should be cleaned more frequently than the recommended interval The ele ments should be replaced if they are damaged Element Removal e For the belt drive torque converter air cleaner re lease the snaps and remove the air cleaner hous ing cover from the housing e Pull the air cleaner element out of the housing e Push a clean lint free towel into the air cleaner housing to keep dirt or other foreign material from entering A Air Cleaner Housing Cover B Snaps A Urethane Foam Element B Holder NOTICE If dirt gets into the belt drive torque con verter excessive wear and loss of driving power may result NOTE O Element installation is performed in the reverse order of removal Element Cleaning e Remove the element see Elem
27. BASIC SAFE DRIVING Protect Yourself Use Proper Riding Gear As appropriate to your operating conditions wear approved helmet eye protection and protective clothing Operating in a recreational setting like trail driving or any aggressive riding could increase the risk of head injury and thus require head protection In these conditions Kawasaki recommends that operators and passengers wear a properly fitting D O T approved helmet Wearing proper protective gear can make driving more comfortable and could reduce the severity of injury in the event of an acci dent Wearing Seat Belt Both the operator and passenger s should al ways wear their seat belts properly Seat belts cannot completely protect you in every accident but in many cases a seat belt can reduce the risk of serious injury Also to avoid injury do not put any part of your body outside of the vehicle for any reason Before Starting the Engine Three musts before starting the engine are 1 Apply the parking brake 2 Putthe gear shift lever in the N neutral posi tion 3 Check the throttle pedal for proper operation It should return to its rest position when released Use the Parking Brake Always apply the parking brake before getting out of your vehicle Obey Local Laws Know and obey all laws and regulations govern ing the use of off highway vehicles in your area Re spect private property Always try to preserve nature and the environ
28. H E Kawasaki Includes Important Safety Information Operating Instructions Maintenance and Storage MULE 4010 TRANS4x4 Utility Vehicle Read this manual carefully It contains safety information OWNER MANUAL Quick Reference Guide This Quick Reference Guide will assist you in finding the information you re looking for A Table of Contents is included after the Foreword GENERAL INFORMATION HOW TO OPERATE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE Whenever you see the symbols shown below heed their instructions Always follow safe operat ing and maintenance practices A DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE NOTICE is used to address practices not re lated to personal injury NOTE O NOTE indicates information that may help or guide you in the operation or service of the vehicle A WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of Cali fornia to cause cancer and birth defects or other reproductive harm EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 exhaust emission 2
29. ION Whichever comes first FREQUENCY First Service Regular Service After 50 hrs Every 250 Every 500 or 1 000 km hrs or 5 000 40 000 kin 600 miles km 3 000 6 000 miles of use miles of use of use Spark plug clean and gap Valve clearance inspect Engine oil change Oil filter replace Throttle pedal play inspect O Idle speed adjust Throttle link lever inspect Spark arrester clean e Radiator clean e e Water hoses and connections inspect 1 year D Fuel hose replace 5 years D Coolant change 2 years D Evaporative emission control system inspect MAINTENANCE AND ADJUSTMENT 85 FREQUENCY Whichever First Service Regular Service comes first Every 500 After 50 hrs Every 250 His or J or 1 000 km hrs or 5 000 10 000 km W 600 miles km 3 000 Every of use miles of use 00D miss OPERATION 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 e e 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 86 MAINTENANCE AND ADJUSTMENT
30. OPERATE 65 NOTE OThe vehicle is equipped with a starter lockout switch This switch prevents the electric starter from operating when the gear shift lever is in the High L Low or R Reverse position 66 HOW TO OPERATE Jump Starting If your vehicle s battery is 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 A DANGER Battery acid generates hydrogen gas which is flammable and explosive under certain conditions It is present within a battery at all times even in a discharged condition Keep all flames and sparks cigarettes away from the battery Wear eye protection when working with a battery In the event of bat tery acid contact with skin eyes or clothing wash the affected areas immediately with water for at least 5 minutes Seek medical attention Connecting Jumper Cables e Make sure the ignition switch key is turned to OFF e Remove the cover under the left end of the front seat A Cover e Connect a jumper cable from the positive ter minal of the booster battery to the positive ter minal of the vehicle battery HOW TO OPERATE 67 A DANGER Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive Do not make this last con nection at the fuel system or battery Take care not to touc
31. Restriction Gauge Element Removal e Pull up the snaps and remove the air cleaner hous ing cap from the housing MAINTENANCE AND ADJUSTMENT 103 A Air Cleaner Housing B Cap C Snaps e Pull the air cleaner element out of the housing e Push a clean lint free towel into the air cleaner housing to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the fuel injection system the throttle may stick or become inoperable resulting in a hazardous operating condition 104 MAINTENANCE AND ADJUSTMENT NOTICE If dirt gets into the engine excessive engine wear and possible engine damage may oc cur A Paper Element NOTE O Element installation is performed in the reverse order of removal O Install the cap with its drain facing downward Element Cleaning e Remove the element see Element Removal e Clean the paper element by tapping it lightly to loosen dust e Blow away the remaining dust by applying com pressed air from the inside to the outside from the clean side to the dirty side e Inspect the element material for damage If any part of the element is damaged the element must be replaced e Reset the air filter restriction gauge push its but ton Dust and or Water Inspection e Push open the drain hose on the bottom of the air cleaner housing to expel dust and or water accu mulated inside A Drain Hose E
32. Shift Levers 55 TABLE OF CONTENTS Gear Shift 55 2WD 4WD Shift 56 Differential Shift 56 Parking Brake 57 SEATS EET 58 Seat Belts oett RR Pe 59 Throttle Pedal eese 60 Trailer Hitch 61 Winch Installation eese 62 HOW 63 Daily Checks eite i ehe 63 Starting the 65 Jump Starting 66 Moving Off er ttes 68 Braking is iiu rire rre ettet 68 Stopping the Engine 69 Parking the Mule 69 HiLo ShiIftING 71 Reversing Gears 72 2WD AWD Shifting sese 72 Shifting the Differential 73 SAFE OPERATION 75 Unfamiliar Terrain 75 Driving in Reverse 76 Driving in 4 76 Turning the Vehicle esee 77
33. U S A P O Box 25252 Santa Ana CA 92799 5252 866 802 9381 consumer services kawasaki usa com 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 vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related parts e Fuel injection system and internal parts e Magneto or electronic battery ignition system e Spark plugs e Fuel filter e Air cleaner element PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product Kawasaki has equipped it with effective intake and exhaust silencing systems They are designed to give optimum performance while maintaining a low noise level Please do not remove these systems or alter them in any way which results in an increase in noise level FOREWORD Congratulations on your purchase of a new Kawasaki Mule It is the result of Kawasaki s engineering exper tise and a tradition of manufacturing high quality consumer prod
34. Y PROTEGEZ LES YEUX LES GAZ EXPLOSIF P PEUVENT BLESSER GU RENDRE AVEUGLE KEEP DUT OF THE REACH OF CHILDREN DO NOT DO NOT OPEN BATTERY Mi TENIR HORS DE LA PORTEE DES ENFANTS NE PAS RENVERSER NE PAS OUVRIR LA BATTERIE servile farpas da ia echa ALEJESE DEL ALCANCE DE LOS NINOS NO VOLTEAR NO ABRIR LA BATERIA jq CAUFORNIA PROPOSITION 65 WARNING Batteries battery posts terminals and related FEN tonta n lead and lear ether cherieals known ta tha State af Calitornta iuctive harm WASH HANDS AFTER HANDLING pi S GO AD A S CF03888B 5 19 20 LOCATION OF LABELS 29 tV E PON AS WARNING Clean filler T removing ied Use only DOT 34 d fluid trom a x v Sealed Con CF03962B 5 BD03299 5 30 LOADING INFORMATION LOADING INFORMATION A WARNING Incorrect loading improper installation or use of accessories or modification of your vehicle may result in an unsafe operating condition Before 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 de sign or application of accessories In some cases improper installation or use of accessories or vehi cle modifications will void the utility vehicle warranty In selecting and using accessories and in loading the v
35. aining or filling the gear case be careful that no oil gets on the tires or rims Clean off any oil that inadvertently gets on them with soap and water e After the oil has completely drained out install the drain plug and gasket If the gasket is damaged replace it with a new one Tightening Torque Drain Plug 20 N m 2 0 kgf m 15 ft lb e Fill the gear case up to the bottom thread of the filler opening with a high quality oil as specified in the table Front Final Gear Case Oil 0 4L 0 4 US qt Oil Capacity API GL 5 or API GL 6 Hypoid gear oil for Limited Slip Differentials SAE90 or SAE140 Oil Type e Install the filler cap and gear case guard Transmission Case Oil In order for the transmission differential pinion and ring gears to function properly check the oil level and change the oil in accordance with the Periodic Maintenance Chart A WARNING Vehicle operation with insufficient deterio rated or contaminated oil causes acceler ated wear of the transmission differential pinion and ring gears and may result in seizure Seizure can lock the rear wheels and skid the rear tires with consequent loss of control accident and injury Check the oil level and change the oil according to the owner s manual Oil Level Inspection e Park the vehicle on level ground e Lift the cargo bed and support it with the rod e Unscrew the oil filler plug wipe
36. are routed into the running engine to be burned or stored in a canister when the engine is stopped Maintenance and Warranty Proper maintenance is necessary to ensure that your vehicle will continue to have low emission levels This Owner s Manual contains those maintenance recommendations for your vehicle Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards As 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 pro vided space at the end of this manual where an authorized Kawasaki dealer or someone equally competent can record the maintenance You should also retain copies of maintenance work orders bills etc as verifica tion of this maintenance If there is a problem with the emission control system within the warranty period you will need to take it and any maintenance records to an authorized Kawasaki dealer for inspection and diagnosis Kawasaki will work closely with your dealer to resolve any warranty issues If you are unable to resolve any problem after consulting with the dealership management and need further assistance contact Kawasaki Motors Corp U S A at the following address Consumer Services Kawasaki Motors Corp
37. ark plug is shown in the table The spark plug should be taken out periodically in ac cordance with the Periodic Maintenance Chart for cleaning inspection and resetting of the plug gap Maintenance If the plug is oily or has carbon built up on it have it cleaned preferably in a sand blasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a brush Measure the gap with a wire type thickness gauge and adjustthe gap if incorrect by bending the outer electrode If the insulator is cracked replace the plug Use the standard plug 0 7 0 8 mm 0 028 0 032 in Spark Plug Standard Plug NGK BPR2ES Plug Gap 0 7 0 8 mm 0 028 0 032 in Tightening Torque 17 N m 1 7 kgf m 13 ft lb MAINTENANCE AND ADJUSTMENT 101 Spark Plug Removal e Lift the cargo bed to support it with the rod e Carefully pull the spark plug caps from the spark plugs A Spark Plug Caps e Unscrew the spark plugs NOTE O After installing the plugs fit the plug caps securely onto the spark plugs and pull the caps tightly to make sure that they are properly installed 102 MAINTENANCE AND ADJUSTMENT Valve Clearance Engine Air Cleaner Valve and valve seat wear decrease valve clear ance upsetting valve timing NOTICE If valve clearance is left unadjusted wear will eventually cause the valves to remain partly open which
38. arning Off Highway Utility Vehicle 2 Warning Front Cargo Hood 3 Notice Shifting 4 Specification 5 Warning General 16 Information Front Hood 20 LOCATION OF LABELS Crowes 6 Warning Pinching Fingers both sides T Important Information Tires Max Load 8 Warning Cargo Bed 9 Warning Refueling 10 Warning Rear Seat Capacity 11 Warning Cargo Bed 15 Specification LOCATION OF LABELS 21 12 Warning Trailer Towing Bracket 13 Warning Hot Surfaces 14 Important Engine Information 22 LOCATION OF LABELS 17 Important Emission Information 18 Battery Danger Poison On the backside 19 Brake Fluid LOCATION OF LABELS 23 20 Radiator Cap Danger 24 LOCATION OF LABELS 1 WARNING This is an off highway utility vehicle which will handle and maneuver differently from an ordinary passenger car Sharp high speed turns or abrupt maneuvers can cause this vehicle to roll over or go out of control Read and understand operating instructions in the Owner s Manual and follow all warning instructions The handling characteristics of this vehicle change depending upon cargo load and driving modes 56070 0050 CF03052BM2 Q An open front cargo hood can distract or impair visibility of the operator causing loss of vehicle control and potential serious injury or death Latch the hood securely before operating the v
39. at and sensitive soils from damage D your part by leaving the area better than you found it properly disposing of waste minimizing the use of fire avoiding the spread of invasive species restoring degraded areas and joining a local enthusiast organi zation Properly discard used batteries tires engine oil other vehicle components or the entire vehicle that you might dispose of in the future Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure 144 MAINTENANCE RECORD MAINTENANCE RECORD Owner EDI C LODICIIBCK MET EE Engine Nu umber e xao rese ine eco dae oid I IDCBTUIITT RR Selling Dealer Name nennen trennen erp nennt rein Ea nuo t ro uuo Eae Addfess E E E citer ree RIXA Dez quo cuir EpL ORE NN END ERREUR AE VAR E Pour ras T FEDES AER Phone ERE be Ee oreet esi TRE eee re ERE eO aks ET eed RYE Warranty Start Date eine iecore cce iere eo cree tice erra Dc Ee ea De cb keen o ce Rau Note Keep this information and a spare key in a secure location Date Traveled Distance Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 145 Date Traveled Distance Maintenance Performed Dealer Nam
40. atch release knob A Latch Release Knob NOTE O When the hood is hard to open pull and lift up the front hood center portion with pulling the knob to open the hood Hood Closing Close the hood until it locks e After the hood is closed push the two edges of the hood to ensure the hood is latched e Pull up the front ends of the hood to make sure latches are securely locked A Push here B Latches GENERAL INFORMATION 51 Horn Button A WARNING An open front cargo hood can distract or im pair visibility of the operator causing loss of vehicle control and potential serious injury or death Latch the hood securely before operating the vehicle Push the horn button to sound the horn A Horn Button 52 GENERAL INFORMATION OFF Engine off All electrical circuits off Ignition Switch All electrical equipment can be used Fuel gauge works ON This is a three position key operated switch The key can be removed from the switch only when it is Electric starter is engaged by holding in the OFF position ignition switch key in this position only when gear shift lever is in N START neutral position Upon release key will return to ON position Hour meter works NOTICE Do not operate the starter continuously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily Wait 15 seconds between each ope
41. can cause serious brain injury or death Do not run the engine in enclosed areas Op erate only in a well ventilated area e Stop the engine e Install the drain plug A Spark Arrester inside the muffler B Drain Plug e Apply the parking brake e In an open area away from combustible materials start the engine with the gear shift lever in the N Neutral position e Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon parti cles are purged from the muffler Throttle Pedal If the throttle pedal has excessive play due to ei ther cable stretch or misadjustment it will cause a delay in throttle response especially at low engine speed Also the throttle may not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary Throttle Pedal Play Inspection e Apply the parking brake e Putthe gear shift lever in the N Neutral position e Start the engine and warm it up thoroughly e Measure the distance the throttle pedal moves be fore the engine begins to pick up speed Free play should be 5 10 mm 0 2 0 4 in e Stop the engine and check that the throttle pedal moves smoothly from full open to close and the throttle closes quickly and completely e If the throttle pedal does n
42. cordance with the Periodic Maintenance Chart have the brake shoe linings checked for wear by an authorized Kawasaki dealer Brake Fluid In accordance with the Periodic Maintenance Chart inspect the brake fluid level in the reservoir and change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Fluid Requirement Use heavy duty brake fluid only from a fresh un opened container marked DOT3 A WARNING Over time brake fluid can absorb moisture lowering its boiling point and reducing brake effectiveness Do not use fluid from a con tainer 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 Don t leave the reservoir cap off for any length of time to avoid moisture con tamination of the fluid Don t add or change brake fluid in the rain or during conditions of blowing dust or debris NOTICE Brake fluid quickly ruins painted surfaces Wipe up any spilled fluid immediately Fluid Level Inspection e With the vehicle on level ground check through the inspection hole in the dashboard that the fluid level in the reservoir is between the upper marked MAX and lower marked MIN level lines MAINTENANCE AND ADJUSTMENT 115 0 19003 Inspection Hole e f the fluid level is lower than the lower level line check for fluid leaks in the brake lines and open the fro
43. does not check the bulb and if necessary adjust the brake light switch MAINTENANCE AND ADJUSTMENT 117 Adjustment e Adjustment is best performed by an authorized Kawasaki dealer since the brake light switch is hard to adjust NOTICE To avoid damaging the electrical connec tions inside the switch be sure that the switch body does not turn during adjust ment 118 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked In accordance with the Periodic Maintenance Chart check that the parking brake lever functions properly Inspection e Pull the rubber boot up on the bottom A Parking Brake Lever B Rubber Boot e Pull the parking brake lever up and to the rear e After 8 to 12 clicks of lever travel the vehicle should not roll while parked A 8 12 clicks e If it does adjust the parking brake lever Adjustment e Loosen the locknut upper nut on the middle of the parking brake lever and turn the nut next to the locknut until the brake lever will only move 8 12 clicks upward CL21g007 A Locknut B Nut e Tighten the locknut securely e Reinstall the rubber boot making sure that the pro jections on its lower edge are completely pushed into the holes in the bracket NOTE OBe sure to hold the cable end with a wrench to prevent the cable from twisting Olf the brake lever can not be adjusted with
44. during oil drain ing API GL 5 Hypoid gear oil above 5 C 41 F SAE 90 below 5 C 41 F SAE 80 Lift the cargo bed and support it with the rod Remove the filler plug Transmission Case Oil Capacity A WARNING 2 5 L 2 6 US qt Oil on tires can make them slippery which can cause an accident and injury When draining or filling the transmission case be careful that no oil gets on the tires or rims Clean off any oil that inadvertently gets on them with soap and water Transmission case oil is a toxic substance Dispose of used oil properly Contact your local authorities for approved disposal methods or possible recycling e Install the filler plug After the oil has completely drained out install the drain plug with its gasket Tighten it to the spec ified torque If the gasket is damaged replace it with a new one Fill the transmission case up to the H High line on the dipstick with a high quality oil as specified in the table 98 MAINTENANCE AND ADJUSTMENT Cooling System A WARNING The cooling system can get extremely hot during normal operation and cause serious burns Do not touch the radiator when it is hot nor open the radiator cap Hot coolant inside will cause severe burns Radiator and Cooling Fan Check and clean the screen and radiator fins for obstruction by insects or mud in accordance with the Periodic Maintenance Chart In dusty areas t
45. e 21 Dashboard LOCATION OF PARTS 17 018021 22 Tail Brake Lights 26 Fuel Tank Cap 23 Muffler Spark Arrester 27 Rear Seat folded 24 Trailer Hitch Bracket 28 Air Cleaner 25 Fuel Tank 18 LOCATION OF PARTS Left Glove Compartment Light Switch Horn Button Fuel Gauge Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light Parking Brake Warning Light Right Glove Compartment Fl Warning Light Power Steering Warning Light Differential Shift Lever Brake Fluid Reserve Tank 42 Brake Pedal 43 Throttle Pedal 44 Gear Shift Lever 45 2WD 4WD Shift Lever 46 Oil Pressure Warning Light LOCATION OF LABELS 19 LOCATION OF LABELS All warning labels which are on your vehicle are repeated here Read labels on your vehicle and un derstand them thoroughly They contain information which is important for your safety and the safety of anyone else who may operate your vehicle There fore it is very important that all warning labels be on your vehicle in the locations shown If any label is missing damaged or worn get a replacement from your Kawasaki dealer and install it in the correct po sition NOTE OThe sample warning labels in this section have part numbers to help you and your dealer obtain the correct replacement O Refer to the actual vehicle label for model specific data grayed out in the illustration Fom P 1 W
46. e starts there may be a problem with the light itself See a dealer for inspection This vehicle is equipped with an electric power steering system The system does not require reg ular maintenance by users Do not tamper with the electronic control unit ECU or loosen the 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 problems refer to the Steering Wheel section in the MAINTENANCE AND ADJUSTMENT chapter The steering wheel position can be adjusted to suit the operator see Steering Wheel section NOTE O The power steering system functions only when engine is running If you install wireless equipment on board contact an authorized dealer Installing such equipment improperly may affect the ECU GENERAL INFORMATION 37 Brake Pedal Converting Rear Seat and Cargo Bed The brake pedal is the left pedal on the foot board This vehicle can be converted to accommodate Depress the pedal to slow or stop the vehicle more passengers and less cargo or fewer passen gers and more cargo The seats and the cargo bed can be converted in the following way From 4 person to 2 person 1 Pull the rear seat stopper pin on the left side A Brake Pedal A Stopp
47. e Dealer Address 146 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 147 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address 148 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 149 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address KAF620RE KAF620SE MARDA ANDON TUN TA TETTE 9979 87 17 68 4 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Printed in Japan Part No 99987 1768
48. e ig nition switch to OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Never fill the tank completely to the top If the tank is filled completely to the top heat may cause the fuel to expand and overflow through the vents in the tank cap After refueling make sure the tank cap is closed securely If gaso line is spilled on the fuel tank wipe it off im mediately Fuel Requirements Fuel Type This vehicle is certified to operate on unleaded gasoline only Use clean fresh unleaded gasoline with a mini mum Antiknock Index of 87 The Antiknock Index is posted on service station pumps in the U S A The octane rating of a gasoline is a measure of its re sistance to detonation or knocking The Antiknock Index is an average of the Research Octane Num ber RON and the Motor Octane Number MON as shown in the table below GENERAL INFORMATION 47 Minimum Rating Octane Rating Method Antiknock RON MON Bs Index 2 NOTICE If engine knocking or pinging occurs use a different brand of gasoline of a higher octane rating If this condition is allowed to continue it can lead to severe engine dam age Gasoline quality is important Fuels of low quality or not meeting standard industry specifications may result in unsatisfac tory performance Operating problems that result from the use of poor q
49. ear shift lever to change gears while driving the vehicle in reverse or the transmission may be damaged Remember e Look behind you before backing up e Open the throttle gradually e To stop gradually apply the brake AWD gives greater traction when you are climb ing steep inclines or driving on bumpy sandy or snowy surfaces It also helps break loose with the differential locked under certain circumstances for example when the vehicle is stuck in the mud If maximum torque is needed in these situations shift into the low position with the shift lever Refer to the Shift Levers section and 2WD 4WD Shifting Shifting the Differential and Hi Lo Shifting sec tions NOTE O Do not drive 4WD on paved surfaces because it increases tire and drive train wear and makes the steering feel tight Remember e Use 4 0 on steep inclines or loose surfaces or when stuck in the mud with the differential locked if necessary e For maximum torque shift into low range e Do not drive 1WD on paved surfaces Turning the Vehicle SAFE OPERATION 77 Hills 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 keep the vehicle from tipping Reduce vehicle spe
50. ecurity as often as possible while the vehicle is stopped and adjust as necessary NOTICE The front body work and fenders are not designed to carry cargo or to support your weight They may break e Always subtract trailer tongue weight from the Maximum Load capacity Refer to the Trailer Hitch Bracket section in the General Informa tion chapter Maximum Vehicle Load Weight of operator passengers and cargo must not exceed 603 kg 1 330 Ib e This vehicle is not designed to carry passengers in the cargo bed Installing additional passenger seating or carrying passengers in the cargo bed can cause changes in vehicle handling A WARNING Passengers riding in the cargo bed can be tossed about or even thrown out causing se rious injury or death Do not install seating or carry passengers in the cargo bed LOADING INFORMATION 31 32 GENERAL INFORMATION GENERAL INFORMATION Lighting Electrical Accessory Connector The lighting electrical accessory 12 volt connector is located on the dashboard An auxiliary light or an accessory may be con nected to this connector A Connector NOTICE Do not connect a light or load of more than 120 watts to this connector or the battery may become discharged very rapidly Light Switch Turn on the headlights and taillights by pushing the light switch in with the ignition switch key in the position The lights go
51. ed before entering the turn and use the throttle to maintain an even speed through the turn AWARNING In the differential mode if either rear wheel leaves the ground it will spin freely and the wheel on the ground will transmit very little power When a spinning wheel touches the ground it may grab abruptly causing the op erator to lose control Do not make sharp turns even in the differential mode in order to avoid loss of control or tipping Remember e Slow down before entering the turn e Maintain an even speed through the turn As with any motor vehicle loading of the vehicle and the surface and steepness of the hill are among the critical considerations in climbing descending or traversing hills Use extreme caution on hills Keep in mind that loading changes a vehicle s center of gravity and that the higher the center of gravity the more likely the vehicle is to tip on uneven surfaces Slippery loose or bumpy surfaces on hills are es pecially hazardous Some hills are just too steep to climb Always use common sense and practice good judgement 78 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 AWD with the differential locked for greater traction and in low range for maximum torque Avoid
52. ed before operating the vehicle Drive Carefully and with Good Judgement We want you to be satisfied with your new Kawasaki vehicle so drive carefully safely and ex ercise good 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 ques tions Off Highway Use Only This vehicle is not an all terrain vehicle it is de signed and equipped to be a multiuse utility vehicle for off highway use only Use of this vehicle on pub lic roads and paved surfaces is hazardous Do not operate this vehicle on public roads or paved sur faces Occupant Capacity Make sure operators are 16 years or older with a valid driver s license Each occupant must be able to sit with back against seat feet flat on floor and hands on steer ing wheel handgrip or handhold The operator should be tall enough to wear the seat belt properly and reach all controls Passenger s should also be tall enough for the seat belt to fit properly and to be able to brace them selves as necessary by placing both feet firmly on the floor while gripping the handhold Stay com pletely inside the vehicle Never Drink and Drive Alcohol and drugs impair your judgement and slow your reactions Even drugs prescribed by a physi cian can be dangerous Check with your doctor 10
53. ehicle 56070 0053 CF03051BM2 C 3 NOTICE Shifting incorrectly can damage transmission Shift only when Engine is at slow idle Yehicle is completely stopped 56071 0128 CF039808 5 4 CF03823BN6 C 5 LOCATION OF LABELS 25 4 WARNING The Owner s Manual and warning labels contain important information on safe operation of this vehicle You must read and fully understand instructions in Owner s Manual and warning labels before operating this vehicle Keep Owner s Manual with this vehicle at all time Improper use of this vehicle can be hazardous Never operate at speeds too fast for your skills or conditions Handling characteristics of this vehicle change depending upon cargo load and driving modes Use proper driving techniques on hills in rough terrain and in water Use of this vehicle on public roads and paved surfaces is hazardous This vehicle is designed and equipped for off highway use only Do not operate this vehicle on public roads or paved surfaces Children may not have skills and judgment to safely operate this vehicle All operators of this vehicle should possess a valid driver s license Protective head gear reduces the risk of head injuries A helmet is recommended when this vehicle is being used for recreational purposes or any aggressive driving Please refer to the Owner s Manual for information on proper riding gear Seat b
54. ehicle you are personally responsible for your own safety and the safety of others NOTE O Kawasaki Parts and Accessories have been spe cially designed for use on Kawasaki utility vehi cles We strongly recommend that all parts and accessories you add to your vehicle be genuine Kawasaki components Because any vehicle is sensitive to increases in weight and changes in weight distribution you must take care in carrying cargo The following general guidelines have been prepared to help you make your determinations e Reduce speed when carrying cargo Braking distance is increased Use extreme caution when climbing and descending hills and traversing slopes Carrying cargo and pulling a trailer can make the vehicle difficult to steer and may affect vehicle handling in an unpredictable manner Do not operate this vehicle faster than 16 km h 10 mph when pulling a trailer All cargo should be carried as low as possible to reduce the effect on the vehicle s center of gravity Cargo weight should be equally distributed from side to side This helps maintain stability by cen tralizing weight Avoid carrying cargo that extends beyond the rear of the vehicle Do not carry cargo on top of the ROPS Do not carry more than 363 kg 800 Ib for the long cargo bed mode and 182 kg 400 Ib for the short cargo bed mode Cargo should be securely anchored Make sure the cargo will not move around while the vehicle is moving Recheck cargo s
55. elts reduce injuries Operator and passengers must always fasten seat belts during vehicle operation Carrying passengers outside the passenger compartment can be hazardous This vehicle is designed to carry the operator and one passenger in the front seat The rear seat is designed for two additional passengers Never carry a passenger in the cargo bed Failure to apply parking brake may result in vehicle moving inadvertently with the potential for causing damage and injury Always apply parking brake before exiting vehicle Alcohol and drugs impair reaction time and judgment Never operate this vehicle under influence of alcohol or drugs 56071 0102 CFO3337BN4 26 LOCATION OF LABELS 6 7 SS SS SS SS S 9 WARNING KISS Reduced clearance between cargo bed and cab frame can cause hand injury Do not hold cab frame in this area 56071 7514 CF03230BM2 7 IMPORTANT INFORMATION Tires Front 23X11 00 10 Rear 23X11 00 10 Cold Tire Pressure Front 69kPa 10psi Rear 187kPa 24psi Hax Vehicle Load 603kgf 133015 including occupants and cargo F 56053 7534 CF03231BM2 C 8 SS WARNING Driving with the bed raised is hazardous Always lower and latch bed before driving 56070 7515 CF03124BM2 WARNING Gasoline is flammable Fire can cause severe injury or death Re
56. ely until they have dried out e Under the rear seat if water gets into the ignition coils or into the spark plug caps it can ground out the spark When this happens the vehicle will not operate properly and the affected parts must be wiped dry e Power Steering System if water gets into the actuator or is sprayed over the ECU they may cause malfunction NOTICE Coin operated high pressure spray wash ers are not recommended Water may be forced into bearings and other components causing eventual failure from rust and cor rosion Some soaps are highly alkaline and may leave a residue or cause spotting NOTE OAbrasive cleaner will damage the camouflage surface and a high pressure washer could cause the camouflage to peel off the bodywork for KAF620S Semi gloss Finish To clean the semi gloss finish e When washing the vehicle always use a mild neu tral detergent and water e The semi gloss finish effect may be lost when the finish is excessively rubbed e f any doubt consult an authorized Kawasaki dealer After Washing e Remove the plastic bag and tape and open the air cleaner intake e Lubricate as indicated in the General Lubrication section e Test the brakes before operation e Start the engine and run it for 5 minutes to dry it thoroughly MAINTENANCE AND ADJUSTMENT 135 Bolt and Nut Tightening In accordance with the Periodic Maintenance Chart have the tightness of the bol
57. emov ing the mounting bolts and nuts A Guard B Nuts Front Side A Bolts Rear Side e With the vehicle level front to rear and side to side remove the filler cap from the front final gear case A Front Final Gear Case B Filler Cap NOTICE Be careful not to allow any dirt or foreign ma terials to enter the gear case e Check the oil level The oil level should come to the bottom thread of the filler opening If it is low add oil through the oil filler opening as necessary MAINTENANCE AND ADJUSTMENT 93 A Front Final Gear Case B Filler Opening C Bottom Thread D Drain Plug e Install the filler cap and tighten it to the specified torque Tightening Torque Filler Cap 29 N m 3 0 kgf m 21 ft Ib NOTE O Use the same type and brand of oil that is already in the gear case 94 MAINTENANCE AND ADJUSTMENT Oil Change NOTE O Before draining the oil warm it up by running the vehicle Warm oil drains easily and picks up any sediment e Remove the front final gear case guard e With the vehicle level place an oil pan beneath the gear case e Remove the filler cap and drain plug A WARNING Gear case oil is a toxic substance Dispose of used oil properly Contact your local au thorities for approved disposal methods or possible recycling A WARNING Oil on tires can make them slippery which can cause an accident and injury When dr
58. ent Removal e Remove the urethane foam element from the holder e Clean the foam element in a bath of high flash point solvent using a soft bristle brush e Squeeze it dry in a clean towel Do not wring the element or blow it dry the element can be dam aged e Inspect the foam element for damage If it is torn punctured or hardened replace it NOTE OReplace the foam element after cleaning it five times or if it is damaged e Clean the holder by tapping it lightly to loosen dust e Blow away the remaining dust by applying com pressed air from the inside to the outside from the clean side to the dirty side MAINTENANCE AND ADJUSTMENT 113 e Inspect the element material for damage If any part of the element is damaged the element must be replaced 114 MAINTENANCE AND ADJUSTMENT Brakes The vehicle is equipped with hydraulically acti vated drum brakes on all four wheels Brake Pedal Brake Pedal Free Play Inspection In accordance with the Periodic Maintenance Chart check the brake pedal free play e Depress the brake pedal lightly by hand e There should be 2 10 mm 0 1 0 4 in of free play A Brake Pedal B 2 10 mm 0 1 0 4 in e f the brake pedal has more or less free play than specified or the pedal action feels rough or catchy have the brake system inspected imme diately by an authorized Kawasaki dealer Brake Shoe Linings Brake Shoe Lining Wear Inspection In ac
59. er 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 to overturn or become stuck or submerged Observe the following rules for operating the vehi cle in water A Axle Cap SAFE OPERATION 81 A WARNING Operating the vehicle in rivers or streams where water is flowing quickly can cause the tires to lose traction and allow the vehicle to be swept into the current Never operate the vehicle in fast flowing water or in water deeper than the bottom edge of the axle caps After prolonged exposure to water the wheel bear ings may require lubrication or replacement Wash the vehicle in fresh water if it has been ex posed to salt water or operated in muddy conditions A WARNING Wet brakes provide greatly reduced effi ciency and could lead to an accident and injury After operation in water always apply the brakes long enough for friction to dry the linings Also the brake that gets wet may wear out faster Check for brake wear more frequently if the vehicle is used in water Remember e Avoid driving through water whenever possible e Don t drive in deep and fast moving water e Dry out the brakes 82 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor dance with the Periodic Maintenance
60. er pin B Rear Seat 2 Push the rear seat back forward 3 Release the latches on both sides 38 GENERAL INFORMATION 01102010 P A Latch A Rear Seat Stored position B Rear Seat Back lowered position B Front Seat Back Push the rear seat assembly forward into the 5 Swing open the cargo bed side plates and fas stored position ten the latches on the both sides A Cargo Bed Side Plates GENERAL INFORMATION 39 B Latch Slide the stopper pins towards inside at the bot tom of the removable screen T A Stopper Pin B Screen Pull and remove the screen from the sockets move forward and insert into the sockets at the end of the side plates 40 GENERAL INFORMATION A Screen B Sockets 8 Latch the stopper pins at the bottom of the screen From 2 person to 4 person Mode e Reverse the procedure for 4 person to 2 person mode conversion NOTE O When folding the cargo bed end side plates be sure to insert the end projections into the counter parts on the screen A Projections B Cargo Bed Side Plate folded Cargo Bed Tailgate Before lowering the tailgate select a firm level sur face and set the parking brake Raise the latch han dles at each end of the tailgate and slide both latches toward the center of the vehicle The tailgate can now be lowered The gate is held level to the cargo bed floor with wire loops Close the tail
61. es heavy Re place 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 con nectors See an authorized dealer for inspection e You can check the 40 A fuse if it is blown at the top of the fuse When replacing the fuse release the bolted leads first 132 MAINTENANCE AND ADJUSTMENT A 40 A Fuse B Bolted Lead C Spare Fuse A WARNING The electrical system can produce painful electrical shocks When replacing the 40 A fuse first remove the cables from the battery terminals to avoid electric shock 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 radi ator fan is free from mud or other obstacle as well as the wiring harness and electrical equipment for bare wires or other possible causes A Breaker B Reset Button C Fuse Box O When you touch the cooling fan be sure to discon nect the cable of the battery since the cooling fan can turn automatically even with the ignition switch off MAINTENANCE AND ADJUSTMENT 133 General Lubrication In accordance with the Periodic Maintenance Chart have the general lubrication performed by an authorized Kawasaki dealer or perform i
62. fer to the Front Cargo Compartment section in the General In formation chapter e Check the coolant level through the coolant level gauge on the reserve tank The coolant level should be between the F Full and L Low marks NOTE O Check the level when the engine is cold room or atmospheric temperature Coolant Capacity 4 6 L 4 9 US qt MAINTENANCE AND ADJUSTMENT 99 Reserve Tank F Full Mark L Low Mark Cap A B C D e If the amount of coolant is insufficient unscrew the cap from the reserve tank and add coolant through the filler opening to the F Full mark Install the cap Recommended Coolant Solution Coolant Mixture Ratio Water 50 Antifreeze 50 1 1 Recommended Antifreeze Permanent type antifreeze ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiator 100 MAINTENANCE AND ADJUSTMENT NOTE 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 an tifreeze concentrate as soon as possible NOTICE If coolant must be added often orthe reserve tank completely runs dry there is probably leakage in the system Have the cooling sys tem inspected by your authorized Kawasaki dealer Coolant Change Have the coolant changed by an authorized Kawasaki dealer Spark Plugs The standard sp
63. fer 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 A WARNING Failure to perform these checks before operation may result in serious damage or an accident Al ways perform daily checks before operation A 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 FUG e bo abelian Enough fuel in tank no leaks Engine oil Oil level between F and L lines on the dipstick when engine is cold no leaks Air Cleaner Check the restriction gauge for the red band in the window epe reb Air pressure when cold Front 69 kPa 0 7 kgf cm 10 psi Rear 167 kPa 1 7 kgf cm 24 psi Check for cuts cracks damage or excessive wear Check for any imbedded stones or other foreign particles in tread 64 HOW TO OPERATE Front Final Gear Case No oil leaks Transmission Case Oil Oil level between and L lines on the dipstick no leaks Coolant Coolant level between level lines when engine is cold no leaks ThOttlle t eene hts Throttle pedal free pla
64. fuel in well ventilated area Shut engine off Keep away from flame or sparks KISS 56071 7501 CF03150BM2 C 10 LOCATION OF LABELS 27 GS QQ SS COS WS SS Y ARN R NG Rear Seat Capacity Two persons All passengers should fasten seatbelts The rear seat is equipped with two seatbelts 11 WARNING Overloading or improper use of the cargo bed can cause changes in handling which can lead to an accident Do not install passenger seats in the cargo bed argo Only no passengers Don t overload convertible cargo bed capacity oShort bed mode 1822 400165 Long bed mode 363kg 800 bs Read your Owner s Manual for additional loading information 56071 0137 CF03335BM2 C 12 56071 7513 CF03232BM5 C WARNING Improperly loading a trailer and failure to use extra care when pulling a trailer can cause an accident and injury Never load more than 50 kg 110 105 tongue weight on the towing bracket Do not tow more than 545 kg 1200 lbs rolling weight trailer plus cargo Allow for increased braking distance and use extreme caution when operating on hills Read carefully the loading information and trailer EH 7 nen lle 56071 0332 CF038948 5 28 LOCATION OF LABELS 13 A WARNING Do not touch hot surfaces engine exhaust pipe muffler
65. gate by sliding both latches toward the center of the vehicle Push the handles down to make sure the latches stay securely closed Do not drive the vehicle with the tailgate lowered A Tailgate B Latch Handle C Wire Loop GENERAL INFORMATION 41 Loading Cargo Bed NOTICE Do not carry more than the maximum load stated here in the convertible cargo bed Short bed mode 182 kg 400 Ib Long bed mode 363 kg 800 Ib A WARNING e 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 e Passengers riding in the cargo bed can be tossed about or even thrown out causing serious injury or death Do not install seat ing or carry passengers in the cargo bed e Driving with the cargo bed tilted may be hazardous Failure to lower and lock the bed into place may cause serious injury or death Always lower and latch the bed after tilting e Lifting and lowering the bed could be dan gerous Be careful not to catch any part of your body such as hands or arms be tween the bed and ROPS or vehicle frame when lifting and lowering the bed 42 GENERAL INFORMATION Raising amp Lowering the Cargo Bed The cargo bed can be tilted by releasing the latches on each side and then lifting the bed with the handgrips Before tilting the cargo bed select a firm level surface and set the parking brake
66. h the positive and negative cables together and do not lean over the bat tery when making this last connection Do not connect to a frozen battery It could ex plode Do not reverse polarity by connecting positive to negative or a battery ex plosion and serious damage to the electrical system may occur A Vehicle Battery Positive Terminal B From Booster Battery Positive Terminal C Unpainted Metal Surface D From Booster Battery Negative Terminal NOTICE Follow the standard engine starting procedure Do not operate the starter continuously for more than 5 seconds or the starter overheat and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power e Connect another jumper cable from the negative terminal of the booster battery to an unpainted metal surface on your vehicle Do not use the negative terminal of the battery After the engine starts disconnect the jumper ca bles Disconnect the negative cable from the vehicle first e Reinstall the battery holder and the cover 68 HOW TO OPERATE Moving Off Braking e Depress the brake pedal e Put the gear shift lever into the H High or L Low position e Release the parking brake e Gradually increase engine speed by pressing on the throttle pedal NOTE O Practice starting and stopping u
67. he ns radiator should be cleaned more frequently than the recommended interval e Clean the screen and radiator fins of any obstruc tions with a stream of low pressure water WARNING e If insects or mud can not be completely removed To avoid injury keep your hands and cloth it should be cleaned by an authorized Kawasaki ing away from the fan blades at all times dealer NOTICE Using high pressure water as from a car wash facility could damage the radiator fins and impair the radiator s effectiveness Do not obstruct or deflect airflow through the radiator by installing unauthorized ac cessories in front of the radiator or behind the cooling fan Interference with the ra diator airflow can lead to overheating and consequent engine damage 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 level is low Change the coolant in accordance with the Periodic Maintenance Chart NOTE OA permanent type of antifreeze is installed in the cooling system when shipped It is colored green and contains ethylene glycol It is mixed at 5096 with water and has a freezing point of 35 C 31 F Coolant Level Inspection e Situate the vehicle on level ground e Lift the front cargo hood up Re
68. itting Bolts NOTE Adjustment should be made for both sides The headlight beams can be adjusted vertically e Remove the holder A Holder e Turn the adjusting screw on each headlight rim in or out to adjust the headlight vertically MAINTENANCE AND ADJUSTMENT 127 Battery The battery is located under the left end of the front seat A 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 Battery Removal A Adjusting Screws e Remove the cover under the front seat left end A Cover e Remove the battery holder 128 MAINTENANCE AND ADJUSTMENT A Holder B Terminal C Terminal e Disconnect the cables from the battery first from the terminal and then the terminal NOTE O There is no need to separate the smaller cables clamped with the main battery cables e Take the battery out e Clean the battery using a solution of baking soda and water Be sure that the lead connections are clean e Perform a visual inspection Inspect for defective or cracked case and cover and loose or damaged terminal posts or cables Replace battery and or cables immediately if any damage is found Battery Installation e Check that the rubber dampers on the battery holder and the floor board are properly in place e Put the battery in place o
69. ized Kawasaki dealer for inspection and diag nosis You can go to any Kawasaki dealer for warranty repairs Your Kawasaki dealer will inspect your vehicle and give you the results of the inspection The dealer will perform the repairs at no cost to you if it is determined that the problem is covered by the warranty Kawasaki will work with your dealer to resolve any warranty issues No authorization for warranty work can be given until your vehicle has been inspected by a Kawasaki dealer What if am not Satisfied With My Warranty Service If you aren t satisfied with your dealership s repair work or operations it is best to discuss the situation with the appropriate dealership manager If you have already done this then contact the dealership s owner or general manager to request a review of the issue If you are unable to resolve a problem after consulting with the dealership management and need further as sistance contact Kawasaki Motors Corp U S A at the address below Please be certain to provide the model vehicle identification number VIN mileage or hours of use accessories dates that events occurred and what action has been taken by both you and your dealer Include the name and address of the dealership To assist us in resolving your inquiry please include copies of related receipts and any other pertinent informa tion including the name of the dealership personnel with whom you have been working Upon receipt of your correspo
70. key code on the tag or your key Store one key at home and keep another spare in your wallet or riding gear in case the original is lost 54 GENERAL INFORMATION 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 The lowest segment blinks in the fuel gauge LED when approximately 5 0 L 1 3 US gal of usable fuel remains Refuel at the earliest opportunity if the most bottom segment of the fuel gauge LED blinks CH17004BM2 A Fuel Gauge LED B Blink Hour Meter The hour meter shows the total hours that the vehi cle has been operated This meter cannot be reset NOTE O The data is maintained even if the battery is dis connected O The hour meter shows the operating hours to a maximum of 5 digits The value is shown to the nearest 0 1 hr until the total reaches 10 000 hrs after which the meter counts in complete hours only O When the figures come to 99999 they turn back to 0 0 and start counting upward again when the vehicle is operated E 1 4 1 2 3 4 F CH17003BM2 A Hour Meter Shift Levers This vehicle is equipped with three different shift levers the gear shift lever the 2WD 4WD shift lever and the differential shift lever Gea
71. le Load Including occupants and cargo 603 kg 1 330 Ib Maximum Cargo Bed Load Short Bed Mode 182 kg 400 Ib Long Bed Mode 363 kg 800 Ib MODEL INFORMATION MULE 4010 TRANS 4 x 4 KAF620R S NOTE O The KAF6208 is identical to the KAF620R in every aspect controls features and specifications except for the camouflage surface treatment Specifications are subject to change without notice 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 event of theft the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it Frame No Engine No d a A Frame Number A Engine Number IA 16 LOCATION OF PARTS Four person mode LOCATION OF PARTS 1 Headlights 2 ROPS 3 Front Cargo Hood 4 Front Cargo Compartment 5 Steering Wheel 6 Front Seat 7 Rear Seat 8 Seat Belts 9 Cargo Bed 10 Front Bumper 11 Radiator 12 Parking Brake 0 8032 P 13 Battery 14 Latch 15 Air Cleaner Belt Drive Torque Converter 16 Belt Drive Torque Converter 17 Handgrip Two person mode 18 Screen 19 Latch Handle 20 Tail Gat
72. ment Refueling Before refueling the vehicle shut the engine off and make sure the area is well ventilated and free of any source of flame or sparks Gasoline is very flammable Tire Air Pressure Tire inflation and type can affect the vehicle s han dling characteristics Check the tire pressure fre quently Use only the recommended tires for re placement 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 x W x H ENGINE Type Displacement Bore x Stroke Compression Ratio SPECIFICATIONS 11 SPECIFICATIONS Front Rear 47 0 N m 4 8 kgf m 34 7 ft lb 2 500 r min rpm 3 9 m 12 80 ft Front 2 persons Rear 2 persons 3 265 mm 128 54 in 1 485 mm 58 46 in 1 925 mm 75 79 in 2 165 mm 85 24 in 1 160 mm 45 67 in 1 180 mm 46 46 in 180 mm 7 09 in 720 kg 1 588 Ib Long bed mode 1 280 x 1 210 x 285 mm 50 39 x 47 64 x 11 22 in Short bed mode 770 x 1 210 x 285 mm 30 31 x 47 64 x 11 22 in OHV 2 oylinder 4 stroke liquid cooled 617 cm 37 6 cu in 76 0 x 68 0 mm 2 99 x 2 68 in 10 3 1 12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Grade Viscosity Capacity Coolant Capacity
73. ment is controlled by the ECU and can not be adjusted If the idle speed is unstable have your dealer inspect the throttle body Specified Idle Speed 950 50 rpm High Altitude Use High altitude adjustment is not required as the ECU electronic control unit controls the air fuel mixture automatically The fuel pump filter can become blocked caus ing fuel pump damage if dirt mud debris or contam inated fuel enters the fuel tank The engine may hesitate or lose power if the fuel pump filter be comes blocked If you suspect that the fuel filter has become blocked have your authorized Kawasaki dealer inspect the fuel pump and fuel tank Fuel Tank Vent MAINTENANCE AND ADJUSTMENT 111 Belt Drive Torque Converter The fuel tank vent hoses must be routed as spec ified The engine may stall or lose power if the fuel tank vent is plugged or if the vent hoses are pinched Inspect the vent hoses before riding and whenever the engine seems to lose power If the fuel tank is full but the engine feels as if it is running out of fuel A Fuel Tank Vent Hoses B Check Valve C Fuel Tank The vehicle is equipped with a belt drive torque converter type automatic transmission The belt driven pulley shoes and drain cap should be checked in accordance with the Periodic Main tenance Chart The belt and driven pulley shoes inspection should be done by an authorized Kawasaki dealer A Belt Drive Torque Converter inside
74. n of this Owner s Manual Keep all receipts for the service and or items necessary to perform the maintenance so that in the event of a failure you can document the service history What Are The Dealership s Responsibilities Your Kawasaki dealer offers a wide range of services parts accessories and information on your product and on Kawasaki Each dealer is independently owned and operated and is responsible for the dealership s operations its repair warranty and service work and its personnel Your dealer is responsible for completing the set up and pre delivery service of your new Kawasaki vehicle The dealership should also explain its operation maintenance and warranty provisions so you understand them at the time of purchase or at any other time you have questions The dealership is responsible for inspecting your Kawasaki vehicle if there is a failure investigating the cause of the problem and getting any needed authorization from Kawasaki if the repair is one that will be covered by the limited warranty The dealership will also file all necessary paperwork The dealership is responsible for correctly completing any necessary repairs whether they are covered by the limited warranty or not YOUR WARRANTY OWNER SATISFACTION 141 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 author
75. n the harness may have blown There are several reasons that the fuses may blow Refer to the Fuse section in this chapter for details e Battery voltage has dropped Voltage drop can happen when the engine starts inspect the battery voltage e Cable harness or connectors may have been dis connected See an authorized dealer for service NOTE Olf the steering becomes irregular or unusual for any reason other than above have an authorized dealer check the steering and relevant compo nents immediately In some cases the power steering s neutral position can be affected by an accident or bump The rims are drop center tubeless tire design Take care not to damage the sealing surfaces of the tire or rim when removing or installing tires Note that the rims like automotive rims are not symmetrical wheels must be installed so that the valve stems are on the outside of the vehicle Wheel Nuts Check for wheel nut tightness in accordance with the Periodic Maintenance Chart Tightening Torque 137 N m 14 kgf m 101 ft lb Tires The front and rear tires are knobby tubeless tires When replacing tires check the valve stems and cores for damage Take care not to damage the tire sealing surfaces of the rims Standard Tires front and rear 23 x 11 00 10 DUNLOP KT869 23 x 11 00 10 DURO DI K968 MAINTENANCE AND ADJUSTMENT 121 Tire Air Pressure when cold 69 kPa ront 0 7 kgf cm 10 psi m 167 kPa
76. n the rubber damper e Connect the three positive cables to the termi nal and then connect the negative cable to the terminal NOTE O Be sure to reconnect any other cables e Put a light coat of grease on the terminals to pre vent corrosion e Reinstall the battery cover and holder A WARNING Loose battery cables can create sparks which can cause a fire or explosion resulting in injury or death Make sure the battery terminal screws are tightened securely and the covers are in stalled over the terminals Battery Characteristics The battery installed in this vehicle is 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 nec essary to check the battery electrolyte level or add distilled water However in order to maximize battery life and en sure that it will provide the power needed to start your vehicle you must properly maintain the battery s charge When used regularly the charging system in your vehicle helps keep the battery fully charged If your vehicle is only used occasionally or for short periods of time the battery is more likely to dis charge Due to their internal composition batteries contin ually self discharge The discharge rate depends on the type of battery and ambient temperature As temperatures rise so does the discharge rate Ev ery 15 C 59 F doubles the
77. ndence Kawasaki Motors Corp U S A will contact the dealership and work with it in resolving your problem 142 YOUR WARRANTY OWNER SATISFACTION Want to Contact Kawasaki 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 U S A P O Box 25252 Santa Ana CA 92799 5252 949 460 5688 ENVIRONMENTAL PROTECTION 143 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 Ve hicle UV please follow these Tread Lightly guidelines Tread Lightly Travel responsibly on designated roads and trails or in permitted areas Respect the rights of others including private property owners and all recreational trail users campers and others to allow them to enjoy their recreational activities undisturbed Educate yourself by obtaining travel maps and regulations from public agencies planning for your trip taking recreation skills classes and knowing how to use and operate your equipment safely Avi sensitive areas such as meadows lakeshores wetlands and streams unless on designated routes This protects wildlife habit
78. ngine speed is running slightly above the idle speed stop the engine immediately and find the cause A Oil Pressure Warning Light Fuel Injection Warning Light GENERAL INFORMATION 35 Parking Brake Warning Light The fuel injection DFI warning light goes on when the ignition switch key is turned to ON and goes off soon after ensuring that its circuit functions prop erly 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 A Fuel Injection Warning Light The parking brake warning light goes on when the parking brake is applied with the ignition switch in the ON position NOTE O This light shows only that the parking brake is on It does not show the degree of parking brake ap plication 36 GENERAL INFORMATION Power Steering Warning Light Steering Wheel The power steering warning light will momentarily illuminate when the engine starts then goes off in one second if the system is in order If the warning light illuminates any other time it indicates the ECU or actuator has malfunctioned or the wiring harness has become disconnected Stop driving immediately and see an authorized Kawasaki dealer to have the system checked A Power Steering Warning Light NOTE O lf the warning light does not go on when the engin
79. nt cargo hood see Front Cargo Compart ment section in the General Information chap ter and fill the reservoir to the upper level line e Remove the rubber cover 116 MAINTENANCE AND ADJUSTMENT A Brake Fluid Reservoir B Upper Level Line MAX C Lower Level Line MIN A 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 com pletely if the fluid level is low but the type and brand of the fluid already in the reservoir are unknown e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings A WARNING Air in brake line can make the brake feel mushy or soft This may cause reduced braking performance or brake failure and result in an accident If brake lever travel is excessive or the brake feels mushy have an authorized Kawasaki dealer inspect it immediately Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer 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 Inspection e Turn the ignition switch to the position e Depress the brake pedal The brake light should go on after about 10 mm 0 4 in of pedal travel A Brake Pedal B 10 mm 0 4 in e If it
80. oid hills with slippery sides that will cause you to lose traction Also avoid traversing hillsides covered with rocks or other ob stacles which may cause you to lose your balance or tip over When driving on soft terrain steer slightly uphill to keep the vehicle on a straight line across the hillside Ifthe vehicle begins to tip steer downhill if possible to regain control Obviously on slippery or loose surfaces special care is required Sliding any vehicle may be haz ardous because the wheels may suddenly regain traction and cause the vehicle to tip or overturn Therefore never drive over your head or when you are unsure or unprepared for the surface Often you can correct a skid by turning the wheels in the direction of the skid Do not apply heavy brak ing force or accelerate when skidding since this may cause further loss of control Use caution and maintain low speeds to avoid un controlled skidding on areas covered with clay mud ice or snow Use 4WD and low range gearing effi ciently These conditions are particularly hazardous when descending a hill or making a turn Remem ber that this vehicle is not for use on public streets roads or highways Remember e Be especially careful on very slippery surfaces e Don t drive on public streets roads or highways Driving through Water Avoid driving through water whenever it is possi ble When driving across shallow water choose a location to ent
81. oke Full Synthetic Oil gt or other 4 stroke oils with API SG SAE 208 40 SH SJ SL SM and JASO MA MA1 SAE 10W 50 MA2 rating Viscosity SAE 10W 40 Capacity 1 3 L 1 4 US qt when filter is not removed 1 5 L 1 6 US qt MED E E 104 F SAE 10W 40 SAE 10W 30 when filter is removed BLO3006BM2 C Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle Con sistent use of these products meets or exceeds war ranty and service requirements and can help to ex tend the life of your Kawasaki NOTE not add any chemical additive to the oil Oils fulfilling the above requirements are fully formu lated and provide adequate lubrication for the en gine 92 MAINTENANCE AND ADJUSTMENT Front Final Gear Case Oil In order for the differential pinion and ring gears to function properly check the oil level and change the oil in accordance with the Periodic Maintenance Chart A WARNING Vehicle operation with insufficient deterio rated or contaminated oil causes acceler ated wear of the differential pinion and ring gears and may result in seizure Seizure can lock the front and rear wheels and skid 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 Oil Level Inspection e Remove the front final gear case guard by r
82. operate the differential shift lever if the ve hicle is moving faster than 8 km h 5 mph Shifting to Locked Axle Mode e Pull the stopper under the differential shift lever knob and while holding it against the knob move the shift lever all the way down LOCK 218006 P A Differential Shift Lever B Stopper C Differential Unlocked Axle Mode Position UN LOCK D Locked Axle Mode Position LOCK 74 HOW TO OPERATE Shifting to Differential Unlocked Axle Mode NOTE e Pull and hold the stopper then move the shift lever O When the shift lever is moved the differential may EN all the way up UN LOCK not immediately lock or unlock until the vehicle has rolled a short distance SAFE OPERATION 75 SAFE OPERATION Safety is an attitude Your common sense and good judgement are your best defenses against accident and injury in everything you do Your safety and the safety of others depends on you and your common sense Use good judgement in the operation of this or any other motor vehicle This vehicle is designed for an operator and one passenger for 2 person mode or an operator and three passengers for 4 person mode Never carry persons in the cargo bed Refer to the Loading Information chapter before operating this vehicle Novice operators should practice braking and turn ing in an open off highway area away from other vehicles and persons The terrain should be flat and free of obstacles with either a lo
83. or too stiff have the sleeves adjusted by an authorized Kawasaki dealer in accordance with the following table e Turn the adjusting sleeves on the shock absorbers to the desired position Spring Action Spring Force Setting Strong Hard A WARNING Improper shock absorber adjustment can cause poor handling and loss of stability which could lead to an accident Always adjust the shock absorbers on the left and right side to the same setting MAINTENANCE AND ADJUSTMENT 125 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 the red button in the buckle to make sure it releases freely Also check the belt webbing for wear cuts or damage f any irregularities are found have the seat belt system checked or replaced by an authorized Kawasaki dealer A Seat Belt B Buckle C Red Button 126 MAINTENANCE AND ADJUSTMENT Cargo Bed Latches Headlight Beam Depending on the cargo loading and or passenger riding conditions latch lever compression needs to be adjusted Release the fitting bolts and adjust the position of the latch assembly so that the latch lever will be se cured without rattling and tighten the bolts A Latch Assembly B Latch Lever C F
84. ore than 10 ethanol or more than 5 methanol Gaso line containing methanol must also be blended with cosolvents and corrosion inhibitors Certain ingredients of gasoline may cause paint fading or damage extra careful not to spill gasoline or gasoline oxygenate blends during refueling When not operating your Kawasaki for 30 to 60 days mix a fuel stabilizer such as STA BIL with the gasoline in the fuel tank Fuel stabilizer additives inhibit oxidation of the fuel which minimizes gummy deposits Never store this product with gasohol in the fuel system Before storage it is recom mended that you drain all fuel from the fuel tank See the STORAGE chapter in this manual 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 com partments to remove any water that may enter Do not put items which must not get wet or dirty in it A Left Glove Compartment GENERAL INFORMATION 49 A Right Glove Compartment 50 GENERAL INFORMATION 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 M Hood Opening Raise the hood until it stops while pulling the l
85. ose or hard dirt sur face but not a mixture of both WARNING Incorrect loading improper installation or use of accessories or modification of 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 Load ing Information chapter Unfamiliar Terrain Before driving in a new area be sure to check for hidden obstacles or hazards Keep your speed down until you know the area well You must know the terrain you intend to drive on and be familiar with your machine and its handling characteristics Use existing trails and stay away from hazardous areas Such as steep rocky slopes or swamps Be cautious when visibility is limited as you may not be able to see obstacles in your path 76 SAFE OPERATION Driving in Reverse Driving in 4WD Start the engine following the procedure in the Starting the Engine section Before shifting into re verse stop the vehicle completely Refer to the Gear Shift Lever in the Shift Levers section and Revers ing Gears section Turn around and look behind you before backing up to be sure there are no obstacles or people in your way Gradually open the throttle and begin backing up cautiously To stop while driving in reverse close the throttle and gradually apply the brake Avoid sudden appli cation of the brake NOTICE Do not operate the g
86. ot return properly check the throttle cable routing pedal free play and ca ble damage Then lubricate the throttle cable MAINTENANCE AND ADJUSTMENT 107 A Throttle Pedal B 5 10 mm 0 2 0 4 in Throttle Pedal Play Adjustment e Lift the cargo bed and support it with the rod e Loosen and turn the throttle cable mounting nuts at the end of the throttle cable e Slide the adjuster until the proper amount of throt tle pedal play is obtained 108 MAINTENANCE AND ADJUSTMENT Throttle Cable Mounting Nuts A B e 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 re quired e Remove the cover by unscrewing the bolt A Cover B Bolt e Loosen the locknut e Screw in the throttle pedal stop bolt e Depress the throttle pedal until the pulley on the main throttle valve touches to the stopper at the fully opened position and hold it there MAINTENANCE AND ADJUSTMENT 109 A Pully Fully Opened Position A Throttle Pedal B Stopper B Locknut C Throttle Pedal Stop Bolt e Turn the throttle pedal stop bolt until the bolt head lightly touches the bottom of the throttle pedal e Tighten the locknut securely e Be sure to check the throttle cable moves smoothly 110 MAINTENANCE AND ADJUSTMENT Idle Adjustment Fuel Pump Filter Idle adjust
87. r Shift Lever The gear shift lever is located on the dashboard to the right of the steering shaft The gear shift lever has four positions High L Low Neu tral and R Reverse Make certain that the vehicle is completely stopped and the engine is idling before shifting from H High or L Low to R Reverse or vice versa Move the gear shift lever up or down as indicated on the label next to the shift lever Refer to the Reversing Gears section in the How to Operate chapter GENERAL INFORMATION 55 A Gear Shift Lever B H High Position C L Low Position D N Neutral Position E R Reverse Position NOTICE Do not shift from H High or L Low to R Reverse and vice versa when the vehicle is moving or with the engine run ning above idling speed or the transmission could be damaged 56 GENERAL INFORMATION This vehicle is equipped with a 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 The high gearing raises the speed range for ordinary off highway use Stop the vehicle before moving the Hi Lo shift lever NOTICE Use of the high range for heavy loads climb ing hills and pulling a trailer can lead to pre mature wear of the torque converter belt and p
88. ration of the starter to let it cool and for the battery to recover power Do not turn the ignition switch key to the START position with the engine running or nition Switch B OPES Boso damage to the starter can result C ON position D START position NOTE E Fuel Gauge F Hour Meter O The vehicle is equipped with a starter lockout switch This switch prevents the electric starter from operating when the gear shift lever is in the High L Low or R Reverse position 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 96 0009090999 0 0 80 o PESENE CH16007BM2 B Key Number Write your key number here Po GENERAL INFORMATION 53 In the event you lose your keys you will need the key number to have a duplicate made If you cannot locate your key number contact the dealer where you purchased your Kawasaki UV It s possible the dealer may have the number in its records If the key number is lost completely you will need to replace the ignition switch and all other locks operated by that key Contact your Kawasaki dealer to purchase addi tional spare keys either using your original key as a master or using the
89. rds while seated upright with their backs against the seatbacks To wear the seat belt properly follow this proce dure 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 Verify the belt retracts to a SNUG FIT A WARNING Too much seat belt slack could reduce its protection effectiveness in an accident Al ways verify that the belt is at a SNUG FIT To unfasten the belt press the red button in the buckle 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 throt tle pedal returns normally before starting the engine In addition there must be adequate throttle pedal play and correct throttle stop position adjustment Refer to the Maintenance and Adjustment chapter A Throttle Pedal GENERAL INFORMATION 61 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 A WARNING Improper towing of a loaded trailer could cause an accident resulting in serious injury or death Never carry a passenger in a trailer Never load more than 50 kg 110 Ib tongue weight on
90. sing the brakes until you are familiar with the controls NOTE O When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking This is caused by the ve hicle s automatic transmission which releases the engine at very low speed to prevent it from stalling Employ the brakes to control the vehicle s speed e Release the throttle pedal completely e Press on the brake pedal evenly and firmly A WARNING Carrying cargo or towing a trailer will in crease braking distances Failure to allow for increased braking distance may result in accident and injury Always allow more dis tance to stop when carrying cargo or towing a trailer Stopping the Engine HOW TO OPERATE 69 Parking the Mule e Release the throttle pedal completely e Put the gear shift lever into the N Neutral posi tion e Apply the parking brake to help prevent the vehicle from rolling e Turn the ignition switch key to the OFF position A WARNING Operating or parking the vehicle near flammable materials can cause a fire and can result in property damage or severe personal injury Do not idle or park your vehicle in an area where tall or dry vegetation or other flammable materials could come into con tact with the muffler or exhaust pipe A WARNING The engine and exhaust system get ex tremely hot during normal operation and can cause serious burns Never
91. t lever cannot e Move the shift lever to the L Low position be shifted when the vehicle is in motion Gear Shift Lever H High Position N Neutral Position A B C L Low Position D E Reverse Position 72 HOW TO OPERATE Reversing Gears 2WD 4WD Shifting e Release the throttle pedal and stop the vehicle e 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 NOTICE Do not shift from High or L Low to R Reverse and vice versa when the vehicle is moving or with the engine run ning above idling speed or the transmission could be damaged e Pull the stopper under the 2WD 4WD shift lever knob and while holding it against the knob move the shift lever to the all way down to 4WD e To shift back into 2WD position pull and hold the stopper then move the shift lever all the way up to 2WD NOTE O When the shift lever is moved from 2WD to AWD the transmission shifts immediately When the shift lever is moved from AWD to 2WD the transmission may not shift all the way into 2WD until the vehicle has rolled a short distance A 2WD 4WD Shift Lever B Stopper 2WD position D 4WD position HOW TO OPERATE 73 Shifting the Differential NOTE O Do not
92. t referring to the Service Manual for this vehicle 134 MAINTENANCE AND ADJUSTMENT Cleaning To prolong the life of your vehicle wash it down immediately after it has been splashed with sea wa ter or exposed to salt air or operated on rainy days rough terrain or in dusty areas A 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 vehicle inspect the engine electrical component and exhaust areas frequently If debris or flammable materials have collected park the vehicle outside and stop the engine Allow the engine to cool then remove any collected debris Do not park or store the vehicle in an enclosed space prior to inspecting for build up of debris or flammable materials Preparation for Washing Before washing precautions must be taken to keep water off the following parts e Muffler rear opening cover with a plastic bag e Ignition switch cover the keyhole with tape e Air cleaner intake middle of the rear ROPS top close opening with tape or stuff in rags e Horn button cover with tape Where to be Careful Avoid spraying water with any great force near the following places e Front and rear brakes if water gets into the brake drums they will not work effectiv
93. the nuts shown here or if there is any doubt as to the condition or braking effectiveness have the parking brake system inspected by an authorized Kawasaki dealer MAINTENANCE AND ADJUSTMENT 119 Steering Wheel In accordance with the Periodic Maintenance Chart check the steering wheel for the specified free play and smooth operation Free Play Inspection e Park the vehicle on level ground e Lightly turn the steering wheel left and right e There should be 0 20 mm 0 0 8 in of free play e f there is excessive free play or strange noises or the steering feels rough or catchy have the steering system checked by an authorized Kawasaki dealer A 0 20 mm 0 0 8 in 120 MAINTENANCE AND ADJUSTMENT Steering Position Adjustment The steering wheel position can be adjusted to suit the operator e Loosen the upper and lower nuts on the steering column bracket and move the steering wheel up or down A Steering Column Bracket B Nuts e Tighten the bolts and nuts Power Steering System Steering may become more difficult than usual for the following reasons e The steering wheel was continuously turned or held to the full turn stops with torque applied by driver In this case the ECU works to protect the system from overheating by stopping the power assisting Stop turning the steering wheel and wait until the system temperature drops and the power steering recovers e Fuses i
94. the dipstick dry and insert it into the filer hole but DO NOT SCREW IT IN MAINTENANCE AND ADJUSTMENT 95 A Transmission Case B Oil Filler Plug NOTICE Be careful not to allow any dirt or foreign ma terials to enter the transmission case e Pull out the dipstick and check the oil level The oil level should be between the H High and L Low lines on the dipstick 96 MAINTENANCE AND ADJUSTMENT A Oil Filler Plug and Dipstick B Insert the dipstick into the filler hole but do not screw it in C High Line D L Low Line e If the oil level is too high remove the excess oil using a syringe or other suitable device through the oil filler opening e If the oil level is too low add the correct amount of oil e Install the filler plug NOTE Use the same type and brand of oil that is already in the transmission case Oil Change NOTE O Before draining the oil warm it up by running the vehicle Warm oil drains easily and picks up any sediment e With the vehicle level place an oil pan beneath the transmission case A Transmission Case B Drain Plug MAINTENANCE AND ADJUSTMENT 97 A WARNING Tightening Torque The exhaust system can get extremely hot Drain Plug 15 Nm 1 5 kgfm 11 16 during normal operation and cause serious burns To avoid a serious burn never touch Transmission Case Type a hot muffler or exhaust pipe
95. ts nuts and fas teners checked by an authorized Kawasaki dealer 136 STORAGE STORAGE Preparation for Storage e Clean the entire vehicle thoroughly e Run the engine for about five minutes to warm the oil shut it off and drain the engine oil A WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local author ities for approved disposal methods or pos sible recycling e Put in fresh engine oil e Empty the fuel from the fuel tank A WARNING Gasoline is extremely flammable and can be explosive under certain conditions Do not smoke Turn the ignition switch OFF Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light A WARNING Gasoline is a toxic substance Dispose of fuel properly Contact your local authorities for approved disposal methods NOTE OAsan alternative to draining the fuel system a fuel stabilizer such as STA BIL may be used Follow the manufacturer s instructions for use A WARNING Fuel stabilizers may contain poisonous sub stances Heed the manufacturer s warnings for use e Remove the spark plugs and spray fogging oil such as Kawasaki K Kare Fogging Oil part num ber K61030 002 directly into each cylinder Turn the engine over several times with the ignition Switch key to coat the cylinder walls Install the spark plugs A WARNING
96. ty coverage offered by the limited warranty can be extended by purchasing Kawasaki s Good Time Protection Plan GTPP See your Kawasaki dealer or go to Kawasaki com for more information if you don t already have the GTPP What 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 140 YOUR WARRANTY OWNER SATISFACTION You will be responsible for paying for routine maintenance including the first scheduled service You can have the required servicing done by your Kawasaki dealer recommended or an equally qualified service facility You can also do your own maintenance work if you have the proper tools service references and mechanical skills However if a failure is found to be caused by improper servicing it would not be covered by the limited warranty You may purchase a Kawasaki Service Manual and any necessary special tools directly from your Kawasaki dealer You will be responsible for paying for repairs needed because of an accident to replace worn parts such as tires chains brakes and for repairs needed because of a lack of maintenance misuse or racing Whether you do it yourself or take your vehicle to a Kawasaki dealer be sure to record your service in the Maintenance Record sectio
97. uality or nonrec ommended fuel may not be covered under warranty Fuels Containing Oxygenates Gasoline frequently contains oxygenates alco hols and ethers especially in areas of the U S and Canada which are required to sell such reformu lated fuels as part of a strategy to reduce exhaust emissions The types and volume of fuel oxygenates ap proved for use in unleaded gasoline by the U S Environmental Protection Agency include a broad 48 GENERAL INFORMATION range of alcohols and ethers but only two compo nents have seen any significant level of commercial use Gasoline Alcohol Blends Gasoline containing up to 1096 ethanol alcohol produced from agricultural products such as corn also known as gasohol is approved for use NOTICE Avoid using blends of unleaded gasoline and methanol wood alcohol whenever possible and never use gasohol containing more than 5 methanol Fuel system damage and performance problems may result Gasoline Ether Blends The most common ether is methyl tertiary butyl ether MTBE You may use gasoline containing up to 1596 MTBE NOTE O Other oxygenates approved for use in unleaded gasoline include TAME up to 16 7 and ETBE up to 17 296 Fuel containing these oxygenates can also be used in your Kawasaki NOTICE Never use gasoline with an octane rat ing lower than the minimum specified by Kawasaki Never use gasohol with m
98. ucts Please read this Owner s Manual carefully before starting your new Mule so that you will be thoroughly familiar with the proper operation of your vehicle s controls 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 Mule dealer The Service Manual contains detailed disassembly and mainte nance information Those who plan to do their own work should of course be competent mechanics and possess the special tools described in the Service Manual Keep this Owner s Manual aboard your Mule at all times so that you can refer to it whenever you need infor mation This manual should be considered a permanent part of the Mule and should remain with the Mule when it is sold All rights reserved No part of this publication may be reproduced without our prior written permission This publication includes the latest information available at the time of printing However there may be minor differences between the actual product and illustrations and text in this manual All products are subject to change without prior notice or obligation KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company 2012 Kawasaki Heavy Industries Ltd Dec 28 2012 1 BASIC SAFE
99. ulleys Use low range for these conditions Refer to the Hi Lo Shifting section in the How to Operate chapter 2WD 4WD Shift Lever This vehicle can be operated either in 2WD or AWD The 2WD 4WD shift lever is located on the dash board to the right of the steering shaft Move the 2WD 4WD shift lever up or down while pulling the stopper as indicated on the label next to the left of the lever Refer to the 2WD 4WD Shifting section in the How to Operate chapter L 2WD 4WD Shift Lever Stopper 2WD Position AWD Position oom Differential Shift Lever This vehicle is equipped with a dual mode rear dif ferential The differential shift lever is located on the dashboard to the left of the steering shaft Move the shift lever up or down while pulling the stopper as in dicated on the label next to the shift lever Refer to the Shifting the Differential section in the How to Operate chapter Differential Shift Lever B Stopper C Differential Unlocked Axle Mode Position UN LOCK D Locked Axle Mode Position LOCK GENERAL INFORMATION 57 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 the lever to the released posi tion
100. vaporative Emission Control System MAINTENANCE AND ADJUSTMENT 105 Spark Arrester This system routes fuel vapors from the fuel sys tem into the running engine or stores the vapors in a canister when the engine is stopped Although no adjustments are required a thorough visual inspec tion must be made at the intervals specified by the Periodic Maintenance Chart Inspection e Check that the hoses are securely connected e Replace any kinked deteriorated or damaged hoses 3 e UN AIR CLEARNER INTAKE MANIFOLD CANISTER LP FILTER FUEL TANK VAPOR HOSES ROUTING DIAGRAM CLi4017B 5 This vehicle is equipped with a spark arrester ap proved for off highway use by the U S Forest Ser vice It must be properly maintained to ensure its efficiency Clean the spark arrester in accordance with the Periodic Maintenance Chart NOTICE The spark arrester must be functioning prop erly to provide adequate fire protection Spark Arrester Cleaning A WARNING The muffler can become extremely hot dur ing normal operation and cause severe burns Since the engine must be running during this procedure wear heat resistant gloves while cleaning the spark arrester e Remove the drain plug from the muffler 106 MAINTENANCE AND ADJUSTMENT A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon monoxide
101. wears down tires become more sus ceptible to puncture and failure e n 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 020018 6 A Tire Depth Gauge Minimum Tread Depth 3 mm 0 12 in e Visually inspectthe tire for cracks and cuts replac ing the tire in case of bad damage Swelling or high spots indicate internal damage requiring tire replacement e Remove any imbedded stones or other foreign particles from the tread MAINTENANCE AND ADJUSTMENT 123 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 authorized Kawasaki dealer B Joint Boot A Steering Knuckle B Tie Rod C Front Axle D Joint Boots 124 MAINTENANCE AND ADJUSTMENT Suspension Rear Shock Absorber Spring Force Adjustment The spring adjusting sleeves on the rear shock ab Sorbers have 5 positions so that the springs can be adjusted for different riding and loading conditions A Shock Absorber B Adjusting Sleeve A Adjusting Sleeve Turn here with a hook wrench If the spring action feels too soft
102. wn MAINTENANCE AND ADJUSTMENT 87 e Park the vehicle on level ground e Pull up the dipstick out of the dipstick tube wipe it dry and insert the dipstick till it bottoms into the tube securely NOTE Oltis necessary to insert the dipstick with its groove mark facing upwards to measure the correct amount of oil 21028015 P A Dipstick B Groove Mark C Rear Seat NOTE Olf the vehicle is in 2 person mode first raise the cargo bed support with the rod and pull the stored rear seat and place it onto the engine 88 MAINTENANCE AND ADJUSTMENT A Rear Seat Folded B Dipstick e Pull out the dipstick and check the oil level The oil level should be between the F Full and L Low lines on the dipstick A Dipstick B F Full Line C L Low Line e Reinsert the dipstick until it bottoms into the tube securely e If the oil level is too high remove the excess oil using a syringe or other suitable device e f the oil level is too low unscrew the oil filler cap and add the correct amount of oil Use the same type and brand of oil that is already in the engine e Install the filler cap Oil and or Oil Filter Change e Warm up the engine thoroughly and then stop the engine MAINTENANCE AND ADJUSTMENT 89 NOTE 4 person mode first fold the rear seat and push its assembly into the stored position and then raise the cargo bed and support it with the rod In 2 person
103. y 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 22d nei aedes Check for braking effectiveness while test running Brake pedal free play 2 10 mm 0 1 0 4 in Brake fluid level between level lines no leaks Parking brake lever travel 8 12 clicks Electrical Equipment All lights and horn work Check for dirt on or damage to lights Starting the Engine A 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 e Wear the seat belts both operator and passen ger e Apply the parking brake e Put the gear shift lever in the N Neutral position e Put the ignition switch key in the switch e Turn the ignition switch key to the START posi tion to activate the electric starter Repeat until the engine starts NOTICE Do not operate the electric starter continu ously for more than 5 seconds or the starter may overheat and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and for battery power to recover HOW TO

Download Pdf Manuals

Related Search

Mule4010Trans4x4CAMO..

Contents

Download Pdf Manuals

Related Search

Related Contents