Kawasaki Mule 4010 diesel 4x4 2012 Owner's manual

Quick Reference Guide

GENERAL INFORMATION j

HOW TO OPERATE j

SAFE OPERATION j

MAINTENANCE AND AD

JUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

This Quick Reference Guide will assist you in

finding the in

formation you’re looking for.

A Table of Contents is included after the

Foreword.

Whenever you see the symbols shown below,

heed their instructions! Always follow safe operat-

ing and maintenance practices.

DANGER

DANGER indicates a hazardous situation

which, if not avoided, will result in death or

serious injury.

WARNING

WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

CAUTION

CAUTION, used with the safety alert symbol,

indicates a hazardous situation which, if not

avoided, could result in minor or moderate

injury.

NOTICE

NOTICE is used to address practices not re-

lated to personal injury.

NOTE



This note symbol indicates points of particular in-

terest for more efficient and convenient operation.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and ex-

haust emission (2) control systems (EM) in compliance with applicable regulations of the United States Envi-

ronmental Protection Agency and California Air Resources Board.

1. Crankcase Emission Control System

A sealed-type crankcase em iss ion control sy stem is used to eliminate blow -by gases. The blow-by gases

are led to the breather chamber through the crankcase 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 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

modified injection pump a nd injection timing characteristics .

The fuel system has been calibrated to provide lean air/fuel mixture characteristics, with a suitable air cleaner

and exhaust system.

A maintenance free injection system provides the most appropriate injection timing and helps maintain a

thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering

the atmosphere.

Maintenance and Warranty

Proper maintenance is necessary to ensure that your engine will continue to have low emission levels. This

Owner ’s Manual contains those maintenance recommendations for your engine. Those items identified by the

Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards.

As the owner of the Mule, you have the responsibility to make su re th at the reco mmended m ain tenance 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 rec ord the maintenance. You s hould also retain c opies of maintenance work orders, bills, etc., as verifica-

tion of this maintenance.

Tampering with Emission Control System is Prohibited

Federal law and California state law prohibit 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 engine 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 engine after such device or

element of design has been removed or rendered inoperative by any person.

Amongthoseactspresumedtoconstitutetamperingaretheactslistedbelow.

Do not tamper with the original emission related parts.

•

Injectionpumpwithfeedpump

•

Injection nozzle

•

Glow plug

•

Fuel filter element

•

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 leve

l. P lease

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 t ra dition of manufa cturing high-quality consum e r products.

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 Man ual conta in s detailed dis assembly a nd main te-

nance information. Those who plan to do their own work should, of course, be competent mechanics and

possess the special tools described in the S ervice 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.

This publication includes the latest information available at the time of printing. However, there may be minor

differences between the actual product and illustrations a nd text in this manua l.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

TABLE OF CONTENTS

BASIC SAFE DRIVING.................................... 8

SPECIFICATIONS.... ........................... ............. 10

SERIAL NUMBER LOCATIONS......... ............. 13

LOCATION OF PARTS .................................... 14

LOCATION OF LABELS..................... ............. 17

LOADING INFORMATION ............................... 26

GENERAL INFORMATION.............................. 28

Cold Weather Information .............................. 28

Lighting/Electrical Accessory Connectors ..... 29

Brake Pedal............................. ...................... 30

Cargo Bed ................ ..................................... 30

Glow Plug Light ............................................ . 32

Coolant Temperature Warning Light.............. 33

Fuel Tank ....................................................... 34

Fuel Requirements: .................................... 34

Fuel Gauge..................... ............................... 35

Air Filter Re striction Gauge ................. .......... 36

Glove Comp artment ......................... ............. 36

Front Cargo Compartment ............................ 37

Horn Button ................. .................................. 39

Main Switch ................................ ................... 39

Keys ......................... ..................................... 40

Hour Meter ................................................... . 41

Light Switch ................................................... 42

Speedometer ............... ........................... ....... 42

Oil Pressure Warning Light... ......................... 43

Shift Levers .......................... ......................... 44

Gear Shift Lever ..................................... .... 44

2WD-4WD Shift L ever . ............................... 45

Differential Shift Lever ................................ 46

Parking Brake Lever ...................................... 46

Parking Brake Warning Light............. ............ 47

Seat ......................................................... ...... 48

Seat Belts ..................... ................................. 48

Steering Whee l................ .............................. 50

Power Steering Warning Light.................... ... 51

Throttle Pedal ............... ................................. 51

Trailer Hitch Bracket ...................................... 52

Winch Installa tion ..................... ..................... 53

HOW TO OPERATE.. ....................................... 56

Daily Safety Checks ....................... ............... 56

Starting the Engine........................................ 58

Cold Weather Starting ................................... 59

Starting After F u el System Service ............... 59

Jump Starting ............... ................................. 60

Moving Off .................... ................................. 62

Braking ........................................ .................. 63

Stopping the Engine ................. ..................... 63

Parking the Mule ........................................... 64

Hi-Lo Shifting................ ................................. 65

Revers ing Gears ............................... ............ 66

2WD-4WD Shifting . ....................................... 66

Shifting the Differential .................................. 67

SAFE OPERATION.......................................... 69

Unfamiliar Terrain .......................................... 69

Driving in Reverse ................................... ...... 70

Driving in “4WD” .......................... .................. 70

Turnin g the Vehicle........................................ 71

Hills................................................................ 71

Climbing Hills................................................. 72

Descending Hills............................................ 73

Traversing Hillsides ....................................... 74

Sliding and Skidding............................ .......... 74

Driving through Water................. ................... 75

MAINTENANCE AND ADJUSTMENT............. 76

Periodic Maintenance Chart ................... ....... 77

Engine Oil..... ....................................... .......... 81

Front Final Gear Case Oil ....... ...................... 86

Transmission Case Oil ......... ......................... 89

Cooling System .. ....................................... .... 92

Valve Clearance ............. ........................... .... 95

Engine Air Cle aner ...... .................................. 95

Spark Arrester ............................... ................ 98

Throttle Pedal ................................................ 99

Injection Pump.......... ..................................... 101

Fuel Filter ........ .............................................. 103

Fuel Tank Vent.................................. ............. 105

Belt Drive Torque Converter ................... ... .... 105

Belt Drive Torq ue Converter Air Cleaner ....... 106

Brakes .... ........................... ............................ 108

Brake Pedal........ ....................................... . 108

Brake Shoe Linings .............. ...................... 108

Brake Fluid ... ....................................... ....... 1 08

Brake Light Switch.......... ............................... 111

Parking Brake Lever. ..................................... 112

Steering Wheel .......................................... .... 113

Power Steering System.............................. 114

Cargo Bed Latches............ ........................... . 115

Wheels ............................................. ............. 116

Rims ......................... .................................. 116

Wheel Nuts.............................. ................... 116

Tires ........................................................... 116

Joint Boots.... ........................... ...................... 118

Suspension............... ..................................... 119

Seat Belts .......................... ............................ 120

Headlight Beam............................................ . 121

Battery ................................................. .......... 122

Fuse . ....................................... ...................... 125

Power Steering System.............................. 126

Breaker ............ ....................................... ....... 1 27

Gener al Lubrica tion ................................ ....... 1 28

Cleaning ...................... .................................. 128

Bolt and Nut Tightening ................................. 129

STORAGE........................................... ............. 130

TROUBLESHOOTING GUIDE......................... 133

YOUR WARRANTY/OWNER SATISFACTION

................................................... ................... 134

ENVIRONMENTAL PROTECTION.................. 138

MAINTENANCE RECORD ........ ...................... 139

8 BASIC SAFE DRIVING

BASIC SAFE DRIVING

Knowing and following these rules for safe oper-

ation will increase your satisfaction with your new

Kawasaki vehicle.

Perform the Daily Safety Checks

Refer to the Daily Safety C hecks section for a list of

items to check each day before use. Habitual per-

formance of these checks will help to in su re safer,

more reliable usage. Be sure that any irregularities

found during these checks are corrected before op-

erating the vehic le.

DriveCarefullyandwithGoodJudgement

We want you to be satisfied with your new

Kawasaki vehicle, so drive carefully, s afely, 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 veh icle; it is de-

signed an d 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.

Operator’s Capacity

All operators should possess a valid driver’s li-

cense. Childre n may not hav e the skills and judge-

ment necessary to operate this vehicle safely.

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.

BASIC SAFE DRIVING 9

Protect Yourself, Use Proper Riding Gear

As appropriate to your operating conditions, wear

approved helmet, eye protection, and protective

clothing. Operating in a recreational settin g, like tra il

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 should wear the

seat belts whenever the vehicle is operated. This

will reduce the severity of injury in case of a sudden

stop or collision.

Also, to reduce chance of injury, always keep arms

and legs inside the cab frame while the vehic le is in

motion.

Before Starting the Engine

Three “musts” before starting the engine are:

1. Apply the parking brake,

2. Put the 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 environment.

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. Diesel fuel 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.

10 SPECIFICATIONS

SPECIFICATIONS

PERFORMANCE

Maximum Torque

52 N·m (5.3 kgf·m, 38.3 ft·lb) @2 800 r/min (rpm)

Minimum Turning Radius

Differential Mode: 3.4 m (11.2 ft)

Seating Capacity

2 persons

DIMENSIONS

Overall Length 3 005 mm (118.31 in.)

Overall Width 1 575 mm (62.01 in.)

Overall Height 1 925 mm (75.79 in.)

Wheelbase

1 870 mm (73.62 in.)

Tread: Front

1 160 mm (45.67 in.)

Rear

1 180 mm (46.46 in.)

Ground Clearance 175 mm (6.89 in.)

CurbMass 725kg(1.599lb)

Cargo Bed (L × W × H)

1 175 × 1 310 × 288 mm

(46.26 × 51.57 × 11.34 in.)

ENGINE

Ty pe Diesel, 3 cylinder, 4-stroke, liquid-cooled

Displacement

953cm³(58.2cuin.)

Bore × Stroke 72.0 × 78.0 mm (2.83 × 3.07 in.)

Compression Ratio

24.8 : 1

Starting System

Electric starter

Cylinder Numbering Method Right to left, 1-2-3

Firing Order

1-2-3

Injection Pump Denso VE Type

Lubrication System Forced Lubrication (wet sump)

SPECIFICATIONS 11

Engine Oil:

Type

API CF or CF-4 class

Viscosity

SAE 10W-40

Capacity 3.3 L (3.5 US qt)

Coolant Capacity 4.1 L (4.3 US qt)

DRIVE TRAIN

Driving Type

4WD/2WD, gear

Transmission Type

2-speed & reverse, automatic

Primary Reduction Ratio

3.7 ∼ 0.98 (Belt drive torque converter)

Final Reduction Ratio 5.429

Overall Drive Ratio:

Forward

9.69 (High)

19.95 (Low)

Reverse

22.454 (Low)

Transmission Gear Ratio:

Forward

1.821 (High)

3.750 (Low)

Reverse

4.220 (Low)

Front Final Gear Case Oil LSD OIL

SAE140 (GL-5) or SAE 90 (GL-6)

Front Final Gear Case Oil Capacity 0.4 L (0.4 US qt)

Transmission Case Oil HYPOID GEAR OIL SAE 90 [above 5°C (41°F)] or

SAE 80 [below 5°C (41°F)]

Transmission Case Oil Capacity 2.5 L (2.6 US qt)

FRAME

Type

Steel tube, ladder type

Steering Assisted with Electric Power Steering (EPS) System

Castor 7.5°

Trail

35 mm (1.4 in .)

Tire Size: Front & Rear

23 × 11-10 Tubeless

12 SPECIFICATIONS

Rim Size: Front & Rear

10 × 8.5

Fuel Tank Capacity 24.2 L (6.4 US gal)

ELECTRICAL EQUIPMENT

Battery 12 V 52 Ah

Headlight 12 V 35 W × 2

Tail/Brake Light 12 V 5/21 W × 2

LOAD CAPACITY

Maximum Vehicle Load

740kg(1632lb)

(Including occupants and cargo)

Maximum Cargo Bed Load 499 kg (1 100 lb)

Specifications subject to change without notice.

SERIAL NUMBER LOCATIONS 13

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 m achine that can help them identify it.

Frame No.

A. Frame Number

Engine No.

A. Engine Number

14 LOCATION OF PARTS

LOCATION OF PARTS

1. Headlights

2. Cab Frame

3. Front Cargo Hood

4. Front Cargo Compartment

5. Steering Wheel

6. Seat

7. Seat Belts

8. Front Bumper

9. Radiator

10. Parking Brake

11. Battery

12. Latch

13. Air Cleaner

(Belt Drive Torque

Converter)

14. Belt Drive Torque

Converter

15. Handgrip

LOCATION OF PARTS 15

16. Air Cleaner (Engine)

17. Screen

18. Tail Gate

19. Cargo Bed

20. Dashboard

21. Coolant Reserve Tank

22. Tail/Brake Lights

23. Trailer Hitch Bracket

24. Muffler (Spark Arrester)

25. Fuel Tank

26. Fuel Tank C ap

16 LOCATION OF PARTS

27. Left Glove Compartment

28. Light Switch

29. Front Cargo Hood Knob

30. Oil Pressure Warning Lig ht

31. Coolant Temperature Warning Light

32. Speedometer

33. Parking Brake Warning L igh t

34. Glow Plug Light

35. Power Steering Warning Light

36. Hour Meter

37. M ain Switch

38. Power Outlet

39. Bottle Holder

40. Right Glove Compartment

41. 2WD-4WD Shift Lever

42. Gear Shift Lever

43. Throttle Pedal

44. Brake Pedal

45. Horn Button

46. Differential Shift Lever

LOCATION OF LABELS 17

LOCATION OF LABELS

1. Warning (Off-Highway Utility Vehicle)

2. Notice (Shifting)

3. Warning (Front Cargo Hood)

4. Notice (Dow nh ill Speed)

5. Warning (General)

6. Specification

7. Important Information (Tires/Max. Load)

8. Warning (Cargo B ed)

9. Specification (ROPS)

16. Danger (Radiator)

17. Warning (Passengers in Cargo Bed)

18. Information (Front Hood)

18 LOCATION OF LABELS

10. Warning (Hot Surfaces)

11. Notice (E ngine Oil Fill)

12. Notice (Engine Oil Level)

13. Important Engine Information

14. Warning (Towing Bracket)

15. Warning (Refueling)

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Kawasaki Mule 4010 diesel 4x4 2012 Owner's manual

Kawasaki Mule 4010 diesel 4x4 2012 Owner's manual

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