Kawasaki MULE 610 4X4 XC 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.

NOTICE

NOTICE is used to

address practices not re-

lated to personal injury.

NOTE

○

NOTE indicates information that may help or guide

you in the opera

tion or service o f the vehicle.

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 a ll live, Kawasaki has incorporated crankcase emission (1) and ex-

haust emission (2) 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 Emiss

ion 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 fr

om the gases while passing through the inside of the breather chamber from the crankcase,

and then ret urned back to the bottom of the crankcase.

2. Exhaust Emission Control S ystem

The exhaust emission control system applied to this engine family is engine modifications that consist of

a catalytic conver

ter in the muffler, a modified carburetor and ignition system having optimum ignition timing

characteristics.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy

withasuitableair

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 e ntering the

atmosphere.

3. Evaporative Emi

ssion 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 are route d

into the running engine to be burned, or stored in a canister when the engine is stopped.

High Altitude Performance Adjustment Information

The original carburetor settings for this vehicle are best for sea level use. When the vehicle is used at high

altitude, the thinne

r atmosphere makes the air/fuel mixture richer reducing performance and increasing fuel

usage. To improve the performance of vehicles operated at high altitude, optional replacement of certain car-

buretor components are available. Have the carburetor adjusted by your authorized Kawasaki dealer if you

intend to use this ve

hicle above 500 m (1 60 0 feet).

However the carburetor must be returned to original settings before using at lower altitudes. Otherwise lean

high-altitud e carburetor setting may cause rough engine id ling, stalling, or engine dama ge.

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 mainten ance recommendations for your vehicle. Those items identified by the

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

As t he own er of this v

ehicle, you have the respons ib ility to make su re tha t the recommended mainte n ance 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 e

nd of this manual where an authorized Kawasaki dealer, or someone equally competent,

can record the main te nance. 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 Serv ice s

Kawasaki Motors Corp., U.S.A.

P.O. Box 25252

Santa Ana, CA 92799-5252

(866) 802-9381

consumer[email protected]

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:

•

Carburetor and internal parts

•

Spark plug

•

Magne to or electronic battery ignition s ystem

•

Fuel filter

•

Air cleaner element

•

Fuel hose s

•

Fuel tank

•

Muffler and carbon c an ist er

PLEASE DO NOT TAMPER WITH N OISE CONTROL SYSTEM

To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust

silencing systems. They are designed t o give optimum performance while maintaining a low noise lev el. Pleas e

do not remove these syst ems, or alter the m in any wa y which res ult s in an incre ase in nois e leve l.

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 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, capab ilitie s, an d lim ita tions.

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.

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

differences betwee n the actual product and illustra tions and te xt in th is manual.

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

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

TABLE OF CONTENTS

BAS

IC SAFE DRIVING......................... ...........

9

SPECIFICATIONS........................ .................... 11

SERIAL NUMBER LOCATIONS...................... 15

LOC

ATION OF PARTS ....................................

16

LOCATION OF LABELS.. ................................ 22

LOADING INFORMATION............................... 32

GE

NERAL INFORMATION.......... ....................

34

Lighting/Electrical Accessory Connector ....... 34

Brake Pedal. ................................................ .. 34

C

argo Bed ... ..................................................

3

5

Tailgate ........ ............................................... 35

Cargo Bed .................................................. 35

Choke Knob............................... .................... 37

Engine Oil Tem perature Warning Light.......... 38

Fuel Tank....................................................... 39

Fuel Gauge.................................................... 41

Glove Comp artment .................. .................... 42

Front Cargo Compartment .. .......................... 42

Ignition Switch .................. ............................. 44

Keys .......................................... .................... 45

Hour Meter .................................................... 46

Light Switch ............. ...................................... 47

Shift Levers .......... ......................................... 47

Gear Shift Lever ............ ............................. 47

2WD-4WD Shift Le ver ................................ 48

Differential Shift L ever ... ............................. 49

Parking Brake Lever .................................... .. 50

Parking Brake Warning Light....................... .. 51

Seat . ................................. ............................. 51

Seat Be lts ...................................................... 52

Throttle Pedal ........................................ ........ 54

Tra

iler Hitch Bracket (Accesso ry) ............. ... ..

54

Winch Installa tion .......................................... 55

HOW TO OPERATE................................. ........ 57

Dai

ly Checks .................................................

57

Starting the Engine.. ...................................... 59

Throttle-linked choke system...................... 59

Ju

mp Starting ................................................

60

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

Braking .......................................................... 62

S

topping the Engine ......................................

6

3

Parking the Mule .......................... ................. 63

Hi-Lo S hifting................................................. 65

Reversing Gears .............. ............................. 66

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

Shifting the D ifferential ................. ................. 67

Catalytic Conve rter....................... ................. 68

SAFE OPERATION.......................................... 70

Unfamiliar Terrain . ............... .......................... 7 0

Driving in Re v erse ......................................... 71

Driving in “4WD” ................................. ........... 71

Turning the Vehicle........... ............................. 72

Hills................................................................ 7 2

Climbing Hills........ ............... ............... ........... 7 3

Descending Hills............................................ 74

Travers ing Hillsides ....................................... 75

Sliding a nd Skidding......... ............................. 75

Driving through Water.................................... 76

MAINTENANCE AND ADJUSTMEN T........ ..... 77

Periodic Mainten ance Chart ... ....................... 77

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

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

Transmission Case Oil .............. .................... 88

Cooling Fan ................................................... 91

Spark Plug...... ............................................... 92

Valve Clearance ............................................ 93

Engine Air Cle aner ........................................ 94

Spark Arrester ............................................... 96

Throttle Pedal ........................................... ..... 98

Choke Knob................ ................................... 100

Carburetor ..................................................... 102

Fuel System .................................................. 104

Fuel Filter ................................................. .. 105

Evaporative Emi

ssion Control System .......

106

Belt Drive Torque Converter .......................... 106

Belt Drive Torque Converter Air C leaner ....... 107

Brakes ........................................................... 1 09

Brake Pedal.......... ...................................... 109

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

Parking Brake

Lever................................. .....

113

Steering Whee l .................... .......................... 114

Wheels .......................................................... 114

Rims ........................................................... 114

Wheel Nuts........ ......................................... 114

Tires ...................................................... ..... 114

Joint Boots

.....................................................

116

Suspension.................................................... 117

Seat Be lts ...................................................... 118

Headlight B

eam. ............................................

119

Battery ........................................................... 119

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

General Lu

brication .......................................

126

Cleaning ................................. ....................... 12 6

Bolt an d Nut Tightening ............. .................... 128

STORAGE............ ............................................ 129

TROUBLESHOO TING GUIDE ......................... 131

YOUR WARRANTY/OWNER SATISFACTION 132

ENVIRONMENTAL PROTECTION.............. .... 136

MAINTENANCE RE CORD

..............................

137

BASIC SAFE DRIVING 9

BASIC SAFE DRIVING

Knowing and following these rules for safe oper-

ation w ill increase yo

ur satisfaction with your new

Kawasaki vehicle.

Perform the Daily Checks

Refer to the Daily Checks se ctio n for a list of items

to check each day before use. Habitual performance

of these checks will help to insure safer, m ore re-

liable usage. Be sure that any irregularities found

during these checks are corrected before operating

the vehicle.

Drive Carefully and w ith Good Judgement

Wewantyoutobesatisfiedwithyournew

Kawasaki vehicle, so drive carefully, safely, and ex-

ercise good judgement. Practice basic maneuvers

so you can drive confide nt ly and sa fely.

Read the Owner’s Manual

Read and understand this Owner’s Manual. This

is especially important for inexperienced drivers.

Refer to this O wner’s Manual if you have any ques-

tions.

Off-Highway Use Only

This vehicle is not an al

l-terrain vehicle; it is de-

signed a nd equipped t o be a multiuse utility vehicle

for off-highway use only. Operation on public roads

is not recommended.

Occupant Capacity

Make sure operators are 16 years or older with a

valid driver’s licen s

e.

Each occupant must be able to s it with back

against seat, feet flat on floor, and hands on steer-

ing w heel, handgrip or

handhold.

The operator should be tall enough to wear the

seat belt properly and re ach all contro ls.

Passenger(s) should

also be tall enough for the

seat belt to fit properly and to be able to brac e them-

selves, as necessary, by placing both feet firmly on

the floor while gripp

ing the handhold. Stay com-

pletely inside the vehicle.

Never Drink and Drive

Alcohol and drugs imp

air your judgement and slow

your reactions. Even drugs prescribed by a physi-

cian can be dangerous. Check with your doctor.

10 BASIC SAFE DRIVING

Use Proper Riding Gea

r

Proper protective gear can reduce the severity of

injury in the event of an accident.

Choose a helmet most a

ppropriate for your use of

this utility v eh icle. A helmet can reduc e the risk of

head injuries. Wear appropriate eye protection and

protective clothin

g.

Wearing Seat Belts

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 s eat 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 th

eEngine

Three “musts” before starting the engine are:

1. Apply the parking b ra ke,

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 prope

rty. Always try to prese rve nature

and the environment.

Refueling

Before refu eling 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 characterist

ics. Check the tire pressure fre-

quently. Use only the recommended tires for re-

placement.

SPECIFICAT IONS 11

SPECIFICATIONS

PERFORMANCE

Maximum Torque

30 N·m (3.1 kgf·m, 22.1 ft·lb) @2 400 r/min (rpm)

Minimum Turning Radius

Differential Mode: 3.6 m (11.8 ft)

DIMENSIONS

Overall Length 2 755 mm (108.46 in.)

Overall Width (D) ( E) 1 3 20 mm (51.97 i

n.) (F) 1 360 mm (53. 54 in.)

Overall Height (D) (E) 1 875 mm (73.82 i

n.) (F) 1 900 mm (74. 80 in.)

Wheelbase

1 780 mm (70.08 in.)

Tread:

Front

1 085 mm (42.72 in.)

Rear

1 050 mm (41.34 in.)

Ground Clearance 205 mm (8.07 in.)

Curb Mass (D) 479 kg (1 056 lb) (E) 485 kg (1 069 lb) (F) 489 kg (1 078 lb)

CargoBed(L×W×H)

1 044 × 900 × 245 mm

(41.10 × 35.43 × 9.65 in.)

ENGINE

Type

OHV, 1-cylinder, 4-stroke, positive air-cooled

Displacement

401 cm³ (24.47 cu in.)

Bore × S troke 82 × 76 mm (3.23 × 2.99 in.)

Compression Ratio

8.6:1

12 SPECIFICATIONS

Starting System

Electric starter

Carburetor NIKKI 6C1026

Ignition System

Magneto and transist

or

Ignition Timing

20° constant

Spark Plug NGK BPR5ES

Lubrication System Forced lubrication (wet sump)

Engine Oil:

Type

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity

SAE 10W-40

Capacity 1.4 L (1.5 US qt)

DRIVE TRAIN

Driving Type

Gear (2WD/4WD)

Transmission Type

2-speed & reverse

, automatic

Primary Reduction Ratio

3.653 ∼ 0.794 (Bel

t drive torque converter)

Final Reduction Ratio:

Front 3.852

Rear 4.000

Overall Drive Rat

io:

Forward

11.000 (High)

16.277 (Low)

Reverse 14.143

SPECIFICATIONS 13

Transmission Gear Ratio:

Forward

3.464 (High)

5.125 (Low)

Reverse 4.453

Front Final Gear Cas

eOil

API GL-5 SA E 140 or AP

I GL-6 SAE 90 Hypoid gear oil for Limited

Slip Differentials.

Front Final Gear Case Oil Capacity 0.35 L (0.37 US qt)

Transmission C ase Oil API GL-5 Hypoid gear oil SAE 90 [above 5°C (41°F)]

SAE 80 [below 5°C (41°F)]

Transm ission Case Oil Capacity 2.40 L (2.5 US qt)

FRAME

Type

Steel tube, ladder type

Castor 8.0°

Trail

40 mm (1.6 in.)

Tire Size:

Front 26 × 9.00R12 Tubel

ess

Rear 26 × 9.00R12 Tubeless

Rim Size:

Front 12 × 7.5AT

Rear 12 × 7.5AT

Fuel Tank Capacit

y

15.5 L (4.1 US gal)

ELECTRICAL EQUIP

MENT

Battery 12 V 14 Ah

14 SPECIFICATIONS

Headlight 12 V 35 W × 2

Tail/Brake Light 12 V 5/21 W × 2

LOAD CAPACITY

Maximum Vehicle Loa

d(Including

occupants and cargo)

(D) (E) 420 kg (924 lb

)(F)410kg(904lb)

Maximum Cargo Be d Load 181 kg (400 lb)

(

D):

K

AF400D

(

E):

K

AF400E

(

F):

K

AF400F

NOTE

○

The KAF400E is identical to the KAF400D in every aspect: controls, features, and specifications except for

the camouflage surface treatment.

○

The K AF 40 0F is identical to t he KAF400D in every aspect: controls, features, and specifications except for

the design of the wheels and steering wheel, and sun top cover.

Specifications are subject to change w ithout 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 N o.

A. Frame Number

B. Seat (Raised P

osition)

Engine No.

A. Engine Number

16 LOCATION OF PARTS

LOCATION OF PARTS

(KAF400D/E)

1. Headlights

2. ROPS (Roll Over Protective

Structure)

3. Front Cargo Hood

4. Front Cargo Compartment

5. Steering Wheel

6. Seat

7. Seat Belts

8. Cargo Bed

9. Grille (Front Bumper)

10. Air C leaner Intake

11. P arking Brake

12. Air Cleaner (Carburetor)

13. Battery

14. Suspensions

15. Carburetor

16. Latch Handle

17. Tail Gate

18. Handgrip

LOCATION OF PARTS 17

18. Handgrip

19. Air Cleaner (Belt Drive

Torque Converter)

20. Belt Drive Torque Converter

21. Latch

22. Dashboard

23. Tail/Brake Light

24. M uffler

25. Fuel Tank

26. Fuel Tank Cap

27. Fuel Gauge

18 LOCATION OF PARTS

28. Differential Shift Lever

29. Choke Knob

30. Horn Button

31. Engine Oil Temperature

Warning Light

32. P arking Brake Warning

Light

33. Hour Meter

34. Gear Shift Le ver

35. Front Cargo Latch

36. 2WD-4WD Shift Lever

37. Ignition Switch

38. Accessory Connector

39. Glove Compartment

40. Brake Fluid Level

41. Brake Light Switch

42. Light Switch

LOCATION OF PARTS 19

(KAF400F)

1. Headlights

2. ROPS (Roll Over Protective

Structure)

3. Front Cargo Hood

4. Front Cargo Compartment

5. Steering Wheel

6. Seat

7. Seat Belts

8. Cargo Bed

9. Grille (Front Bumper)

10. Air Cleaner Intake

11. Parking Brake

12. Air Cleaner (Carb uretor)

13. Battery

14. Suspensions

15. Carburetor

16. Latch Hand le

17. Tail Gate

18. Handgrip

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Kawasaki MULE 610 4X4 XC Owner's manual

Kawasaki MULE 610 4X4 XC Owner's manual

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