Owners Manual
Page 8
... Kawasaki's engineering expertise and a tradition of this manual. The Service Manual contains detailed disassembly and maintenance information. However, there may be thoroughly familiar with the Mule when it whenever you will be reproduced without prior notice or obligation. FOREWORD Congratulations on their own work should remain with the proper operation of a new Kawasaki Mule. Please read this Owner's Manual carefully before starting your vehicle's controls...
... Kawasaki's engineering expertise and a tradition of this manual. The Service Manual contains detailed disassembly and maintenance information. However, there may be thoroughly familiar with the Mule when it whenever you will be reproduced without prior notice or obligation. FOREWORD Congratulations on their own work should remain with the proper operation of a new Kawasaki Mule. Please read this Owner's Manual carefully before starting your vehicle's controls...
Owners Manual
Page 9
... Warning Light ...Parking Brake Warning Light...Power Steering Warning Light...Steering Wheel...Brake Pedal...Cargo Bed ...Fuel Tank ...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Fuel Gauge/Hour Meter...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever ...Differential Shift Lever ...Parking Brake Lever...Seats ...Seat Belts ...9 11 15 16 19 29 31 31 31 32 33 34 34 35 35 36 36 38 41 42 44 44 45 46 48 48 49 49 50 51 52 Throttle...
... Warning Light ...Parking Brake Warning Light...Power Steering Warning Light...Steering Wheel...Brake Pedal...Cargo Bed ...Fuel Tank ...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Fuel Gauge/Hour Meter...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever ...Differential Shift Lever ...Parking Brake Lever...Seats ...Seat Belts ...9 11 15 16 19 29 31 31 31 32 33 34 34 35 35 36 36 38 41 42 44 44 45 46 48 48 49 49 50 51 52 Throttle...
Owners Manual
Page 10
...Maintenance Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Pump Filter ...Fuel Tank Vent...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Power Steering System...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam ...Battery...
...Maintenance Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Pump Filter ...Fuel Tank Vent...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Power Steering System...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam ...Battery...
Owners Manual
Page 12
... wear the seat belts whenever the vehicle is very flammable. Always try to your vehicle. approved helmet. Apply the parking brake, Put the gear shift lever in motion. Wearing proper protective gear can affect the vehicle's handling characteristics. Check the throttle pedal for replacement. Before Starting the Engine Three "musts" before getting out of an accident. Use only the recommended tires for proper operation. Tire Air Pressure Tire inflation...
... wear the seat belts whenever the vehicle is very flammable. Always try to your vehicle. approved helmet. Apply the parking brake, Put the gear shift lever in motion. Wearing proper protective gear can affect the vehicle's handling characteristics. Check the throttle pedal for replacement. Before Starting the Engine Three "musts" before getting out of an accident. Use only the recommended tires for proper operation. Tire Air Pressure Tire inflation...
Owners Manual
Page 13
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) Front Rear 3 265 mm (128.54 in.) 1 485 mm (58.46 in.) 1 925 mm (75.79 in.) 2 165 mm (85.24...39 × 47.64 × 11.22 in.) Short bed mode 770 × 1 210 × 285 mm (30.31 × 47.64 × 11.22 in.) ENGINE Type Displacement Bore × Stroke Compression Ratio OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 ×...
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) Front Rear 3 265 mm (128.54 in.) 1 485 mm (58.46 in.) 1 925 mm (75.79 in.) 2 165 mm (85.24...39 × 47.64 × 11.22 in.) Short bed mode 770 × 1 210 × 285 mm (30.31 × 47.64 × 11.22 in.) ENGINE Type Displacement Bore × Stroke Compression Ratio OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 ×...
Owners Manual
Page 14
12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Grade Viscosity Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio: Overall Drive Ratio: Front Rear Forward Reverse 4WD gear 2-speed & reverse, automatic 3.9 ∼ 0.85 (Belt drive torque converter) 5.200 5.429 8.404 (High) 17.303 (Low) 19.475 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5° BTDC @750 r/min (rpm...
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 DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio: Overall Drive Ratio: Front Rear Forward Reverse 4WD gear 2-speed & reverse, automatic 3.9 ∼ 0.85 (Belt drive torque converter) 5.200 5.429 8.404 (High) 17.303 (Low) 19.475 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5° BTDC @750 r/min (rpm...
Owners Manual
Page 15
... Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 Front & Rear Front & Rear Steel tube, ladder type Assisted with Electric Power Steering (EPS) System 7.5° 35 mm (1.4 in.) 23 × 11.00-10 Tubeless 10 × 8.5 24 L (6.3 US gal) 1.821 (High) 3.750 (Low) 4.220 API GL-5 or API GL-6 Hypoid gear oil for Limited Slip Differentials...
... Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 Front & Rear Front & Rear Steel tube, ladder type Assisted with Electric Power Steering (EPS) System 7.5° 35 mm (1.4 in.) 23 × 11.00-10 Tubeless 10 × 8.5 24 L (6.3 US gal) 1.821 (High) 3.750 (Low) 4.220 API GL-5 or API GL-6 Hypoid gear oil for Limited Slip Differentials...
Owners Manual
Page 16
Specifications are subject to the KAF620R in every aspect: controls, features, and specifications except for the camouflage surface treatment. 14 SPECIFICATIONS LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load 603 kg (1 330 lb) Short Bed Mode: 182 kg (400 lb) Long Bed Mode: 363 kg (800 lb) MODEL INFORMATION MULE 4010 TRANS 4 × 4...KAF620R/S NOTE żThe KAF620S is identical to change without notice.
Specifications are subject to the KAF620R in every aspect: controls, features, and specifications except for the camouflage surface treatment. 14 SPECIFICATIONS LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load 603 kg (1 330 lb) Short Bed Mode: 182 kg (400 lb) Long Bed Mode: 363 kg (800 lb) MODEL INFORMATION MULE 4010 TRANS 4 × 4...KAF620R/S NOTE żThe KAF620S is identical to change without notice.
Owners Manual
Page 18
Latch 15. Air Cleaner (Belt Drive Torque Converter) 16. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Belt Drive Torque Converter 17. Handgrip Battery 14. Headlights ROPS Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. 16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6.
Latch 15. Air Cleaner (Belt Drive Torque Converter) 16. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Belt Drive Torque Converter 17. Handgrip Battery 14. Headlights ROPS Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. 16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6.
Owners Manual
Page 20
Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light Parking Brake Warning Light 37. FI Warning Light 39. Brake Fluid Reserve Tank 42. 43. 44. 45. 46. Differential Shift Lever 41. Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Right Glove Compartment 38. 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. Power Steering Warning Light 40.
Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light Parking Brake Warning Light 37. FI Warning Light 39. Brake Fluid Reserve Tank 42. 43. 44. 45. 46. Differential Shift Lever 41. Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Right Glove Compartment 38. 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. Power Steering Warning Light 40.
Owners Manual
Page 22
Load) Warning (Cargo Bed) Warning (Refueling) Warning (Rear Seat Capacity) Warning (Cargo Bed) Specification 20 LOCATION OF LABELS 6. 7. 8. 9. 10. 11. 15. Warning (Pinching Fingers: both sides) Important Information (Tires/Max.
Load) Warning (Cargo Bed) Warning (Refueling) Warning (Rear Seat Capacity) Warning (Cargo Bed) Specification 20 LOCATION OF LABELS 6. 7. 8. 9. 10. 11. 15. Warning (Pinching Fingers: both sides) Important Information (Tires/Max.
Owners Manual
Page 31
... maintain stability by centralizing weight. Because any vehicle is sensitive to steer and may affect vehicle handling in carrying cargo. Before you must take care in an unpredictable manner. speed when carrying cargo. Make sure the cargo will void the utility vehicle warranty. NOTICE The front body work and fenders are personally responsible for use on Kawasaki utility vehicles. Cargo should be equally...
... maintain stability by centralizing weight. Because any vehicle is sensitive to steer and may affect vehicle handling in carrying cargo. Before you must take care in an unpredictable manner. speed when carrying cargo. Make sure the cargo will void the utility vehicle warranty. NOTICE The front body work and fenders are personally responsible for use on Kawasaki utility vehicles. Cargo should be equally...
Owners Manual
Page 37
... has malfunctioned, or the wiring harness has become disconnected. If the warning light illuminates any other steering problems, refer to suit the operator (see "Steering Wheel" section). A. Stop driving immediately and see an authorized Kawasaki dealer. Power Steering Warning Light NOTE żIf the warning light does not go on board, contact an authorized dealer. GENERAL INFORMATION 35 j Power Steering Warning Light The power steering warning light will be a problem with an electric power steering system. The system...
... has malfunctioned, or the wiring harness has become disconnected. If the warning light illuminates any other steering problems, refer to suit the operator (see "Steering Wheel" section). A. Stop driving immediately and see an authorized Kawasaki dealer. Power Steering Warning Light NOTE żIf the warning light does not go on board, contact an authorized dealer. GENERAL INFORMATION 35 j Power Steering Warning Light The power steering warning light will be a problem with an electric power steering system. The system...
Owners Manual
Page 47
... the battery power will return to the starter can be used for the battery to have a duplicate made. Key Number żThe vehicle is in this position, only when gear shift lever is equipped with a starter lockout switch. It's possible the Included with the engine running, or damage to "ON" position. Do not turn the ignition switch key to the "START" position with the key is a key number...
... the battery power will return to the starter can be used for the battery to have a duplicate made. Key Number żThe vehicle is in this position, only when gear shift lever is equipped with a starter lockout switch. It's possible the Included with the engine running, or damage to "ON" position. Do not turn the ignition switch key to the "START" position with the key is a key number...
Owners Manual
Page 58
... death. Check for the action required to return the vehicle to a safe operating condition. Fuel ...Enough fuel in a well-ventilated area. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Do not run the engine in the window. Air Cleaner ...Check the restriction gauge for cuts, cracks, damage, or excessive wear. Tires ...Air pressure (when cold): Front Rear 69 kPa (0.7 kgf/cm², 10 psi) 167...
... death. Check for the action required to return the vehicle to a safe operating condition. Fuel ...Enough fuel in a well-ventilated area. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Do not run the engine in the window. Air Cleaner ...Check the restriction gauge for cuts, cracks, damage, or excessive wear. Tires ...Air pressure (when cold): Front Rear 69 kPa (0.7 kgf/cm², 10 psi) 167...
Owners Manual
Page 86
or 5,000 km (3,000 (600 miles) miles) of use of use j CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect Front final gear case oil and transmission case oil-change* 1 year D • D • D •...
or 5,000 km (3,000 (600 miles) miles) of use of use j CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect Front final gear case oil and transmission case oil-change* 1 year D • D • D •...
Owners Manual
Page 98
.... 96 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can get extremely hot during oil draining. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. To avoid a serious burn, never touch a hot muffler or exhaust pipe during normal operation and cause serious burns. Transmission case oil is damaged, replace it with its gasket. the cargo bed and support...
.... 96 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can get extremely hot during oil draining. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. To avoid a serious burn, never touch a hot muffler or exhaust pipe during normal operation and cause serious burns. Transmission case oil is damaged, replace it with its gasket. the cargo bed and support...
Owners Manual
Page 118
... j • • Turn the ignition switch to adjust. Depress the brake pedal. A. The brake light switch should go on . The brake light should be sure that the switch body does not turn during adjustment. 116 MAINTENANCE AND ADJUSTMENT Brake Light Switch When the brake pedal is hard to the "ON" position. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is depressed, the brake light goes on...
... j • • Turn the ignition switch to adjust. Depress the brake pedal. A. The brake light switch should go on . The brake light should be sure that the switch body does not turn during adjustment. 116 MAINTENANCE AND ADJUSTMENT Brake Light Switch When the brake pedal is hard to the "ON" position. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is depressed, the brake light goes on...
Owners Manual
Page 135
... the spark plug caps, it has been splashed with a plastic bag. Muffler rear opening with tape. cover with sea water or exposed to salt air, or operated on rainy days, rough terrain, or in dusty areas. • Horn button - MAINTENANCE AND ADJUSTMENT 133 Cleaning To prolong the life of your vehicle, wash it down immediately after it can cause mechanical problems and...
... the spark plug caps, it has been splashed with a plastic bag. Muffler rear opening with tape. cover with sea water or exposed to salt air, or operated on rainy days, rough terrain, or in dusty areas. • Horn button - MAINTENANCE AND ADJUSTMENT 133 Cleaning To prolong the life of your vehicle, wash it down immediately after it can cause mechanical problems and...
Owners Manual
Page 139
...; Spark plug wire not on spark plug • Spark plug dirty • Engine Stops fuel in tank • No in fuel • Water Air filter clogged or intake blocked • Fuel tank vent clogged • Engine overheated • Too much idling or low speed • enough air flow) • Overloaded spark plug • Wrong clogged • Radiator Coolant level too low • deteriorated • Coolant Cooling fan breaker functioned • Engine oil low • running (not Power Steering Won't Work functioned to prevent overheating. • ECU Fuse...
...; Spark plug wire not on spark plug • Spark plug dirty • Engine Stops fuel in tank • No in fuel • Water Air filter clogged or intake blocked • Fuel tank vent clogged • Engine overheated • Too much idling or low speed • enough air flow) • Overloaded spark plug • Wrong clogged • Radiator Coolant level too low • deteriorated • Coolant Cooling fan breaker functioned • Engine oil low • running (not Power Steering Won't Work functioned to prevent overheating. • ECU Fuse...