Professional Documents
Culture Documents
Utility Vehicle
Assembly & Preparation
Manual
Foreword
In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most
commonly removed parts have a direct bearing on a vehicles reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims
and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers.
This Assembly and Preparation Manual explains step by step procedures of the following
items for all Kawasaki utility vehicles.
1.
2.
3.
4.
Crate Handling
Uncrating
Assembly
Preparation
The selling dealer assumes sole responsibility for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale.
Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.
NOTICE
NOTICE is used to address practices not
related to personal injury.
NOTE
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.
Mar., 2013
Table of Contents
Crate Handling..............................................................................
Crate Handling Precautions for RSC (Returnable Steel Crate)
(US Model only) ........................................................................
Crate Handling Precautions (Other than US Model) ...................
Uncrating ......................................................................................
Opening Crate (US Model only) ..................................................
Opening Crate (Other than US Model) ........................................
Parts Check .................................................................................
Assembly ......................................................................................
Steering Wheel ............................................................................
Center Bar ...................................................................................
Front Bar .....................................................................................
Rear Bar ......................................................................................
Front Seat Back...........................................................................
Rear Seat ....................................................................................
Front Guard .................................................................................
Front Fenders (Left and Right) ....................................................
Rear Fender Front Flaps and Covers (Left and Right) ................
Cargo Bed and Screen (Convertible) ..........................................
Converting Rear Seat and Cargo Bed.........................................
French Labels for Canadian Models ...........................................
Preparation ...................................................................................
Charged Battery Service (US Model) ..........................................
Uncharged Battery Service (Other than US Model) ....................
Transmission Oil..........................................................................
Front Final Gear Case Oil ...........................................................
Brake Fluid ..................................................................................
Brake Pedal .................................................................................
Brake Light Switch.......................................................................
Steering Position Adjustment ......................................................
Parking Brake Lever ....................................................................
Steering Wheel ............................................................................
Tire Pressure ...............................................................................
Fuel .............................................................................................
Coolant ........................................................................................
Engine Oil....................................................................................
Throttle Pedal ..............................................................................
Idle Speed ...................................................................................
Headlight Beam ...........................................................................
Wheel Alignment .........................................................................
Fastener Check ...........................................................................
Standard Torque Table ................................................................
Test Ride Checklist ......................................................................
3
3
3
4
4
8
14
20
20
21
22
22
25
25
25
26
27
28
31
33
34
34
37
41
41
43
44
44
44
45
45
46
46
46
47
48
49
49
49
52
54
54
CRATE HANDLING 3
Crate Handling
Crate Handling Precautions for
RSC (Returnable Steel Crate)
(US Model only)
Crate Position:
Always place the crate upright on its base.
The crate has been designed to carry the weight
of the vehicle only in that position. The sides
and top of the crate are not strong enough to
act as the base of the crate. If the crate is tilted
very far or set on its end or side, loose parts
may be dislodged and fall inside the crate.
4 UNCRATING
Uncrating
Opening Crate (US Model only)
Loading and Unloading Trucks:
To load or unload crates, use a fork lift, a lift
-type tail gate, or a ramp. Never unload crates
by hand. NEVER DROP crates off a truck.
WARNING
Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrating to prevent injury.
WARNING
The steel crate panel plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection
when uncrating to prevent injury.
UNCRATING 5
A. Upright
wheel.
Remove the screen from the unit. Have a
second person help to remove this piece as
it can be awkward to handle.
A. Steering Wheel
B. Screen
A. Rear Upright
B. Bolt of Diagonal Brace
C. Locknut of Diagonal Brace
6 UNCRATING
card them.
Have a second person help to move this piece
as it can be awkward to handle. Take care
when letting the cargo bed down from the unit,
it is heavy and may fall.
UNCRATING 7
A. Stopper
B. Supporting Rod
the left and right cargo bed pivot pins
Insert
into the frame pivots from the outside of the
vehicle, then insert the snap pins into the pivot
pins.
A. Cargo Bed
B. Supporting Rod
8 UNCRATING
A. Tie-downs (Front)
A. Tie-downs (Rear)
the vehicle off the crate base after in Roll
stalling the steering wheel (see Steering
Wheel section in the assembly chapter). It
is recommended to remove the upright from
the base if roll-off is planned.
RETURN SHIPMENT
A. Braces
A. Uprights
Opening Crate
(Other than US Model)
WARNING
Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrating to prevent injury.
UNCRATING 9
Removing Panels
a BPS3 square drive bit (ex. IM Using
PORT APEX Square Recess Power Bits1/4 Hex-size #3 or MAGNA Insert Bits-size
#3 with quick change holder), remove the
screws from the sides and ends into the top.
WARNING
Staples, nails and other fasteners have
sharp points that can cause injury. Remove or bend into the wood all staples,
nails or other fasteners in the crate base.
out all the bolts, nuts, screws, and fas Take
teners and remove the top and side panels of
the wood crate.
Trying
NOTE
10 UNCRATING
wheel.
Remove the screen from the unit. Have a
second person help to remove this piece as
it can be awkward to handle.
Trying
NOTE
A. Steering Wheel
B. Screen
the foam pieces that protect the
Remove
screen, and discard them.
the parts box containing the stays,
Remove
guards and covers from the cargo bed.
UNCRATING 11
card them.
Have a second person help to move this piece
as it can be awkward to handle. Take care
when letting the cargo bed down from the unit,
it is heavy and may fall.
12 UNCRATING
A. Cargo Bed
B. Supporting Rod
A. Stopper
B. Supporting Rod
the left and right cargo bed pivot pins
Insert
into the frame pivots from the outside of the
vehicle, then insert the snap pins into the pivot
pins.
A. Tie-downs (Front)
NOTE
UNCRATING 13
A. Tie-downs (Rear)
NOTE
14 UNCRATING
Parts Check
NOTE
There may be minor differences in appearance between these illustrations and the actual vehicle
parts.
the parts and check the crate base and packaging materials carefully for lost parts. Order
Remove
any parts that are missing from the crate. Part numbers are provided in the following charts. Check
the parts against the illustrations. In the following charts under Remarks, D = diameter in millimeters,
and L = length in millimeters.
UNCRATING 15
No.
Part Name
1 KAF620R9 RC/S9 SC
Steering Wheel
Spring Washer
Nut, Steering Wheel
Horn Button
2 KAF620RD RE/SD SE
Steering Wheel
Washer, Steering Wheel
Nut, Steering Wheel
Steering Wheel Cover
Mark, Steering Wheel Cover
3 Center Bar with
4
5
Qty
1
(1)
(1)
1
1
(1)
(1)
1
1
1
1
(8)
(8)
(4)
(4)
(6)
(6)
(4)
(1)
(1)
(1)
(1)
1
1
(1)
(1)
(1)
1
4
1
(2)
(4)
(4)
(4)
(6)
(6)
(4)
2
4
4
Remarks
D = 12
D = 12
D = 12.1
D = 12
D = 10, L = 20
D = 10
D = 10.5
D = 10, L = 20
D = 10, L = 25
D = 10.2
D = 10
D = 14, L = 36
D = 10, L = 50
D = 10, L = 50
D = 10
D = 10, L = 25
D = 10.2
D = 10
D = 10, L = 20
D = 10
Part Number
46003-1308
461DA1200
92210-1249
14091-1247
46003-0595
92200-0455
92210-1249
14092-1029
56054-1188
(*1) 55047-7512
(*2) 55047-0025
55047-0331
130BB1020
462DB1000
92022-1396
130BB1020
130BB1025
92200-7506
92210-0276
(*3) 53061-7507
53061-0315
(*3) 53061-7508
53061-0316
(*4) 53066-7503
53066-0258
55047-7503
39156-7506
14091-7559
55047-7510
92153-1282
55047-0020
92161-0020
(*3) 130BB1050
130BA1050
92015-1428
130BB1025
92200-7506
92210-0276
55047-7504
130BB1020
462DB1000
16 UNCRATING
UNCRATING 17
No.
Part Name
6 Rear Seat, Upper and
Lower with
Bolt, Rear Seat
Bolt, Rear Seat
Flat Washer, Rear Seat
Nut, Rear Seat
Nut, Rear Seat
Sleeve, Rear Seat
7 Cargo Bed with
Seat Belt, Cargo Bed with Rear Seat
Qty
1
Remarks
(1)
(1)
(2)
(1)
(1)
(1)
1
1
(2)
(2)
(2)
(2)
1
D = 12, L = 117
D = 12, L = 117
D = 12
D = 12
D = 12
1
(2)
2
2
2
2
1
4
4
1
2
2
2
Part Number
(*4) 53066-7507
53066-0259
(*3) 92150-1895
92154-0867
411AB1200
(*3) 92015-1190
92210-0274
42036-7501
(*3) (53029-0061)
(53029-0313)
(*3) 53061-7506
53061-0314
92043-1428
554DA1200
14037-7501
D = 6, L = 16
L=4
55020-0387
92066-7503
130BB1020
130BA1020
92002-1661
92015-1433
14091-0817
92009-1621
92143-1087
D = 10, L = 20
D = 12, L = 75
D = 12
55020-0876
130BA1020
92002-1661
92015-1433
D = 10, L = 20
D = 10, L = 20
D = 12, L = 75
18 UNCRATING
No.
Part Name
10 Stay, Flap LH
Stay, Flap RH
Bolt, Upper, Stay
Bolt, Lower, Stay
Bolt, Lower, Stay
Rear Flap LH
Rear Flap RH
Flap Cover LH
Flap Cover RH
Front Side Cover LH
Front Side Cover RH
Rear Side Cover LH
Rear Side Cover RH
Front Fender LH
Front Fender RH
(Continued from previous page)
Rivet, Fender and Cover
Screw, Fender and Cover
Tapping Screw, Fender and Cover
Screw, Fender
Tapping Screw, Fender
Collar, Fender
Collar, Fender and Cover
Collar, Fender and Cover
Crip-Nut, Fender and Cover
Crip-Nut, Fender and Cover
Qty
1
1
4
4
2
2
1
1
1
1
1
1
1
1
1
1
20
22
12
2
2
2
20
4
12
12
Remarks
D
D
D
D
=
=
=
=
6,
6,
6,
6,
L
L
L
L
D = 6, L
D = 6, L
D = 6, L
D = 5, L
L = 9.5
L=4
L=6
=
=
=
=
=
=
=
=
20
20
14
14
16
20
22
20
Part Number
35063-0451
35063-0452
(*4) 130BB0620
130BA0620
(*3) 130BB0614
130BA0614
35019-0066
35019-0067
14091-0819
14091-0820
14091-0823
14091-0824
14091-0825
14091-0826
35004-0123
35004-0124
92039-1229
(*3) 92009-1621
92172-0488
92009-1256
92172-1072
92027-1767
92143-1087
92143-1057
(*3) 92015-1678
92210-0624
UNCRATING 19
No.
Part Name
11 French Labels and Instruction for
Canadian Models only
Instruction, Label
Specification
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
2
13 Owners Manual
*1:
*2:
*3:
*4:
*5:
*6:
KAF620R9/S9
KAF620RA/RB/SA/SB
KAF620R9 RB/S9 SB
KAF620R9 RA/S9 SA
KAF620RA RD/SA SD
KAF620R9 RD/S9 SD
Remarks
Part Number
(*1) 56030-0272
(*5) 56030-0313
560300821
(*6) 56053-7519
56053-0731
(*1) 56053-7529
56053-7530
56071-7504
56070-0055
(*6) 56071-7512
560710335
56071-7505
56070-0058
56070-1207
(*1) 56070-1211
56071-0129
(*1) 56071-0108
56071-0139
56071-0110
56071-7506
56071-7508
YTX20L-BS, 12 V 18
26022-3703
Ah
20 ASSEMBLY
Assembly
Steering Wheel
Steering Wheel Installation (KAF620R9
RC/S9 SC)
A. Horn Button
B. Self-lock Nut and Spring Washer
C. Steering Wheel
the horn button on the steering wheel
Install
by fitting the projections of the button into the
notches of the wheel.
A. Steering Shaft
B. Contact Assy
grease to the contact face of the steer Apply
ing wheel.
A. Horn Button
NOTICE
Be careful not to puncture a tire with
sharp fasteners when rolling off the vehicle from the crate base.
A. Steering Wheel
B. Apply Grease
the steering wheel on the steering
Mount
shaft so that it is straight ahead, and install
ASSEMBLY 21
Center Bar
Center Bar Installation
A.
B.
C.
D.
E.
NOTICE
Be careful not to puncture a tire with
sharp fasteners when rolling off the vehicle from the crate base.
any nails from the crate base that
Remove
might puncture a tire.
Roll the vehicle off the crate base.
A. Supporting Rod
B. Stopper
the upper mounting bolts (D = 10, L
Remove
= 20) (8) and the spring washers (8) from the
center bar.
Remove the center bar and rear bar lower
mounting bolts (D = 10, L = 25) (12) (D = 10,
L = 50) (4), flat washers (D = 10.2) (12) and
the nuts (12) from the chassis.
22 ASSEMBLY
A. Center Bar
B. Bolts (D = 10, L = 25) and Flat Washers
(D = 10.2)
C. Nuts (D = 10)
other than California model and
For
KAF620RB RE/SB SE, route the fuel
A.
B.
C.
D.
E.
Center Bar
Fuel Tank Breather Hose
Steel Clamp
to Check Valve
to Floor Board
Front Bar
Front Bar Installation
Rear Bar
Rear Bar Installation
ASSEMBLY 23
NOTE
rear bar.
Install the two joint bars between the center
bar and the rear bar with the mounting bolts
(D = 10, L = 20) (8), and spring washers (8),
so that the bracket parts of joint bar face upward, and tighten the bolts.
A. Joint Bars
B. Bracket Parts
C. Bolts (D = 10, L = 20) and Spring
Washers
24 ASSEMBLY
NOTE
A. Clamp
B. About 3 mm (0.12 in.)
NOTE
A. Clamp
B. About 3 mm (0.12 in.)
ASSEMBLY 25
Rear Seat
Rear Seat Installation
on the seat.
Apply grease to the rear seat pivot bracket.
Install the rear seat to the pivot bracket on
frame with the bolt, flat washers and nut as
shown in the figure.
Front Guard
the front guard on the frame with the
Install
upper bolts (D = 10, L = 20) (2), lower bolts
(D = 12, L = 75) (2) and nuts (2), and tighten
them securely.
A. Handrail
B. Front Seat Back
C. Bolts (D = 10, L = 20) and Flat Washers
(D = 10.5)
26 ASSEMBLY
A. Front Guard
B. Upper Bolts (D = 10, L = 20)
C. Lower Bolts (D = 12, L = 75)
D. Nuts (D = 12)
the front guard cover on the front guard
Install
with the screws (D = 6, L = 16) (4) and collars
(L = 4) (4), and tighten the screws.
A. Front Guard
B. Upper Bolts (D = 10, L = 20)
C. Lower Bolts (D = 12, L = 75)
D. Nuts (D = 12)
A. Clip-nuts (D = 6)
each left and right side hook portion
Insert
of the front cover into each slot of the front
fender.
ASSEMBLY 27
28 ASSEMBLY
Cargo
Bed
(Convertible)
and
Screen
NOTE
ASSEMBLY 29
A. Stopper Pin
B. Screen
both guide pins of the screen into the
Insert
sockets at the rear side panels.
A. Screws (D = 6, L = 14)
B. Brackets
C. Damper
both end projections of the front side
Insert
panels into the dampers on the screen, and
then tighten the damper bracket screws.
A. Screen
B. Guide Pin
C. Socket
the stopper pins toward the outside at
Slide
the bottom of the screen to lock the screen.
A. Stopper Pin
the damper bracket screws (D = 6, L
Loosen
= 14) (4) and free the brackets.
A. Stopper Pin
B. Rear Seat
30 ASSEMBLY
A. Clamps
the taillight lead through the plastic
Route
clamp and connect it to the harness connector at the dust boot, then cover the connector
with the boot.
A. Hook
B. Latch Lever
C. Mounting Bolts (D = 8, L = 20)
D. Rear Seat
NOTE
Taillight Lead
Plastic Clamp
Connector
Dust Boot
1.
2.
3.
4.
5.
6.
Cargo Bed
Right Panel
Tailgate
Left Panel
Bolts (D = 8, L = 20) and Nuts
Push the panel with both hands.
ASSEMBLY 31
Viewed from A:
The seats and the cargo bed can be converted in the following way.
A.
B.
C.
D.
Left Panel
Lock Lever
Tailgate
5 mm (0.2 in.) or less
A. Stopper Pin
B. Rear Seat
2. Push the rear seat back forward.
3. Release the latches on both sides.
A. Latch
B. Rear Seat Back (lowered position)
4. Push the rear seat assembly forward into the
stored position.
WARNING
If passengers ride in the cargo bed, they
could be tossed about or thrown from
the vehicle, causing serious injury or
death. Never carry passengers in the
cargo bed. Tilting the cargo bed when
it is loaded may cause the vehicle to tip
over backwards, causing serious injury
or death. Never tilt the cargo bed when
it is loaded. Driving with the cargo bed
tilted may be hazardous. Always lower
and latch the bed before driving.
32 ASSEMBLY
A. Hook
B. Latch and Lever
C. Mounting Bolts (D = 8, L = 20)
D. Cargo Bed
NOTE
A. Stopper Pin
B. Screen
7. Pull and remove the screen from the sockets, move forward and insert into the sockets
at the end of the front side panels.
4-person to
NOTE
A. Screen
B. Sockets
8. Latch the stopper pins at the bottom of the
screen.
ASSEMBLY 33
A. End Projections
B. Cargo Bed Front Side Panels (folded)
French
Models
Labels
for
Canadian
NOTE
Apply the French labels over the English labels on the unit when required.
34 PREPARATION
NOTE
next step.
Preparation
Charged
Model)
Battery
Service
(US
A. Voltmeter
the reading is below the specification re Iffreshing
charge is required. See the Battery
Removal and Refreshing Charge section.
The battery used in this Mule utility vehicle is a
pre-filled, pre-charged, sealed battery, eliminating the need for dealers to prepare the battery
by filling it with electrolyte. However, dealers
should still check each batterys state of charge
periodically to be sure it meets the minimum
PREPARATION 35
Battery Installation
Battery Specifications
Battery Capacity
Battery P/No.
12 V 14 Ah
26012-0107
Refreshing Charge
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can
cause serious injury and burns if ignited.
Keep the battery away from sparks and
open flames during charging. When
using a battery charger, connect the
battery to the charger before turning on
the charger. This procedure prevents
sparks at the battery terminals which
could ignite any battery gases.
NOTICE
A. Protective Cap
B. Positive Cable (+)
C. Negative Cable ()
D. Battery Holder
E. Battery
the positive terminal (+) with its red pro Cover
tective cap.
Battery Removal
NOTE
fore charging.
leave a battery on a trickle charger
longer than 48 hours. Serious damage to the
battery will occur.
Never
A. Nuts
B. Battery Holder
C. Battery
WARNING
This battery is sealed battery type.
Never remove seal sheet or cap even at
charging. Never add water. Charge with
current and time as stated below.
36 PREPARATION
KAF620R9 RD/S9 SD
battery condition after charging.
Determine
Determine the condition of the battery 30 min-
utes after completion of the charge by measuring the terminal voltage according to the
table below.
Criteria
Judgement
12.6 V or higher
Good
Charge insufficient
12.0 12.6 V
Recharge
Unserviceable
12.0 V or lower
Replace
Battery Installation
A. Protective Cap
B. Positive Cable (+)
C. Negative Cable ()
D. Battery Holder
E. Battery
PREPARATION 37
KAF620RE/SE
Battery Removal
A. Protective Cap
B. Positive Cable (+)
C. Negative Cable ()
D. Battery Holder
E. Battery
the battery cover
Reinstall
Brake Lever section).
(see Parking
A. Nuts
B. Battery Holder
C. Battery
Battery Specifications
Make
Battery Type
Battery Capacity
Electrolyte Capacity
Battery/Electrolyte Set P/No.
Yuasa
YTX20L-BS
12 V 18 Ah
0.93 L
26012-3730
Battery Activation
Electrolyte Filling
NOTICE
Incorrect Battery Activation will reduce
battery performance and service life. Be
sure to strictly follow the Battery Service
instructions in this Manual.
38 PREPARATION
NOTICE
Each battery comes with its own specific
electrolyte container; using the wrong
container may overfill the battery with
incorrect electrolyte, which can shorten
battery life and deteriorate battery performance. Be sure to use the electrolyte
container with the same model name as
the battery since the electrolyte volume
and specific gravity vary with the battery
type.
A. Sealing Sheet
B. Filler Ports
the electrolyte container from the
Remove
vinyl bag.
the strip of caps from the container
Detach
and set aside, these will be used later to seal
the battery.
NOTE
NOTICE
Do not remove the aluminum sealing
sheet from the filler ports until just prior
to use. Be sure to use the dedicated
electrolyte container for correct electrolyte volume.
DANGER
Sulfuric acid in battery electrolyte can
cause severe burns. To prevent burns,
wear protective clothing and safety
glasses when handling electrolyte. If
the electrolyte comes in contact with
your skin or eyes, wash the area with
liberal amounts of water and seek medical attention for more severe burns.
the battery on a level surface.
Place
to see that the sealing sheet has no
Check
peeling, tears, or holes in it.
Remove the sealing sheet.
NOTE
If the sealing
sheet has leaked air into the battery, it may
require a longer initial charge.
A. Strip of Caps
B. Sealed Cells
the electrolyte container upside down
Place
with the six sealed cells into the filler ports
of the battery. Hold the container level, push
down to break the seals of all six cells. You
will see air bubbles rising into each cell as the
ports fill.
NOTE
PREPARATION 39
NOTE
A. Strip of Caps
A. Air Bubbles
B. Tap the Container
the container in place. Dont remove
Keep
the container from the battery, the battery requires all the electrolyte from the container for
proper operation.
NOTICE
Removal of the container before it is
completely empty can shorten the service life of the battery. Do not remove the
container until it is completely empty.
NOTICE
Once the strip of caps is installed onto
the battery, never remove the caps, nor
add water or electrolyte to the battery.
NOTE
Initial Charge
1.8 A 5 10 hours
40 PREPARATION
Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO 2
Yuasa MB-2040/2060
Christie C10122S
the above chargers are not available, use
Ifequivalent
one.
Let
battery
30 minutes after initial charge,
then check sitvoltage
using a voltmeter. (Volt-
KAF620R9 RD/S9 SD
age immediately after charging becomes temporarily high. For accurate measuring, let the
battery sit for given time.)
Charging
NOTE
Battery Installation
NOTE
A. Protective Cap
B. Positive Cable (+)
C. Negative Cable ()
D. Battery Holder
E. Battery
KAF620RE/SE
A. Protective Cap
B. Positive Cable (+)
C. Negative Cable ()
D. Battery Holder
E. Battery
(see Parking
PREPARATION 41
Transmission Oil
Transmission Oil Level Inspection
NOTE
Transmission Oil
Type:
Viscosity:
Capacity:
NOTICE
Be careful not to allow any dirt or foreign
materials to enter the transmission case.
out the oil filler plug and check the oil
Pull
level. The oil level should be between the H
(High) and L (Low) lines on the dipstick.
42 PREPARATION
Torque:
29 Nm (3.0 kgfm, 22 ftlb)
A. Bolts (D = 10, L = 16)
the vehicle on level ground.
Park
Remove
case. the filler cap from the front final gear
NOTE
Viscosity:
Capacity:
NOTICE
Be careful not to allow any dirt or foreign materials to enter the front final
gear case.
PREPARATION 43
Brake Fluid
Brake Fluid Level Inspection
WARNING
When working with the disc brake, observe the precautions listed below.
Never reuse old brake fluid.
Do not use fluid from a container that
has been left unsealed or that has been
open for a long time.
Do not mix two types and brands of
fluid for use in the brake. This lowers
the brake fluid boiling point and could
cause the brake to be ineffective. It
may also cause the rubber brake parts
to deteriorate.
Dont leave the reservoir cap off for
any length of time to avoid moisture
contamination of the fluid.
Dont change the fluid in the rain or
when a strong wind is blowing.
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
If any of the brake line fittings or the
bleed valve is opened at any time,
the AIR MUST BE BLED FROM THE
BRAKE LINE.
Hood Closing
the hood.
Lower
After
the
hood touches the damper boot, push
the two parts
of the hood to ensure the hood
A. Inspection Hole
B. Upper Level Line (MAX)
C. Lower Level Line (MIN)
is latched.
44 PREPARATION
A. Boot
B. Push the two parts.
WARNING
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 vehicle.
A. Brake Pedal
B. 10 mm (0.4 in.)
it does not, check the bulb and, if necessary,
Ifadjust
the brake light switch.
Brake Pedal
A. Brake Pedal
B. 2 10 mm (0.08 0.40 in.)
PREPARATION 45
A. 8 12 clicks
A. Screws (D = 6, L = 16)
B. Plastic Rivets
C. Battery Cover
the O-ring forward and pull the rubber
Move
boot up on the bottom.
A. Locknut
B. Nut
Steering Wheel
Steering Wheel Free Play Inspection
46 PREPARATION
Tire Pressure
Tire Air Pressure Adjustment
Antiknock
Index
(RON + MON)
2
Front:
Rear:
WARNING
Operating with unequally or improperly
pressurized tires can adversely affect
steering or handling. Inflate both front
tires to the same pressure and both rear
tires to the same pressure.
Coolant
Coolant Reservoir Tank Level Check
NOTE
Fuel
WARNING
Gasoline is extremely flammable and
can be explosive under certain conditions, creating the potential for serious
burns. When filling the tank, turn the
ignition switch 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.
87
Minimum
Rating
A.
B.
C.
D.
Reserve Tank
Cap
F (Full) Mark
L (Low) Mark
the cap.
Install
Close the front cargo hood.
PREPARATION 47
Engine Oil
Engine Oil Level Inspection
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.
A. Dipstick
B. Groove Mark
C. Rear Seat
NOTE
NOTE
A. Dipstick Tube
B. Mark
C. Indent
D. Dipstick
E. Oil Filler Cap
the dipstick until it bottoms into the
Reinsert
tube securely.
NOTICE
If the engine is run without oil, it will be
severely damaged.
48 PREPARATION
Throttle Pedal
Throttle Pedal Free Play Inspection
A. Dipstick
B. "F" (Full) Line
C. "L" (Low) Line
oil level is too high, remove the excess
Ifoil,theusing
a syringe or other suitable device.
oil level is too low, unscrew the oil filler
Ifcaptheand
add oil to reach the correct level.
Reinsert
dipstick until it bottoms into the
tube, andthe
install the filler cap.
Viscosity:
Capacity:
NOTE
Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity
may need to be changed to accommodate
atmospheric conditions in your riding area.
A. Throttle Pedal
B. 5 10 mm (0.20 0.40 in.)
PREPARATION 49
Headlight Beam
The headlight beams can be adjusted vertically.
Turn the adjusting screw on the reverse side
of the headlight to adjust the headlight vertically.
A. Mounting Nuts
B. Throttle Cable
A. Throttle Pedal
B. Locknut
C. Throttle Pedal Stop Bolt
Idle Speed
Idle Speed Inspection
A. Adjusting Screw
Wheel Alignment
Toe-in is the amount that the front wheels
are closer together in front than at the rear at
the axle height. When there is toe-in, the distance A (Rear) is greater than B (Front) as
shown. The purpose of toe-in is to prevent
the front wheels from getting out of parallel at
any time, and to prevent any slipping or scuffing action between the tires and the ground.
If toe-in is incorrect, the front wheels will be
dragged along the ground, scuffing and wearing the tread knobs.
Caster and camber are built-in and require no
adjustment.
A (Rear) B (Front) = Amount of Toe-in
(Distance A and B are measured at hub
height)
50 PREPARATION
Toe-in Adjustment
NOTE
PREPARATION 51
52 PREPARATION
Fastener Check
PREPARATION 53
No.
Fastener
Steering
1 Tie-rod end locknuts (Left and Right)
Frame
2 Seat belt mounting bolts
3 Front bar mounting bolts (Upper)
4 Front bar mounting bolts (Lower)
5 Center bar mounting bolts and nuts
6 Joint bar mounting bolts
7 Rear bar mounting bolts and nuts (middle)
8 Rear bar mounting bolts and nuts (lower)
9 Front seat back mounting bolts
Wheel
10 Wheel nuts
Suspension
Rear shock absorber upper mounting nuts (Left and
11
Right)
12 Front suspension arm pivot bolts (Left and Right)
13 Leaf spring front mounting bolts (Left and Right)
14 Leaf spring rear mounting nuts (Left and Right)
Engine
15 Engine oil drain plug
16 Front final gear case oil drain plug
17 Transmission oil drain plug
Cotter pin or Snap Pin
18 Tie-rod end nut cotter pins (Left and Right)
19 Front axle nut cotter pins
20 Rear axle nut cotter pins
21 Strut clamp nut cotter pins (Left and Right)
22 Front suspension arm joint nut cotter pin (Left and Right)
23 Cargo bed mounting snap pins
Nm
Torque
kgfm
ftlb
49
5.0
36
34
44
98
64
44
44
64
64
3.5
4.5
10.0
6.5
4.5
4.5
6.5
6.5
25
33
72
47
33
33
47
47
137
14.0
101
59
6.0
43
98
98
59
10.0
10.0
6.0
72
72
43
32
20
15
3.3
2.0
1.5
24
14
11
Remarks
54 PREPARATION
General Fasteners:
Threads
dia. mm
5
6
8
10
12
14
16
18
20
Nm
3.4 4.9
5.9 7.8
14 19
25 34
44 61
73 98
115 155
165 225
225 325
Torque
kgfm
0.35 0.50
0.60 0.80
1.4 1.9
2.6 3.5
4.5 6.2
7.4 10.0
11.5 16.0
17.0 23.0
23 33
ftlb
30 43 inlb
52 69 inlb
10.0 13.5
19.0 25
33 45
54 72
83 115
125 165
165 240
No Unusual Noises:
No Fuel, Oil, Brake Fluid, or Coolant
Leaks:
Make a thorough visual check after the test
ride.
PREPARATION IS COMPLETE.
If any of the above items were found to operate improperly, refer to the Kawasaki Mule 4010
TRANS 4 4 Service Manual for repair and adjustment procedures.
MODEL APPLICATION
Year
2009
2009
2010
2010
2011
2011
2012
2012
2013
2013
2014
2014
Model
KAF620R9
KAF620S9
KAF620RA
KAF620SA
KAF620RB
KAF620SB
KAF620RC
KAF620SC
KAF620RD
KAF620SD
KAF620RE
KAF620SE
MULE
MULE
MULE
MULE
MULE
MULE
MULE
MULE
MULE
MULE
MULE
MULE
4010
4010
4010
4010
4010
4010
4010
4010
4010
4010
4010
4010
Name
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44