MULE 4010 TRANS44

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

NOTE indicates information that may help or

guide you in the operation or service of the
vehicle.

Kawasaki Heavy Industries, Ltd. accepts no

liability for any inaccuracies or omissions in this
publication, although every possible measure
has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without notice.
Illustrations and photographs in this publication are intended for reference use only and
may not depict actual model component parts.

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.

2008 Kawasaki Heavy Industries, Ltd.

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.

A. Pull chain around fork pocket area.

Stacking Returnable Steel Crates:

The number of crates that may be stacked on
top of one another depends on the condition
of the crates and your forklifts capacity. Mule
utility vehicle RSCs are designed for integrated
stacking. Do not stack any other type of crate
or any other materials atop a Mule RSC.
In any case, do not stack returnable steel
crates more than two high for trucking, and
three high for storage.

Loading and Unloading Trucks for

RSC:
To load or unload crates, use a fork lift. Never
attempt to unload crates by hand. NEVER
DROP crates off a truck.
Be sure to use the proper handling equipment for safe unloading, storing and stacking
of crated Mule utility vehicles. The weight of
a large Mule utility vehicle plus the RSC exceeds 2,200 lbs., therefore, two stacked crates
will weigh approximately 4,500 lbs.
Use forklifts with at least 5,000 lb. lifting
capacity and 60-inch tapered fork blades not
greater than 1-1/2 inches thick. Forklifts should
also be equipped with all safety items, such as
operator cages and fork back rests.

Pulling Crate from Trucks for RSC:

If pulling is necessary to unload from trailer,
please put rope or chain on fork pocket area at
end.

Crate Handling Precautions

(Other than US Model)
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

Moving Crated Vehicle:

WARNING
Crate bands are only designed to hold
the cardboard cover in place. If used as
handles they can snap, causing you or
the crate to fall resulting in injury. Do
not move or lift the crate using the crate
bands.
Whenever moving the crate from one place to
another, use a fork lift or flat bed hand truck. Vehicle crates are too big and heavy to be moved
by hand. While moving a crate, never stand it
on end or tip it over on its side. DO NOT DROP
crated vehicles.

Stacking Disposable Wooden Crates:

The number of crates that may be stacked on
top of one another depends on the condition of
the crates more than any other single factor.
Also, take into consideration the weight of the
upper crate(s), the sizes of all the crates in a
stack, and the strength of the bottom crate(s)
base on the type of crate construction (steel,
wood, bracing, etc.).
In any case, do not stack crates more than two
high for trucking, and three high for storage.

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.

Tying Down Crates:

Always tie down crates when transporting
them. Put the tie downs across the crate at the
crates internal vertical braces. Do not use any
hooks on the crate.

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

down the front and rear uprights. To do

Lay
so, lift up on the upright to disengage its sock-

ets from the pallet.

Now the upright may be pivoted down to the
ground. (It remains attached to the pallet.) Be
careful not to drop it on anyone.

a space about 6 m (20 ft.) square to

Clear
give yourself plenty of space to work.
the crate upright on its base.
Place
Remove
the outer cover and inspect the unit
for concealed
damage. If concealed damage

is evident, document the damage as outlined

in the Kawasaki Warranty Policies and Procedures Manual before proceeding to uncrate
the unit.
Remove the cardboard cover.

To work efficiently, start work at the rear of the

crate.
the bolts (2) of the diagonal brace
Remove
and locknuts (2) of the diagonal brace to dis-

connect the rear diagonal braces (2) from the

rear upright.
Repeat these steps for the front upright.
Discard the bolts (4) the of diagonal brace and
locknuts (4) of the diagonal brace.
Allow the diagonal braces to pivot out and
down to the ground. They remain attached
to the pallet.

A. Upright

Removing the Center and Front Bars

and Parts from the Unit
Steering Wheel, Screen and Parts Box
Removal

the tie bands that retain the steering

Cut
wheel and screen, and remove the steering

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

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.

Side Tie-down Removal

KAF620R9/S9, remove the right side tie

For
-down that retain the center bar by fully opening and disengaging latch. Take care to undo
these evenly as there is heavy tension in each
tie-down.

6 UNCRATING

Front Seat Back and Rear Seat Removal

the tie bands that retain the front seat

Cut
back, rear bar and the rear seat.
Remove the front seat back from the unit.

A. Right Side Tie-down

B. Front Bar
C. Center Bar
For KAF620RA RE/SA SE, remove the
both
side tie-down that retain the front bar
by fully opening and disengaging latch. Take
care to undo these evenly as there is heavy
tension in each tie-down.

A. Tie-downs (Both Sides)

B. Front Bar

Center Bar and Front Bar Removal

the tie bands that retain the center bar

Cut
and the front bar.
the center bar and the front bar from
Remove
the unit. Have a second person help to remove this piece as it can be awkward to handle. Take care when letting the center bar and
the front bar down from the unit, it is heavy
and may fall.

Removing the Rear Bar from the Unit

NOTICE
To prevent damaging the belt converter
air cleaner housing with the rear bar, install the cargo bed so that it is securely
fixed with the supporting rod before removing the rear bar from its shipping position.

A. Front Seat Back

the tie bands that retain the rear seat as Cut
sembly and the rear bar.
Remove the rear seat assembly from the unit.

A. Rear Seat Assembly

B. Rear Bar

Cargo Bed Removal and Installation

the screws and flat washers that re Remove

tain the lower side of the cargo bed, and dis-

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. Screw and Flat Washer

B. Cargo Bed
the cargo bed pivot pins and snap
Remove
pins from the frame pivots.
grease to the pivot pins.
Apply
Move
the cargo bed to the correct position,
and mount
the cargo bed on the frame pivots
clearing the supporting rod from the stopper
on the frame.

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. Left Pivot of Cargo Bed

B. Pivot Pin
C. Snap Pin
the foam pieces that protect the
Remove
cargo bed, and discard them.
up the cargo bed to prevent the belt con Tilt
verter air cleaner housing damaged, and support it with the supporting rod.

A. Cargo Bed
B. Supporting Rod

Rear Bar Removal

the rubber band from the end of the

Remove
rear bar.
the rear bar from the unit. Have a
Remove
second person help to remove this piece as it

can be awkward to handle. Take care when

letting the rear bar down from the unit, it is
heavy and may fall.
Remove the foam pieces that protect the rear
bar, and discard them.

Front Tie-down Removal

front tie-downs by opening fully and

Remove
disengaging latch. Take care to undo these
evenly as there is heavy tension in the tie
-down.

8 UNCRATING

up slightly on the rear upright to disen Pick

gage its sockets. Pivot it down onto the crate
pallet. Be careful not to drop on anyone.

A. Tie-downs (Front)

Rear Tie-down Removal

rear tie-downs by opening fully and

Remove
disengaging latch. Take care to undo these
evenly as there is heavy tension in the tie
-down.

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

the crate for return shipment.

Prepare
Fold
braces
in so they lay on the crate pallet.

A. Braces

A. Uprights

Repeat these steps for the other upright.

These items are discarded:

- Outer
Cover, Tie-downs (Qty.

4), Bolts (Qty.

4) of Diagonal Brace and Locknuts (Qty.
4) of Diagonal Brace

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

a space about 6 m (20 ft.) square to

Clear
give yourself plenty of space to work.
the crate upright on its base.
Place
Remove
the outer cover and inspect the unit
for concealed
damage. If concealed damage

Top Panel Removal

the screws from the top crate.

Remove
There
are
two screws in every corner.

is evident, document the damage as outlined

in the Kawasaki Warranty Policies and Procedures Manual before proceeding to uncrate
the unit.
Remove the cardboard cover.

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.

A. Power Bit (APEX)

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.

Remove the screws in every cross member.

panel can be lifted from the unit. Have a

Top
second person help to remove this piece as it
can be awkward to handle. Discard this assembly. Take care when letting the top panel
down from the top, it is heavy and may fall.

Side Panel Removal

the screws shown below. The panel

Remove
should come loose without excess force;
check for any missed screws if the panel will
not come off easily.

Trying

NOTE

to break the panels off can result in

damage to the unit.

10 UNCRATING

Removing the Center and Front Bars

and Parts from the Unit
Steering Wheel, Screen and Parts Box
Removal

the tie bands that retain the steering

Cut
wheel and screen, and remove the steering

wheel.
Remove the screen from the unit. Have a
second person help to remove this piece as
it can be awkward to handle.

procedure for the other side of the

Repeat
unit. Discard these panels.

End Panel Removal

the screws shown below. The panel

Remove
should come loose without excess force,
check for any missed screws if panel will not
come off easily.

Trying

NOTE

to break the panels off can result in

damage to the unit.

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.

Side Tie-down Removal

KAF620R9/S9, remove the right side tie

For
-down that retain the center bar by fully open-

as above for the rear panel. Discard

Repeat
these panels.

ing and disengaging latch. Take care to undo

these evenly as there is heavy tension in each
tie-down.

A. Right Side Tie-down

B. Front Bar
C. Center Bar

UNCRATING 11

For KAF620RA RE/SA SE, remove the

both
side tie-downs that retain the front bar
by fully opening and disengaging latch. Take
care to undo these evenly as there is heavy
tension in each tie-down.

A. Front Seat Back

A. Tie-downs (Both Sides)

B. Front Bar

the tie bands that retain the rear seat as Cut

sembly and the rear bar.
Remove the rear seat assembly from the unit.

Center Bar and Front Bar Removal

the tie bands that retain the center bar

Cut
and the front bar.
the center bar and the front bar from
Remove
the unit. Have a second person help to remove this piece as it can be awkward to handle. Take care when letting the center bar and
the front bar down from the unit, it is heavy
and may fall.

Removing the Rear Bar from the Unit

NOTICE
To prevent damaging the belt converter
air cleaner housing with the rear bar, install the cargo bed so that it is securely
fixed with the supporting rod before removing the rear bar from its shipping position.

Front Seat Back and Rear Seat Removal

A. Rear Seat Assembly

B. Rear Bar

Cargo Bed Removal and Installation

the screws and flat washers that re Remove

tain the lower side of the cargo bed, and dis-

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.

the tie bands that retain the front seat

Cut
back, rear bar and the rear seat.
Remove the front seat back from the unit.

A. Screw and Flat Washer

B. Cargo Bed

12 UNCRATING

the cargo bed pivot pins and snap

Remove
pins from the frame pivots.
grease to the pivot pins.
Apply
Move
the cargo bed to the correct position,
and mount
the cargo bed on the frame pivots
clearing the supporting rod from the stopper
on the frame.

A. Cargo Bed
B. Supporting Rod

Rear Bar Removal

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.

the rubber band from the end of the

Remove
rear bar.
the rear bar from the unit. Have a
Remove
second person help to remove this piece as it

can be awkward to handle. Take care when

letting the rear bar down from the unit, it is
heavy and may fall.
Remove the foam pieces that protect the rear
bar, and discard them.

Front Tie-down Removal

front tie-down by fully opening and

Remove
disengaging latch. Take care to undo these
evenly as there is heavy tension in the tie
-down.

A. Left Pivot of Cargo Bed

B. Pivot Pin
C. Snap Pin
the foam pieces that protect the
Remove
cargo bed, and discard them.
up the cargo bed to prevent the belt con Tilt
verter air cleaner housing damaged, and support it with the supporting rod.

A. Tie-downs (Front)

NOTE

It is important to remove the top panel as the

unit will rise when the tie-downs are undone.

Failure to do so will result in damage to the
unit.

Rear Tie-down Removal

rear tie-downs by fully opening and

Remove
disengaging latch. Take care to undo these
evenly as there is heavy tension in the tie
-downs.

UNCRATING 13

A. Tie-downs (Rear)

NOTE

It is important to remove the top panel as the

unit will rise when the tie-downs are undone.

Failure to do so will result in damage to the
unit.

Remove the crate base blocks.

A. Crate Base Blocks

the vehicle off the crate base after in Roll
stalling the steering wheel (see Steering
Wheel section in the assembly chapter).

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

Bolt, Center Bar

Spring Washer, Center Bar
Flat Washer, Seat Back, Black
Bolt, Seat Back
Bolt, Lower, Center Bar
Flat Washer, Lower, Center Bar, Plated
Nut, Lower, Center Bar
Seat Belt, Center Bar RH
Seat Belt, Center Bar LH
Front Seat Back

4
5

Bar, Front Seat Back

Pad, Bar, Front Seat Back
Pad Cover, Bar, Front Seat Back
Front Bar
Bolt, Lower
Rear Bar with
Damper
Bolt, Middle, Rear Bar
Bolt, Middle, Rear Bar
Nut, Middle, Rear Bar
Bolt, Lower, Rear Bar
Flat Washer, Lower, Rear Bar, Plated
Nut, Lower, Rear Bar
Joint Bar
Bolt, Joint Bar
Spring Washer, Joint Bar

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

Pin, Cargo Bed Pivot

Snap Pin, Cargo Bed Pivot
Screen
KAF620R9 RC/S9 SC
Front Guard
Plug
Bolt, Upper, Front Guard
Bolt, Upper, Front Guard
Bolt, Lower, Front Guard
Nut, Lower, Front Guard
Front Guard Cover
Screw, Front Guard Cover
Collar, Front Guard Cover
KAF620RD RE/SD SE
Front Guard
Bolt, Upper, Front Guard
Bolt, Lower, Front Guard
Nut, Lower, Front Guard

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

Label, Information, Cargo Bed

Label, Tire/Max. Load
Label, Warning, Cargo Bed
Label, Warning, Off Highway Utility Vehicle
Label, Warning, Trailer-Towing Bracket

1
1
1
1
1
1
1

Label, Warning, Refueling

Label, Warning, Front Cargo Hood
Label, Warning, Hot Surfaces
Label, Caution, Shifting

1
1
1
1

Label, Warning, Passengers in Cargo Bed

Label, Warning, General

Label, Warning, Rear Seat Capacity
Label, Warning, Pinching Fingers

1
1
2

12 Battery Electrolyte (non-U.S. model)

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)

the self-lock nut (D = 12) and the

Remove
spring washer.
Set the front wheels straight ahead.

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

the spring washer and self-lock nut (D = 12).

Tighten the self-lock nut to the specified
torque.
Torque : 52 Nm (5.3 kgfm, 38 ftlb)

any nails from the crate base that

Remove
might puncture a tire.
Roll the vehicle off the crate base.

Steering Wheel Installation (KAF620RD

RE/SD SE)

the self-lock nut (D = 12) and the

Remove
washer (D= 12.1) from the steering shaft.
Set the front wheels straight ahead.

ASSEMBLY 21

Center Bar
Center Bar Installation

the cargo bed and support it with the rod

Lift
as shown in the figure.

A. Self-lock nut (D = 12)

B. Washer (D= 12.1)
C. Steering Shaft
the steering wheel on the steering
Mount
shaft so that it is straight ahead, and install

the washer (D = 12.1) and self-lock nut (D =

12).
Tighten the self-lock nut to the specified
torque.
Torque : 52 Nm (5.3 kgfm, 38 ftlb)

the steering wheel cover on the steer Install

ing wheel by fitting the projections of the
steering wheel cover into the notches of the
steering wheel.

A.
B.
C.
D.
E.

Self-lock Nut and Washer (D = 12.1)

Steering Wheel Cover
Steering Wheel
Projections
Notches

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.

A. Bolts (D = 10, L = 25) and Flat Washers

(D = 10.2)
B. Bolts (D = 10, L = 50)
C. Nuts (D = 10)
the center bar on the frame with the
Install
lower mounting bolts (D = 10, L = 25) (6), flat
washers (D = 10.2) (6) and the nuts (4), and
tighten the bolts. Have a second person help
to install this piece as it can be awkward to
handle. Take care when installing the center
bar on the unit, it is heavy and may fall.

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. Bolts (D = 14, L = 36)

B. Front Bar
the rear ends of the front bar and the
Join
center bar with the bolts (D = 10, L = 20) (4)
and the spring washers (4), and tighten the
bolts.

tank breather hose and install its end into the

steel clamp on the center bar as shown in
the figure. Do not bend or pinch the breather
hoses.

A.
B.
C.
D.
E.

Center Bar
Fuel Tank Breather Hose
Steel Clamp
to Check Valve
to Floor Board

Front Bar
Front Bar Installation

the front bar on the frame with the

Install
lower mounting bolts (D = 14, L = 36) (4), and
tighten the bolts. Have a second person help
to install this piece as it can be awkward to
handle. Take care when installing the front
bar on the unit, it is heavy and may fall.

A. Front Bar (Right)

B. Center Bar
C. Bolts (D = 10, L = 20) and Spring
Washers

Rear Bar
Rear Bar Installation

the rear bar on the frame with the lower

Install
mounting bolts (D = 10, L = 25) (6) (D = 10,
L = 50) (4), flat washers (D = 10.2) (6) and
nuts (8), and tighten the bolts. Have a second
person help to install this piece as it can be
awkward to handle. Take care when installing
the rear bar on the unit, it is heavy and may
fall.

ASSEMBLY 23

A. Rear Bar (Left)

B. Bolts (D = 10, L = 25) and Flat Washers
(D = 10.2)
C. Bolts (D = 10, L = 50)
D. Nuts (D = 10)

NOTE

When installing the right middle pipe, tighten

the bolts and nuts as shown in the figure.

A. Right Middle Pipe

B. Front
the upper mounting bolts (D = 10, L
Remove
= 20) (4) and the spring washers (4) from the

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

Belt Converter Air Cleaner Installation

For KAF620RC RE/SC SE, install the belt

converter
air cleaner housing as shown.
Tighten
the
bolts and nuts.

Torque : 16 Nm (1.6 kgfm, 12 ftlb)

A. Belt Converter Air Cleaner Housing

B. Bolt (D = 8, L = 40)
C. Washer (D = 9)
D. Damper (The shorter side faces lower
side)
E. Collar
F. Nut (D = 8)
the clamp bolt on the front end of the
Loosen
belt converter air cleaner duct and connect
the duct to the left middle pipe of the rear bar
and fasten it with the clamp.

24 ASSEMBLY

A. Left Middle Pipe

B. Clamp
C. Belt Converter Air Cleaner Duct

NOTE

Install the clamp at about 3 mm (0.12 in.) from

the end of belt converter air cleaner duct.

A. Clamp
B. About 3 mm (0.12 in.)

Air Cleaner (Engine) Installation

the air cleaner mounting bolts (D =

Remove
8, L = 14) (2) from the flame.
the rear clamp bolt on the air cleaner
Loosen
duct and connect the duct to the right mid-

A. Right Middle Pipe

B. Clamp
C. Air Cleaner Duct
the air cleaner with the mounting bolts
Install
(2), and tighten the bolts.
Torque : 20 Nm (2.0 kgfm, 15 ftlb)

A. Air Cleaner (Engine)

B. Bolts (D = 8, L = 14)

NOTE

Install the clamp at about 3 mm (0.12 in.) from

the end of air cleaner duct.

dle pipe of the rear bar and fasten it with the

clamp.

A. Clamp
B. About 3 mm (0.12 in.)

ASSEMBLY 25

the joint bar, front bar upper, rear bar

Tighten
lower, rear bar middle, center bar, front bar
lower mounting bolt to the specified torque.

Joint Bar Mounting Bolt Torque:

44 Nm (4.5 kgfm, 33 ftlb)

Front Bar Upper Mounting Bolt Torque:

44 Nm (4.5 kgfm, 33 ftlb)

Rear Bar Lower Mounting Bolt Torque:

Rear Seat
Rear Seat Installation

the rear seat bolt (D = 12, L = 117),

Remove
flat washers, and nut from the pivot bracket

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.

64 Nm (6.5 kgfm, 47 ftlb)

Rear Bar Middle Mounting Bolt Torque:

44 Nm (4.5 kgfm, 33 ftlb)

Center Bar Mounting Bolt Torque:

64 Nm (6.5 kgfm, 47 ftlb)

Front Bar Lower Mounting Bolt Torque:

98 Nm (10 kgfm, 72 ftlb)

Front Seat Back

Front Seat Back Installation

the front seat back mounting bolts

Remove
(D = 10, L = 20) (4) and the flat washers (D =

A. Pivot Bolt (D = 12, L = 117)

B. Rear Seat Pivot Bracket
C. Nut
D. Flat Washers

10.5) (4) from the center bar.

Install the front seat back on the center bar
with the mounting bolts (4) and flat washers (4), so that the handrail faces upward.
Tighten the bolts to the specified torque.

keep the rear seat assembly for Temporarily,

ward into the stored position.

Torque : 64 Nm (6.5 kgfm, 47 ftlb)

Front Guard Installation (KAF620R9

RC/S9 SC)

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)

Front Fenders (Left and Right)

Front Fenders (Left and Right) Installation
the clip-nuts (5) on each left and right
Install
side of the front cover and each lower fender.

A. Front Guard Cover

B. Screws (D = 6, L = 16) and Collars (L =
4)

Front Guard Installation (KAF620RD

RE/SD SE)
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. 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

A. Hook Portion (Front Cover)

B. Slot (Left Front Fender)
each left and right front fender with the
Install
screws or tapping screws (D = 6, L = 16 or 20)
(5) (D = 6, L = 22) (1), tapping screw (D =5,
L = 20) (1), collars (L = 4) (5) (L = 6) (1) (L =
9.5) (1) and plastic rivets (4).

A. Left Front Fender

B. Screws or Tapping Screws (D = 6, L =
16 or 20) and Collars (L = 4)
C. Screw (D = 6, L = 22) and Collar (L = 6)
D. Tapping Screw (D = 5, L = 20) and
Collar (L = 9.5)
E. Plastic Rivets

Rear Fender Front Flaps and

Covers (Left and Right)
Rear Fender Front Flaps and Covers
(Left and Right) Installation

each rear fender front left and right flap

Install
stay on the frame with the upper bolts (D = 6,
L = 20) (2) and lower bolt (D = 6, L = 14) (1),
and tighten the bolts securely.

A. Rear Fender Left Flap Stay

B. Upper Bolts (D = 6, L = 20)
C. Lower Bolt (D = 6, L = 14)
each rear fender front left and right flap
Install
on the stay with the screw (D = 6, L = 16)
(1), collar (L = 4) (1) and plastic rivet (1), and
tighten them.

A. Rear Fender Front Left Flap

B. Screw (D = 6, L = 16) and Collar (L = 4)
C. Plastic Rivet
the tapping screws (D = 6, L = 16)
Remove
(2) and collar (L = 4) (2) from the frame.
the clip-nut (1) on the rear side cover.
Insert
Install
rear left and right rear side cover
on the each
frame with the tapping screws (D = 6, L
= 16) (2), screw (D = 6, L = 16) (1), collars (L
= 4) (3) and plastic rivet (1), and tighten them.

28 ASSEMBLY

A. Rear Left Side Cover

B. Clip-nut (D = 6)
C. Tapping Screws (D = 6, L = 16) and
Collars (L = 4)
D. Screw (D = 6, L = 16) and Collar (L = 4)
E. Plastic Rivet
KAF620R9 RB/S9 SBmodel, install
For
each rear fender front left and right flap cover

with the screws (D = 6, L = 16) (2), collars (L =

4) (2) and plastic rivets (2), and tighten them.
For KAF620RC RE/SC SE model, install
each rear fender front left and right flap cover
with the screws (D = 6, L = 16) (1), tapping
screw (D = 6, L = 20) (1), collars (L = 4) (2)
and plastic rivets (2), and tighten them.

A. Front Left Side Cover

B. Screws (D = 6, L = 16) and Collars (L
= 4)
C. Screws (D = 6, L = 16) and Collars (L
= 6)
D. Plastic Rivets

Cargo
Bed
(Convertible)

and

Screen

Cargo Bed and Screen Installation (4

Passengers Mode)

Lower the cargo bed.

To

NOTE

lower the cargo bed, follow the reverse

procedure for raising. Be sure to restore the
seat as before and put the latches on. Never
drive the Mule without putting the latches to
the cargo bed.

open both front side panels of the

Swing
cargo bed.

A. Rear Fender Front Left Flap Cover

B. Screws (D = 6, L = 16) and Collars (L
= 4)
C. Plastic Rivets
each front left and right side cover with
Install
the screws (D = 6, L = 16) (2), collar (L = 4)
(1) (L = 6) (1) and plastic rivets (2), and tighten
them.

A. Front Side Panel

both stopper pins toward the inside at
Slide
the bottom of the screen.

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. Front Side Panels

B. End Projections
C. Dampers
the rear seat assembly.
Lower
the rear seat stopper pin on the left side
Pull
and pull up the seat back.

A. Stopper Pin
the damper bracket screws (D = 6, L
Loosen
= 14) (4) and free the brackets.

A. Stopper Pin
B. Rear Seat

Hold the rear seat with both latches.

30 ASSEMBLY

Taillight Lead Connection

the taillight lead from the clamps on

Remove
the cargo bed and taillights.

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

Latch Position Adjustment

the latch and loosen the mounting

Release
bolts (D = 8, L = 20).
the latch to the suitable place by
Reposition
sliding it within the elliptical bolt holes.
Retighten the mounting bolts.

NOTE

Adjustment must be made on both sides.

Cargo Bed Assembly Inspection

Shut the tailgate completely.

A.
B.
C.
D.

Taillight Lead
Plastic Clamp
Connector
Dust Boot

the taillight lead and fasten it with the

Reinstall
clamps.

Latch Position Inspection

The rear seat must be latched securely on the
hooks without rattling.
If there is rattling or a loose fit, adjust the latch
positions for a snug fit.

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.

the 2 dimensions [D] of the upper

Measure
ends of the left and right panels indicated
in the figure with the lock lever pins inserted
with a pair of vernier calipers (Make sure that
both the right and the left lock lever pins are
securely inserted).

ASSEMBLY 31

Viewed from A:

The seats and the cargo bed can be converted in the following way.

Convert the Rear Seat and Cargo Bed

from 4-person to 2-person
1. Pull the rear seat stopper pin on the left side.

A.
B.
C.
D.

Left Panel
Lock Lever
Tailgate
5 mm (0.2 in.) or less

Furthermore, visually inspect the panels (both

right and left) for bend or warp.
If they are warped and/or if the dimensions [D]
of areas shown in the figure exceed 5 mm (0.2
in.), loosen the three mounting nuts (3, right
and left) at each lower end of the cargo bed
panel.
Open the tailgate.
Tighten all the mounting nuts while strongly
pushing the rear upper ends of the panels
with both hands (both right and left) toward
the inside of cargo bed.
Close the tailgate.
If each dimension exceeds 5 mm (0.2 in.) after measuring, repeat the procedures until the
specified dimensions are acquired.

Converting Rear Seat and Cargo

Bed
This vehicle can be converted to accommodate more passengers and less cargo or fewer
passengers and more cargo.

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.

A. Rear Seat (Stored position)

B. Front Seat Back
C. Warning Label

32 ASSEMBLY

5. Swing open the cargo bed side plates and

fasten the latches on the both sides.

Cargo Bed Latch Position Inspection

The cargo bed must be latched securely on
the hooks without rattling.
If there is rattling or looseness, adjust the
latch position.

A. Front Side Panels

B. Latch
6. Slide the stopper pins at the bottom of the
removable screen to the inside.

A. Hook
B. Latch and Lever
C. Mounting Bolts (D = 8, L = 20)
D. Cargo Bed

Cargo Bed Latch Position Adjustment

the latch and loosen the mounting

Release
bolts (D = 8, L = 20).
the latch to the suitable place by
Reposition
sliding it within the elliptical bolt holes.
Retighten the mounting bolts.

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.

Adjustment must be made on both sides.

Convert the Rear Seat and Cargo Bed
from 2-person to 4-person Mode
the procedure for
Reverse
2-person mode conversion.

4-person to

NOTE

When folding the cargo bed front side panels,

be sure to insert the end projections into the
dampers on the screen.

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

5. Pinching Fingers Warning (56071-7508)

6. Tire Pressure & Maximum Loading
Important Information (56053-7530)
7. Cargo Bed Warning (56071-7504)
8. Rear Seat Capacity Warning
(56071-7506)
9. Specification (56053-7519)

Apply the French labels over the English labels on the unit when required.

off any oil or grease from the English

Wipe
labels. Refer to the following photographs in

the label locations.

Peel each French label off the backing sheet
and apply it over the English label.

10. Refueling Warning (56071-7505)

1. Off-Highway Utility Vehicle Warning

(56070-0055)
2. Front Cargo Hood Warning (56070-0058)
Shifting Caution (56070-1211/56071
3.
-0129)
4. General Warning (56071-0110)

11. Cargo Bed Information (56053-7529)

(KFA620R9/S9)
Passengers in Cargo Bed Warning
(56071-0139) (KAF620RA RE/SA SE)
12.Passengers in Cargo Bed Warning
(56071-0108) (KFA620R9/S9)

34 PREPARATION

12.6 volt specification and charge it to 100%

state of charge during Assembly & Preparation.
The new battery is built to automotive industry standards and should hold a charge of 75%
or above for approximately six months at 72
-77 degrees Fahrenheit. Because the battery
will discharge at different rates based on varying conditions, it is recommended that it be
checked every three months on any inventory
unit.

Battery Charging Condition Inspection

Battery charging condition can be checked by
measuring battery terminal voltage.
The battery is located under the left end of the
drivers seat.
Remove the battery cover (see Parking
Brake Lever section).
Remove the protective tapes on the battery
terminals and discard them.
Measure the battery terminal voltage.

13. Trailer-Towing Bracket Warning

(56071-7512/0335)

NOTE

Measure with a digital voltmeter that can be

read to at least one decimal place voltage.

Battery Terminal Voltage

Standard: 12.6 V or more
14. Hot Surfaces Warning (56070-1207)

next step.

Preparation
Charged
Model)

Battery

the reading is above the specification re Iffreshing

charge is not required. Go on to the

Service

(US

Pre-filled, Pre-charged Battery

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

Turn the main switch OFF.

Route the battery cables as shown, and first
connect the red protective capped positive
cable to the battery positive terminal (+), then
connect the negative cable to the negative
terminal ().
Put a light coat of grease on the terminals to
prevent corrosion.

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

the nuts to remove the battery holder.

Loosen
Remove
holder and take the bat tery out ofthethebattery
battery case. Be careful that
any rubber dampers are not pulled out of position.

Always remove the battery from the

vehicle for charging. If the battery is
charged while still installed, battery
electrolyte may spill and corrode the
frame or other parts of the vehicle.
Charging the battery at a rate higher than
specified may ruin the battery. Charging
at a high rate causes excess heat which
can warp the plates and cause internal
shorting.
Higher-than-normal charging rates also
cause the plates to shed active material.
Deposits will accumulate, and can cause
internal shorting.
If the temperature of the electrolyte
rises above 45C (113F) during charging, reduce the charging rate to lower
the temperature, and increase charging
time proportionately.

NOTE

Never attempt to charge a frozen battery.

Allow it to warm up to room temperature be-

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

A. Seal Sheet or Cap

A. Battery Case Damper

to the Battery Charging Time Table for

Refer
the charging.

the battery in the battery case.

Put
Reinstall
nuts, battery holder rod and bat tery in thethereverse
of removal.
Route
the
battery
cables
shown, and first
connect the red protectiveas capped
positive

cable to the battery positive terminal (+), then

connect the negative cable to the negative
terminal ().
Put a light coat of grease on the terminals to
prevent corrosion.
Cover the positive terminal (+) with its red protective cap.

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

the main switch OFF.

Turn
Check
the rubber dampers on the battery
holder that
and the battery case are properly in
place.

A. Protective Cap
B. Positive Cable (+)
C. Negative Cable ()
D. Battery Holder
E. Battery

PREPARATION 37

sure to use the electrolyte packed in the

Make
crate with the unit.

KAF620RE/SE

Battery Removal

the battery cover (see Parking

Remove
Brake Lever section).
the nuts to remove the battery holder.
Loosen
the battery holder and take the bat Remove
tery out of the battery case. Be careful that
any rubber dampers are not pulled out of position.

A. Protective Cap
B. Positive Cable (+)
C. Negative Cable ()
D. Battery Holder
E. Battery
the battery cover
Reinstall
Brake Lever section).

(see Parking

Uncharged Battery Service (Other

than US Model)
Sealed Battery Type

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

sure that the model name of the elec Make

trolyte container matches the model name of
The battery used in this Mule utility vehicle is
a sealed type. Follow the procedure for activating a new battery to ensure the best possible
battery performance.
Activating the battery requires two steps,
filling the battery with electrolyte, and charging.
Read the Battery Safety label shown below and
following procedures carefully before battery
activation.

NOTICE
Incorrect Battery Activation will reduce
battery performance and service life. Be
sure to strictly follow the Battery Service
instructions in this Manual.

the battery. These names must be the same.

Battery Model Name

KAF620R/S: YTX20L-BS

38 PREPARATION

A. Model Name of the Electrolyte

B. Model Name of the Battery

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

Do not pierce or otherwise open the sealed

cells of the electrolyte container. Do not attempt to separate individual cells.

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

The battery is vacuum sealed.

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

Do not tilt the electrolyte container.

PREPARATION 39

filling, let the battery sit for 20 60

After
minutes with the electrolyte container kept in

the electrolyte flow.

Check
If
no
air
are coming up from the filler
ports, orbubbles
if the container cells have not emp-

place, which is required for the electrolyte to

fully permeate into the plates.
Make sure that the container cells have emptied completely, and remove the container
from the battery.
Place the strip of caps loosely over the filler
ports, press down firmly with both hands to
seat the strip of caps into the battery (dont
pound or hammer). When properly installed,
the strip of caps will be level with the top of
the battery.

tied completely, tap the container a few times.

NOTE

Be careful not to have the battery fall down.

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

Charging the battery immediately after filling

can shorten service life.

Initial Charge

activated sealed batteries require an

Newly
initial charge.
Standard Charge:

1.8 A 5 10 hours

40 PREPARATION

a recommended battery charger, fol Iflowusing

the chargers instructions for newly activated sealed battery.

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-

the battery in the battery case.

Put
Reinstall
nuts, battery holder rod and bat tery in thethereverse
of removal.
Route
the
battery
cables
shown, and first
connect the red protectiveas capped
positive

cable to the battery positive terminal (+), then

connect the negative cable to the negative
terminal ().
Put a light coat of grease on the terminals to
prevent corrosion.
Cover the positive terminal (+) with its red protective cap.

KAF620R9 RD/S9 SD

age immediately after charging becomes temporarily high. For accurate measuring, let the
battery sit for given time.)

Charging

NOTE

rates will vary depending on how

long the battery has been stored, temperature, and the type of charger used. If voltage
is not at least 12.8 volts, repeat charging cycle.
To ensure maximum battery life and customer
satisfaction, it is recommended the battery be
load tested at three times its amp-hour rating
for 15 seconds.
Re-check voltage and if less than 12.8 volts
repeat the charging cycle and load test. If still
below 12.8 volts the battery is defective.

Battery Installation
NOTE

A. Protective Cap
B. Positive Cable (+)
C. Negative Cable ()
D. Battery Holder
E. Battery

KAF620RE/SE

The procedure of the installation is the same

as the above Charged Battery Service (US
Model).

the main switch OFF.

Turn
Check
the rubber dampers on the battery
holder that
and the battery case are properly in
place.

A. Protective Cap
B. Positive Cable (+)
C. Negative Cable ()
D. Battery Holder
E. Battery

A. Battery Case Damper

B. Battery Holder Damper

the battery cover

Reinstall
Brake Lever section).

(see Parking

PREPARATION 41

Transmission Oil
Transmission Oil Level Inspection

Check oil level and drain plug tightness.

Transmission Oil Drain Plug Torque:

15 Nm (1.5 kgfm, 11 ftlb)

A. Oil Filler Plug

B. "H" (High) Line
C. "L" (Low) Line
oil level is too high, remove the excess
Ifoil,theusing
a syringe or other suitable device,
A. Transmission Case
B. Drain Plug
the vehicle on level ground.
Park
the rear seat up and release the cargo bed
Lift
latches.
the oil filler plug, wipe its dipstick dry,
Unscrew
and insert it into the filler opening but DO NOT
SCREW IT IN.

through the oil filler opening.

If the oil level is too low, add enough oil to
reach the correct level.
When replacing the filler plug, be sure the
O-ring is in place, and screw the plug in finger
tight.

NOTE

Use the same type of oil that is already in the

transmission case.

Transmission Oil
Type:
Viscosity:
Capacity:

hypoid gear oil

SAE 90 [above 5C (41F)] or
SAE 80 [below 5C (41F)]
2.5 L (2.6 US qt)

Front Final Gear Case Oil

Front Final Gear Case Oil Level Inspection
A. Transmission Case
B. Oil Filler Plug

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.

the front final gear case guard by

Remove
removing the mounting bolts (D = 10, L = 16)
and nuts (D = 10).

42 PREPARATION

the oil level. The oil level should come

Check
to the bottom of the filler opening. If it is low,
add oil through the oil filler opening as necessary.

A. Front Final Gear Case Guard

B. Nuts (D = 10)
A. Front Final Gear Case
B. Filler Opening
C. Bottom of Filler Opening
D. Drain Plug
the filler cap and tighten it to the
Reinstall
specified torque.

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

Use the same type of oil that is already in the

gear case.

Front Final Gear Case Oil

Type:

Viscosity:
Capacity:

hypoid gear oil for LSD

(Limited Slip Differential
gears)
SAE 140 (GL-5) or
SAE 90 (GL-6)
0.40 L (0.42 US qt)

Front Final Gear Case Oil Drain Plug Torque:

20 Nm (2.0 kgfm, 14 ftlb)

A. Front Final Gear Case
B. Filler Cap

NOTICE
Be careful not to allow any dirt or foreign materials to enter the front final
gear case.

Reinstall the gear case guard.

PREPARATION 43

fluid level is lower than the lower level

Ifline,thecheck
for fluid leaks in the brake lines,

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.

and open the front cargo hood and fill the

reservoir to the upper level line with D.O.T.3
brake fluid.
Pull the hood latch release knob and raise the
hood.

A. Hood Latch Release Knob

B. Front Cargo Hood

Remove the maintenance cover.

the vehicle on level ground, check that,

With
through the inspection hole in the dashboard,
the fluid level in the reservoir is between the
upper (marked MAX) and lower (marked MIN)
level lines.
A. Maintenance Cover
B. Brake Fluid Reservoir
the brake pedal several times.
Operate
If
it
feels
brake lines.spongy, there might be air in the
check for fluid leakage around the fit Also
tings.

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

Brake Light Switch

Brake Light Switch Inspection

the main switch to the ON position.

Turn
Depress
pedal. The brake light
should gotheon brake
after about 10 mm (0.4 in.) of
pedal travel.

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

Brake Light Switch Adjustment

Brake Pedal Free Play Inspection

Have the brake light switch adjusted by an

authorized Kawasaki dealer.

the brake pedal lightly by hand.

Depress
There
should
of free play. be 2 10 mm (0.08 0.40 in.)
If it does not, adjust the brake pedal play.

Brake Pedal Free Play:

2 10 mm (0.08 0.40 in.)

A. Brake Pedal
B. 2 10 mm (0.08 0.40 in.)

Brake Pedal Free Play Adjustment

Have the brake pedal free play adjusted by an
authorized Kawasaki dealer.

Steering Position Adjustment

The steering wheel position can be adjusted
to suit the operator.
Loosen the upper and lower nuts on the steering column bracket and move the steering
wheel up or down.

A. Steering Column Bracket

B. Nuts

Tighten the bolts and nuts.

PREPARATION 45

Parking Brake Lever

Parking Brake Lever Travel Inspection

the two screws (D = 6, L = 16) and

Remove
the four plastic rivets, then remove the battery
cover.

A. 8 12 clicks

If it rolls, adjust the parking brake lever.

Parking Brake Lever Travel Adjustment
the locknut (upper nut) on the middle
Loosen
of the parking brake lever, and turn the nut
next to the locknut until the brake lever will
only move 8 12 clicks upward.

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

A. Parking Brake Lever

B. O-ring
C. Rubber Boot
the parking brake lever up and to the rear.
Pull
After
of lever travel, the vehicle
should8 tonot12rollclicks
while parked.
Parking Brake Travel: 8 12 Clicks

the locknut securely.

Tighten
Reinstall
boot making sure that the
projectionstheonrubber
its lower edge are completely

pushed into the holes in the bracket.

Reinstall the battery cover with the screws (D
= 6, L = 16) (2) and plastic rivets (4).

Steering Wheel
Steering Wheel Free Play Inspection

steering wheel free play.

Check
the vehicles front tires straight ahead.
Set
Gently turn the steering wheel left and right.
The steering wheel free play is the amount of
travel in the steering wheel, before the front
wheels begin to turn.

Steering Wheel Free Play:

0 20 mm (0 0.8 in.)

46 PREPARATION

the fuel tank with one gallon/or four liters of

Fill
unleaded gasoline. Use gasoline with a minimum Antiknock Index rating in accordance
with the regulations of your country. Refer to
the following table.
The antiknock index is an average of the Research Octane Number (RON) and the Motor
Octane Number (MON), as shown in the table.

For US and Canadian Models

Octane Rating Method
A. 0 20 mm (0 0.8 in.)
B. Gently turn.
free play is incorrect, check and tighten
Ifthethesteering
wheel mounting nut and the

steering system parts, and adjust the steering gear preload.

Refer to the Steering Inspection and the
Steering Gear Preload Adjustment procedures in the Service Manual.

Tire Pressure
Tire Air Pressure Adjustment

the pressures to the specified values

Adjust
in the front and rear, and make sure to tighten

Antiknock
Index

(RON + MON)
2

Front:
Rear:

69 kPa (0.7 kgf/cm, 10 psi)

167 kPa (1.7 kgf/cm, 24 psi)

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

the vehicle on level ground.

Park
Lift
the
front cargo hood up.
Check the
level through the coolant
level gaugecoolant
on the reserve tank. The coolant
level should be between the F (Full) and L
(Low) marks.

NOTE

Check the level when the engine is cold (room

or atmospheric temperature).

coolant level is low, then unscrew the

Ifcapthefrom
the reserve tank and add coolant
through the filler opening to the F (Full)
mark.

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

the fuel tank cap and check for any

Close
leaks and correct them.

the caps securely.

Tire Air Pressure (when cold)

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.

This vehicles engine is filled with 10W-30 oil

A. Dipstick
B. Groove Mark
C. Rear Seat

Engine Oil Drain Plug Torque:

it dry, and insert it into the tube securely

Wipe
with the indent upward.
out the dipstick and check that the engine
Pull
has oil.

NOTE

from the factory. DO NOT DRAIN and refill

the crankcase before use. Check oil level and
drain plug tightness.
32 Nm (3.3 kgfm, 24 ftlb)

NOTE

It is necessary to match indent of the dipstick

with the mark on the tube to measure a correct

amount of oil.

A. Oil Drain Plug

the vehicle so that it is level, both side-to
Park
-side and front-to-rear.
starting the engine, check that the en Before
gine has oil.
out the dipstick from the hole under the
Pull
rear seat.

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

the engine and run it for several minutes

Start
at idle speed. Stop the engine, then wait sev-

eral minutes until the oil settles.

Pull out the dipstick and check the oil level.
The oil level should be between the F (Full)
and L (Low) lines on the dipstick.

Throttle Pedal
Throttle Pedal Free Play Inspection

that the throttle pedal has 5 10

Check
mm (0.2 0.4 in.) of free play and moves
smoothly from full open to close.
Throttle Pedal Free Play:
5 10 mm (0.20 0.40 in.)

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.

Recommended Engine Oil

Type:

Viscosity:
Capacity:

API SF, or SG class

API SH or SJ with JASO MA,
MA1 or MA2 class
SAE 10W-40
1.0 L (1.1 US qt)
When filter is not removed.
1.3 L (1.4 US qt)
When filter is removed.

NOTE

Do not add any chemical additive to the oil.

Oils fulfilling the above requirements are fully
formulated and provide adequate lubrication
for the engine.

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.)

Throttle Pedal Free Play Adjustment

the cargo bed and support it with the rod.

Lift
Loosen
turn the throttle cable mounting
nuts on and
the cable bracket until the proper
amount of throttle pedal play is obtained.

PREPARATION 49

Idle Speed Adjustment

the idle speed adjusted by an autho Have

rized Kawasaki dealer.

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

Tighten the mounting nuts securely.

Throttle Pedal Stop Position Adjustment

The full throttle pedal stop position can be adjusted to prevent pulling the throttle cable more
than required.
Loosen the locknut.
Screw in the throttle pedal stop bolt.
Depress the throttle pedal until the speed control lever above the transmission case is in the
fully opened position and hold it there.
Turn the throttle pedal stop bolt until the bolt
head lightly touches the bottom of the throttle
pedal.
Tighten the locknut securely.

A. Throttle Pedal
B. Locknut
C. Throttle Pedal Stop Bolt

Idle Speed
Idle Speed Inspection

the engine and warm it up thoroughly.

Start
Lift
the
cargo bed and support it with the rod.
Use a suitable
tachometer to measure the idle
RPM.
Idle Speed:

950 50 r/min (rpm)

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

the measurement of the front from

Subtract
the measurement of the rear to get the toe-in.

Toe-in of Front Wheels

Standard: 0 20 mm (0 0.79 in.) at 1G
the length is out of specification adjust the
Iftie-rod
length.
Loosen
locknuts [A] on each tie-rod and
turn the the
adjusting rods [B] the same number
of turns and the same direction on both sides
to achieve the specified toe-in.

Toe-in Adjustment

the front wheels off the ground.

Lift
Apply
a heavy coat of chalk near the center of
the front
tires.
a needle nose scriber, make a thin
Using
mark near the center of the chalk coating

while turning the wheel.

Set the wheels so that the marks on the tires
are at the front side and at the level of the axle
height.
Ground the front wheels.
Set the steering wheel straight ahead.
At the level of the axle height, measure the
distance between the scribed lines with a
measure.

NOTE

The toe-in will be near the specified range, if

the length of the tie-rod distance between the

rod groove [A] and the locknut [B] is 43.5 mm
(1.71 in.) [C] on both the left and right tie-rods.

the vehicle rearward until the marks on

Move
the front tires are at the rear side and at the

same level as the axle.

Measure the distance between the scribed
lines.

the toe-in again.

Check
Tighten
the tie-rod end locknuts to the speci fied torque.
Torque : 49 Nm (5.0 kgfm, 36 ftlb)

Test drive the vehicle.

PREPARATION 51

This page intentionally left blank.

52 PREPARATION

Fastener Check

torque values listed are for assembly and

The
preparation items only, see the appropriate
Service Manual for a more comprehensive
list. Check tightness of all fasteners that are
in the table before retail delivery. Also check
to see that each cotter pin or circlip is in place.

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

Standard Torque Table

This table relating tightening torque to thread
diameter, lists the basic torque for bolts and
nuts. Use this table only for the bolts and nuts
not listed above. All of the values are for use
with dry solvent-cleaned threads.

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

Test Ride Checklist

Complete the test ride checklist.

Steering:

Action is free from

lock-to-lock.
Suspension:
Check operation.
Engine:
The starter works
properly and engine
starts promptly. Good
throttle response and
return.
Belt Drive Torque Smooth operation.
Converter:
Differential:
Smooth operation.
Forward-Reverse Smooth operation.
Shift:
Hi-Low Shift:
Smooth operation.
2WD-4WD Shift: Smooth operation.
Brakes:
Adequate, smooth
stopping power. Do
not drag.
Seat Belt:
Proper function.
Electrical System:
Headlight - check operation.
Tail/Brake Light - check operation.
Hourmeter - check operation.

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

Part No. 99931-1495-03

Name
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44
TRANS44