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MULE 4010 TRANS4×4 Utility Vehicle Assembly & Preparation Manual

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  • MULE 4010 TRANS44

    Utility VehicleAssembly & Preparation

    Manual

  • ForewordIn order to ship Kawasaki vehicles as effi-

    ciently as possible, they are partially disassem-bled before crating. Since some of the mostcommonly removed parts have a direct bear-ing on a vehicles reliability and safety, consci-entious pre-sale assembly and preparation be-comes extremely important. Good setup pro-cedures can prevent needless warranty claimsand give customers a greater sense of confi-dence in Kawasaki and their Kawasaki Dealers.This Assembly and Preparation Manual ex-

    plains step by step procedures of the followingitems for all Kawasaki utility vehicles.

    1. Crate Handling2. Uncrating3. Assembly4. Preparation

    The selling dealer assumes sole responsibil-ity for any unauthorized modifications prior tosale. Refer to your Service Binder for any Ser-vice Bulletins specifying Factory Directed Mod-ifications (Special Claims) which must be per-formed before the vehicle is ready for sale.Whenever you see the following symbols

    heed their instructions! Always follow safeoperating and maintenance practices.

    DANGERDANGER indicates a hazardous situa-tion which, if not avoided, will result indeath or serious injury.

    WARNINGWARNING indicates a hazardous situa-tion which, if not avoided, could resultin death or serious injury.

    NOTICENOTICE is used to address practices notrelated to personal injury.

    NOTENOTE indicates information that may help orguide you in the operation or service of thevehicle.

    Kawasaki Heavy Industries, Ltd. accepts noliability for any inaccuracies or omissions in thispublication, although every possible measurehas been taken to make it as complete and ac-curate as possible. All procedures and specifi-cations subject to change without notice.Illustrations and photographs in this publica-

    tion are intended for reference use only andmay not depict actual model component parts.

    2008 Kawasaki Heavy Industries, Ltd. Mar., 2013

  • Table of Contents

    Crate Handling.............................................................................. 3Crate Handling Precautions for RSC (Returnable Steel Crate)(US Model only) ........................................................................ 3

    Crate Handling Precautions (Other than US Model) ................... 3Uncrating ...................................................................................... 4Opening Crate (US Model only) .................................................. 4Opening Crate (Other than US Model) ........................................ 8Parts Check................................................................................. 14

    Assembly ...................................................................................... 20Steering Wheel............................................................................ 20Center Bar ................................................................................... 21Front Bar ..................................................................................... 22Rear Bar ...................................................................................... 22Front Seat Back........................................................................... 25Rear Seat .................................................................................... 25Front Guard ................................................................................. 25Front Fenders (Left and Right) .................................................... 26Rear Fender Front Flaps and Covers (Left and Right) ................ 27Cargo Bed and Screen (Convertible) .......................................... 28Converting Rear Seat and Cargo Bed......................................... 31French Labels for Canadian Models ........................................... 33

    Preparation ................................................................................... 34Charged Battery Service (US Model) .......................................... 34Uncharged Battery Service (Other than US Model) .................... 37Transmission Oil.......................................................................... 41Front Final Gear Case Oil ........................................................... 41Brake Fluid .................................................................................. 43Brake Pedal................................................................................. 44Brake Light Switch....................................................................... 44Steering Position Adjustment ...................................................... 44Parking Brake Lever.................................................................... 45Steering Wheel............................................................................ 45Tire Pressure ............................................................................... 46Fuel ............................................................................................. 46Coolant ........................................................................................ 46Engine Oil .................................................................................... 47Throttle Pedal .............................................................................. 48Idle Speed ................................................................................... 49Headlight Beam........................................................................... 49Wheel Alignment ......................................................................... 49Fastener Check ........................................................................... 52Standard Torque Table ................................................................ 54Test Ride Checklist ...................................................................... 54

  • CRATE HANDLING 3

    Crate HandlingCrate Handling Precautions forRSC (Returnable Steel Crate)(US Model only)Crate Position:Always place the crate upright on its base.

    The crate has been designed to carry the weightof the vehicle only in that position. The sidesand top of the crate are not strong enough toact as the base of the crate. If the crate is tiltedvery far or set on its end or side, loose partsmay be dislodged and fall inside the crate.

    Loading and Unloading Trucks forRSC:To load or unload crates, use a fork lift. Never

    attempt to unload crates by hand. NEVERDROP crates off a truck.Be sure to use the proper handling equip-

    ment for safe unloading, storing and stackingof crated Mule utility vehicles. The weight ofa large Mule utility vehicle plus the RSC ex-ceeds 2,200 lbs., therefore, two stacked crateswill weigh approximately 4,500 lbs.Use forklifts with at least 5,000 lb. lifting

    capacity and 60-inch tapered fork blades notgreater than 1-1/2 inches thick. Forklifts shouldalso be equipped with all safety items, such asoperator 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 atend.

    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 conditionof the crates and your forklifts capacity. Muleutility vehicle RSCs are designed for integratedstacking. Do not stack any other type of crateor any other materials atop a Mule RSC.In any case, do not stack returnable steel

    crates more than two high for trucking, andthree high for storage.

    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 weightof the vehicle only in that position. The sidesand top of the crate are not strong enough toact as the base of the crate. If the crate is tiltedvery far or set on its end or side, loose partsmay be dislodged and fall inside the crate.

  • 4 UNCRATING

    Moving Crated Vehicle:

    WARNINGCrate bands are only designed to holdthe cardboard cover in place. If used ashandles they can snap, causing you orthe crate to fall resulting in injury. Donot move or lift the crate using the cratebands.

    Whenever moving the crate from one place toanother, use a fork lift or flat bed hand truck. Ve-hicle crates are too big and heavy to be movedby hand. While moving a crate, never stand iton end or tip it over on its side. DO NOT DROPcrated vehicles.

    Loading and Unloading Trucks:To load or unload crates, use a fork lift, a lift

    -type tail gate, or a ramp. Never unload cratesby hand. NEVER DROP crates off a truck.

    Tying Down Crates:Always tie down crates when transporting

    them. Put the tie downs across the crate at thecrates internal vertical braces. Do not use anyhooks on the crate.

    Stacking Disposable Wooden Crates:The number of crates that may be stacked on

    top of one another depends on the condition ofthe crates more than any other single factor.Also, take into consideration the weight of theupper crate(s), the sizes of all the crates in astack, 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 cratesmore than two

    high for trucking, and three high for storage.

    UncratingOpening Crate (US Model only)

    WARNINGCrates have sharp edges and may havenails or screws that can cause cuts andinjury. Always wear protective gloves,boots and eye protection when uncrat-ing to prevent injury.

    WARNINGThe steel crate panel plates and fasten-ers have sharp edges. Always wear pro-tective gloves, boots and eye protectionwhen uncrating to prevent injury.

  • UNCRATING 5

    Clear a space about 6 m (20 ft.) square togive yourself plenty of space to work. Place the crate upright on its base.Remove the outer cover and inspect the unitfor concealed damage. If concealed damageis evident, document the damage as outlinedin the Kawasaki Warranty Policies and Pro-cedures Manual before proceeding to uncratethe unit. Remove the cardboard cover.To work efficiently, start work at the rear of the

    crate.

    Remove the bolts (2) of the diagonal braceand locknuts (2) of the diagonal brace to dis-connect the rear diagonal braces (2) from therear upright. Repeat these steps for the front upright. Discard the bolts (4) the of diagonal brace andlocknuts (4) of the diagonal brace. Allow the diagonal braces to pivot out anddown to the ground. They remain attachedto the pallet.

    A. Rear UprightB. Bolt of Diagonal BraceC. Locknut of Diagonal Brace

    Lay down the front and rear uprights. To doso, lift up on the upright to disengage its sock-ets from the pallet. Now the upright may be pivoted down to theground. (It remains attached to the pallet.) Becareful not to drop it on anyone.

    A. Upright

    Removing the Center and Front Barsand Parts from the UnitSteering Wheel, Screen and Parts BoxRemovalCut the tie bands that retain the steeringwheel and screen, and remove the steeringwheel. Remove the screen from the unit. Have asecond person help to remove this piece asit can be awkward to handle.

    A. Steering WheelB. Screen

    Remove the foam pieces that protect thescreen, and discard them.Remove the parts box containing the stays,guards and covers from the cargo bed.Side Tie-down RemovalFor KAF620R9/S9, remove the right side tie-down that retain the center bar by fully open-ing and disengaging latch. Take care to undothese evenly as there is heavy tension in eachtie-down.

  • 6 UNCRATING

    A. Right Side Tie-downB. Front BarC. Center Bar

    For KAF620RA RE/SA SE, remove theboth side tie-down that retain the front barby fully opening and disengaging latch. Takecare to undo these evenly as there is heavytension in each tie-down.

    A. Tie-downs (Both Sides)B. Front Bar

    Center Bar and Front Bar RemovalCut the tie bands that retain the center barand the front bar. Remove the center bar and the front bar fromthe unit. Have a second person help to re-move this piece as it can be awkward to han-dle. Take care when letting the center bar andthe front bar down from the unit, it is heavyand may fall.Removing the Rear Bar from the Unit

    NOTICETo prevent damaging the belt converterair cleaner housing with the rear bar, in-stall the cargo bed so that it is securelyfixed with the supporting rod before re-moving the rear bar from its shipping po-sition.

    Front Seat Back and Rear Seat Re-movalCut the tie bands that retain the front seatback, rear bar and the rear seat. Remove the front seat back from the unit.

    A. Front Seat Back

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

    A. Rear Seat AssemblyB. Rear Bar

    Cargo Bed Removal and InstallationRemove the screws and flat washers that re-tain the lower side of the cargo bed, and dis-card them.Have a second person help to move this pieceas it can be awkward to handle. Take carewhen letting the cargo bed down from the unit,it is heavy and may fall.

  • UNCRATING 7

    A. Screw and Flat WasherB. Cargo Bed

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

    A. StopperB. Supporting Rod

    Insert the left and right cargo bed pivot pinsinto the frame pivots from the outside of thevehicle, then insert the snap pins into the pivotpins.

    A. Left Pivot of Cargo BedB. Pivot PinC. Snap Pin

    Remove the foam pieces that protect thecargo bed, and discard them. Tilt up the cargo bed to prevent the belt con-verter air cleaner housing damaged, and sup-port it with the supporting rod.

    A. Cargo BedB. Supporting Rod

    Rear Bar RemovalRemove the rubber band from the end of therear bar. Remove the rear bar from the unit. Have asecond person help to remove this piece as itcan be awkward to handle. Take care whenletting the rear bar down from the unit, it isheavy and may fall. Remove the foam pieces that protect the rearbar, and discard them.Front Tie-down RemovalRemove front tie-downs by opening fully anddisengaging latch. Take care to undo theseevenly as there is heavy tension in the tie-down.

  • 8 UNCRATING

    A. Tie-downs (Front)

    Rear Tie-down RemovalRemove rear tie-downs by opening fully anddisengaging latch. Take care to undo theseevenly as there is heavy tension in the tie-down.

    A. Tie-downs (Rear)

    Roll the vehicle off the crate base after in-stalling the steering wheel (see SteeringWheel section in the assembly chapter). Itis recommended to remove the upright fromthe base if roll-off is planned.RETURN SHIPMENTPrepare the crate for return shipment. Fold braces in so they lay on the crate pallet.

    A. Braces

    Pick up slightly on the rear upright to disen-gage its sockets. Pivot it down onto the cratepallet. Be careful not to drop on anyone.

    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)

    WARNINGCrates have sharp edges and may havenails or screws that can cause cuts andinjury. Always wear protective gloves,boots and eye protection when uncrat-ing to prevent injury.

  • UNCRATING 9

    Clear a space about 6 m (20 ft.) square togive yourself plenty of space to work. Place the crate upright on its base.Remove the outer cover and inspect the unitfor concealed damage. If concealed damageis evident, document the damage as outlinedin the Kawasaki Warranty Policies and Pro-cedures Manual before proceeding to uncratethe unit. Remove the cardboard cover.Removing PanelsUsing a BPS3 square drive bit (ex. IM-PORT APEX Square Recess Power Bits-1/4 Hex-size #3 or MAGNA Insert Bits-size#3 with quick change holder), remove thescrews from the sides and ends into the top.

    A. Power Bit (APEX)

    WARNINGStaples, nails and other fasteners havesharp points that can cause injury. Re-move or bend into the wood all staples,nails or other fasteners in the crate base.

    Take out all the bolts, nuts, screws, and fas-teners and remove the top and side panels ofthe wood crate.

    Top Panel RemovalRemove the screws from the top crate. There are two screws in every corner.

    Remove the screws in every cross member.

    Top panel can be lifted from the unit. Have asecond person help to remove this piece as itcan be awkward to handle. Discard this as-sembly. Take care when letting the top paneldown from the top, it is heavy and may fall.Side Panel RemovalRemove the screws shown below. The panelshould come loose without excess force;check for any missed screws if the panel willnot come off easily.

    NOTETrying to break the panels off can result indamage to the unit.

  • 10 UNCRATING

    Repeat procedure for the other side of theunit. Discard these panels.End Panel RemovalRemove the screws shown below. The panelshould come loose without excess force,check for any missed screws if panel will notcome off easily.

    NOTETrying to break the panels off can result indamage to the unit.

    Repeat as above for the rear panel. Discardthese panels.

    Removing the Center and Front Barsand Parts from the UnitSteering Wheel, Screen and Parts BoxRemovalCut the tie bands that retain the steeringwheel and screen, and remove the steeringwheel. Remove the screen from the unit. Have asecond person help to remove this piece asit can be awkward to handle.

    A. Steering WheelB. Screen

    Remove the foam pieces that protect thescreen, and discard them.Remove the parts box containing the stays,guards and covers from the cargo bed.Side Tie-down RemovalFor KAF620R9/S9, remove the right side tie-down that retain the center bar by fully open-ing and disengaging latch. Take care to undothese evenly as there is heavy tension in eachtie-down.

    A. Right Side Tie-downB. Front BarC. Center Bar

  • UNCRATING 11

    For KAF620RA RE/SA SE, remove theboth side tie-downs that retain the front barby fully opening and disengaging latch. Takecare to undo these evenly as there is heavytension in each tie-down.

    A. Tie-downs (Both Sides)B. Front Bar

    Center Bar and Front Bar RemovalCut the tie bands that retain the center barand the front bar. Remove the center bar and the front bar fromthe unit. Have a second person help to re-move this piece as it can be awkward to han-dle. Take care when letting the center bar andthe front bar down from the unit, it is heavyand may fall.Removing the Rear Bar from the Unit

    NOTICETo prevent damaging the belt converterair cleaner housing with the rear bar, in-stall the cargo bed so that it is securelyfixed with the supporting rod before re-moving the rear bar from its shipping po-sition.

    Front Seat Back and Rear Seat Re-movalCut the tie bands that retain the front seatback, rear bar and the rear seat. Remove the front seat back from the unit.

    A. Front Seat Back

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

    A. Rear Seat AssemblyB. Rear Bar

    Cargo Bed Removal and InstallationRemove the screws and flat washers that re-tain the lower side of the cargo bed, and dis-card them.Have a second person help to move this pieceas it can be awkward to handle. Take carewhen letting the cargo bed down from the unit,it is heavy and may fall.

    A. Screw and Flat WasherB. Cargo Bed

  • 12 UNCRATING

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

    A. StopperB. Supporting Rod

    Insert the left and right cargo bed pivot pinsinto the frame pivots from the outside of thevehicle, then insert the snap pins into the pivotpins.

    A. Left Pivot of Cargo BedB. Pivot PinC. Snap Pin

    Remove the foam pieces that protect thecargo bed, and discard them. Tilt up the cargo bed to prevent the belt con-verter air cleaner housing damaged, and sup-port it with the supporting rod.

    A. Cargo BedB. Supporting Rod

    Rear Bar RemovalRemove the rubber band from the end of therear bar. Remove the rear bar from the unit. Have asecond person help to remove this piece as itcan be awkward to handle. Take care whenletting the rear bar down from the unit, it isheavy and may fall. Remove the foam pieces that protect the rearbar, and discard them.Front Tie-down RemovalRemove front tie-down by fully opening anddisengaging latch. Take care to undo theseevenly as there is heavy tension in the tie-down.

    A. Tie-downs (Front)

    NOTEIt is important to remove the top panel as theunit will rise when the tie-downs are undone.Failure to do so will result in damage to theunit.

    Rear Tie-down RemovalRemove rear tie-downs by fully opening anddisengaging latch. Take care to undo theseevenly as there is heavy tension in the tie-downs.

  • UNCRATING 13

    A. Tie-downs (Rear)

    NOTEIt is important to remove the top panel as theunit will rise when the tie-downs are undone.Failure to do so will result in damage to theunit.

    Remove the crate base blocks.

    A. Crate Base Blocks

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

  • 14 UNCRATING

    Parts Check

    NOTEThere may be minor differences in appearance between these illustrations and the actual vehicleparts.

    Remove the parts and check the crate base and packaging materials carefully for lost parts. Orderany parts that are missing from the crate. Part numbers are provided in the following charts. Checkthe parts against the illustrations. In the following charts under Remarks, D = diameter in millimeters,and L = length in millimeters.

  • UNCRATING 15

    No. Part Name Qty Remarks Part Number1 KAF620R9 RC/S9 SC

    Steering Wheel 1 46003-1308Spring Washer (1) D = 12 461DA1200Nut, Steering Wheel (1) D = 12 92210-1249Horn Button 1 14091-1247

    2 KAF620RD RE/SD SESteering Wheel 1 46003-0595Washer, Steering Wheel (1) D = 12.1 92200-0455Nut, Steering Wheel (1) D = 12 92210-1249Steering Wheel Cover 1 14092-1029Mark, Steering Wheel Cover 1 56054-1188

    3 Center Bar with 1 (*1) 55047-75121 (*2) 55047-0025

    55047-0331Bolt, Center Bar (8) D = 10, L = 20 130BB1020Spring Washer, Center Bar (8) D = 10 462DB1000Flat Washer, Seat Back, Black (4) D = 10.5 92022-1396Bolt, Seat Back (4) D = 10, L = 20 130BB1020Bolt, Lower, Center Bar (6) D = 10, L = 25 130BB1025Flat Washer, Lower, Center Bar, Plated (6) D = 10.2 92200-7506Nut, Lower, Center Bar (4) D = 10 92210-0276Seat Belt, Center Bar RH (1) (*3) 53061-7507

    (1) 53061-0315Seat Belt, Center Bar LH (1) (*3) 53061-7508

    (1) 53061-0316Front Seat Back 1 (*4) 53066-7503

    1 53066-0258Bar, Front Seat Back (1) 55047-7503Pad, Bar, Front Seat Back (1) 39156-7506Pad Cover, Bar, Front Seat Back (1) 14091-7559

    4 Front Bar 1 55047-7510Bolt, Lower 4 D = 14, L = 36 92153-1282

    5 Rear Bar with 1 55047-0020Damper (2) 92161-0020Bolt, Middle, Rear Bar (4) D = 10, L = 50 (*3) 130BB1050Bolt, Middle, Rear Bar (4) D = 10, L = 50 130BA1050Nut, Middle, Rear Bar (4) D = 10 92015-1428Bolt, Lower, Rear Bar (6) D = 10, L = 25 130BB1025Flat Washer, Lower, Rear Bar, Plated (6) D = 10.2 92200-7506Nut, Lower, Rear Bar (4) D = 10 92210-0276

    Joint Bar 2 55047-7504Bolt, Joint Bar 4 D = 10, L = 20 130BB1020Spring Washer, Joint Bar 4 D = 10 462DB1000

  • 16 UNCRATING

  • UNCRATING 17

    No. Part Name Qty Remarks Part Number6 Rear Seat, Upper and 1 (*4) 53066-7507

    Lower with 53066-0259Bolt, Rear Seat (1) D = 12, L = 117 (*3) 92150-1895Bolt, Rear Seat (1) D = 12, L = 117 92154-0867Flat Washer, Rear Seat (2) D = 12 411AB1200Nut, Rear Seat (1) D = 12 (*3) 92015-1190Nut, Rear Seat (1) D = 12 92210-0274Sleeve, Rear Seat (1) 42036-7501

    7 Cargo Bed with 1 (*3) (53029-0061)1 (53029-0313)

    Seat Belt, Cargo Bed with Rear Seat (2) (*3) 53061-7506(2) 53061-0314

    Pin, Cargo Bed Pivot (2) 92043-1428Snap Pin, Cargo Bed Pivot (2) 554DA1200

    Screen 1 14037-75018 KAF620R9 RC/S9 SC

    Front Guard 1 55020-0387Plug (2) 92066-7503Bolt, Upper, Front Guard 2 D = 10, L = 20 130BB1020Bolt, Upper, Front Guard 2 D = 10, L = 20 130BA1020Bolt, Lower, Front Guard 2 D = 12, L = 75 92002-1661Nut, Lower, Front Guard 2 92015-1433

    Front Guard Cover 1 14091-0817Screw, Front Guard Cover 4 D = 6, L = 16 92009-1621Collar, Front Guard Cover 4 L = 4 92143-1087

    9 KAF620RD RE/SD SEFront Guard 1 55020-0876Bolt, Upper, Front Guard 2 D = 10, L = 20 130BA1020Bolt, Lower, Front Guard 2 D = 12, L = 75 92002-1661Nut, Lower, Front Guard 2 D = 12 92015-1433

  • 18 UNCRATING

    No. Part Name Qty Remarks Part NumberStay, Flap LH 1 35063-0451Stay, Flap RH 1 35063-0452Bolt, Upper, Stay 4 D = 6, L = 20 (*4) 130BB0620

    4 D = 6, L = 20 130BA0620Bolt, Lower, Stay 2 D = 6, L = 14 (*3) 130BB0614Bolt, Lower, Stay 2 D = 6, L = 14 130BA0614

    Rear Flap LH 1 35019-0066Rear Flap RH 1 35019-0067Flap Cover LH 1 14091-0819Flap Cover RH 1 14091-0820Front Side Cover LH 1 14091-0823Front Side Cover RH 1 14091-0824Rear Side Cover LH 1 14091-0825Rear Side Cover RH 1 14091-0826Front Fender LH 1 35004-0123

    10

    Front Fender RH 1 35004-0124(Continued from previous page)Rivet, Fender and Cover 20 92039-1229Screw, Fender and Cover 22 D = 6, L = 16 (*3) 92009-1621Tapping Screw, Fender and Cover 12 D = 6, L = 20 92172-0488Screw, Fender 2 D = 6, L = 22 92009-1256Tapping Screw, Fender 2 D = 5, L = 20 92172-1072Collar, Fender 2 L = 9.5 92027-1767Collar, Fender and Cover 20 L = 4 92143-1087Collar, Fender and Cover 4 L = 6 92143-1057Crip-Nut, Fender and Cover 12 (*3) 92015-1678Crip-Nut, Fender and Cover 12 92210-0624

  • UNCRATING 19

    No. Part Name Qty Remarks Part Number11 French Labels and Instruction for

    Canadian Models onlyInstruction, Label 1 (*1) 56030-0272

    (*5) 56030-0313560300821

    Specification 1 (*6) 56053-75191 56053-0731

    Label, Information, Cargo Bed 1 (*1) 56053-7529Label, Tire/Max. Load 1 56053-7530Label, Warning, Cargo Bed 1 56071-7504Label, Warning, Off Highway Utility Vehicle 1 56070-0055Label, Warning, Trailer-Towing Bracket 1 (*6) 56071-7512

    560710335Label, Warning, Refueling 1 56071-7505Label, Warning, Front Cargo Hood 1 56070-0058Label, Warning, Hot Surfaces 1 56070-1207Label, Caution, Shifting 1 (*1) 56070-1211

    56071-0129Label, Warning, Passengers in Cargo Bed 1 (*1) 56071-0108

    56071-0139Label, Warning, General 1 56071-0110Label, Warning, Rear Seat Capacity 1 56071-7506Label, Warning, Pinching Fingers 2 56071-7508

    12 Battery Electrolyte (non-U.S. model) 1 YTX20L-BS, 12 V 18Ah 26022-3703

    13 Owners Manual 1

    *1: KAF620R9/S9*2: KAF620RA/RB/SA/SB*3: KAF620R9 RB/S9 SB*4: KAF620R9 RA/S9 SA*5: KAF620RA RD/SA SD*6: KAF620R9 RD/S9 SD

  • 20 ASSEMBLY

    AssemblySteering WheelSteering Wheel Installation (KAF620R9 RC/S9 SC)Remove the self-lock nut (D = 12) and thespring washer. Set the front wheels straight ahead.

    A. Steering ShaftB. Contact Assy

    Apply grease to the contact face of the steer-ing wheel.

    A. Steering WheelB. Apply Grease

    Mount the steering wheel on the steeringshaft so that it is straight ahead, and installthe spring washer and self-lock nut (D = 12). Tighten the self-lock nut to the specifiedtorque.Torque : 52 Nm (5.3 kgfm, 38 ftlb)

    A. Horn ButtonB. Self-lock Nut and Spring WasherC. Steering Wheel

    Install the horn button on the steering wheelby fitting the projections of the button into thenotches of the wheel.

    A. Horn Button

    NOTICEBe careful not to puncture a tire withsharp fasteners when rolling off the ve-hicle from the crate base.

    Remove any nails from the crate base thatmight puncture a tire. Roll the vehicle off the crate base.Steering Wheel Installation (KAF620RD RE/SD SE)Remove the self-lock nut (D = 12) and thewasher (D= 12.1) from the steering shaft. Set the front wheels straight ahead.

  • ASSEMBLY 21

    A. Self-lock nut (D = 12)B. Washer (D= 12.1)C. Steering Shaft

    Mount the steering wheel on the steeringshaft so that it is straight ahead, and installthe washer (D = 12.1) and self-lock nut (D =12). Tighten the self-lock nut to the specifiedtorque.Torque : 52 Nm (5.3 kgfm, 38 ftlb)

    Install the steering wheel cover on the steer-ing wheel by fitting the projections of thesteering wheel cover into the notches of thesteering wheel.

    A. Self-lock Nut and Washer (D = 12.1)B. Steering Wheel CoverC. Steering WheelD. ProjectionsE. Notches

    NOTICEBe careful not to puncture a tire withsharp fasteners when rolling off the ve-hicle from the crate base.

    Remove any nails from the crate base thatmight puncture a tire.Roll the vehicle off the crate base.

    Center BarCenter Bar Installation Lift the cargo bed and support it with the rodas shown in the figure.

    A. Supporting RodB. Stopper

    Remove the upper mounting bolts (D = 10, L= 20) (8) and the spring washers (8) from thecenter bar. Remove the center bar and rear bar lowermounting bolts (D = 10, L = 25) (12) (D = 10,L = 50) (4), flat washers (D = 10.2) (12) andthe 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)

    Install the center bar on the frame with thelower mounting bolts (D = 10, L = 25) (6), flatwashers (D = 10.2) (6) and the nuts (4), andtighten the bolts. Have a second person helpto install this piece as it can be awkward tohandle. Take care when installing the centerbar on the unit, it is heavy and may fall.

  • 22 ASSEMBLY

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

    (D = 10.2)C. Nuts (D = 10)

    For other than California model andKAF620RB RE/SB SE, route the fueltank breather hose and install its end into thesteel clamp on the center bar as shown inthe figure. Do not bend or pinch the breatherhoses.

    A. Center BarB. Fuel Tank Breather HoseC. Steel ClampD. to Check ValveE. to Floor Board

    Front BarFront Bar Installation Install the front bar on the frame with thelower mounting bolts (D = 14, L = 36) (4), andtighten the bolts. Have a second person helpto install this piece as it can be awkward tohandle. Take care when installing the frontbar on the unit, it is heavy and may fall.

    A. Bolts (D = 14, L = 36)B. Front Bar

    Join the rear ends of the front bar and thecenter bar with the bolts (D = 10, L = 20) (4)and the spring washers (4), and tighten thebolts.

    A. Front Bar (Right)B. Center BarC. Bolts (D = 10, L = 20) and Spring

    Washers

    Rear BarRear Bar Installation Install the rear bar on the frame with the lowermounting bolts (D = 10, L = 25) (6) (D = 10,L = 50) (4), flat washers (D = 10.2) (6) andnuts (8), and tighten the bolts. Have a secondperson help to install this piece as it can beawkward to handle. Take care when installingthe rear bar on the unit, it is heavy and mayfall.

  • 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)

    NOTEWhen installing the right middle pipe, tightenthe bolts and nuts as shown in the figure.

    A. Right Middle PipeB. Front

    Remove the upper mounting bolts (D = 10, L= 20) (4) and the spring washers (4) from therear bar. Install the two joint bars between the centerbar 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 up-ward, and tighten the bolts.

    A. Joint BarsB. Bracket PartsC. Bolts (D = 10, L = 20) and SpringWashers

    Belt Converter Air Cleaner InstallationFor KAF620RC RE/SC SE, install the beltconverter air cleaner housing as shown. Tighten the bolts and nuts.Torque : 16 Nm (1.6 kgfm, 12 ftlb)

    A. Belt Converter Air Cleaner HousingB. Bolt (D = 8, L = 40)C. Washer (D = 9)D. Damper (The shorter side faces lowerside)

    E. CollarF. Nut (D = 8)

    Loosen the clamp bolt on the front end of thebelt converter air cleaner duct and connectthe duct to the left middle pipe of the rear barand fasten it with the clamp.

  • 24 ASSEMBLY

    A. Left Middle PipeB. ClampC. Belt Converter Air Cleaner Duct

    NOTEInstall the clamp at about 3 mm (0.12 in.) fromthe end of belt converter air cleaner duct.

    A. ClampB. About 3 mm (0.12 in.)

    Air Cleaner (Engine) InstallationRemove the air cleaner mounting bolts (D =8, L = 14) (2) from the flame. Loosen the rear clamp bolt on the air cleanerduct and connect the duct to the right mid-dle pipe of the rear bar and fasten it with theclamp.

    A. Right Middle PipeB. ClampC. Air Cleaner Duct

    Install the air cleaner with the mounting bolts(2), and tighten the bolts.Torque : 20 Nm (2.0 kgfm, 15 ftlb)

    A. Air Cleaner (Engine)B. Bolts (D = 8, L = 14)

    NOTEInstall the clamp at about 3 mm (0.12 in.) fromthe end of air cleaner duct.

    A. ClampB. About 3 mm (0.12 in.)

  • ASSEMBLY 25

    Tighten the joint bar, front bar upper, rear barlower, rear bar middle, center bar, front barlower 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: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 BackFront Seat Back InstallationRemove the front seat back mounting bolts(D = 10, L = 20) (4) and the flat washers (D =10.5) (4) from the center bar. Install the front seat back on the center barwith the mounting bolts (4) and flat wash-ers (4), so that the handrail faces upward.Tighten the bolts to the specified torque.Torque : 64 Nm (6.5 kgfm, 47 ftlb)

    A. HandrailB. Front Seat BackC. Bolts (D = 10, L = 20) and Flat Washers(D = 10.5)

    Rear SeatRear Seat InstallationRemove the rear seat bolt (D = 12, L = 117),flat washers, and nut from the pivot bracketon the seat. Apply grease to the rear seat pivot bracket. Install the rear seat to the pivot bracket onframe with the bolt, flat washers and nut asshown in the figure.

    A. Pivot Bolt (D = 12, L = 117)B. Rear Seat Pivot BracketC. NutD. Flat Washers

    Temporarily, keep the rear seat assembly for-ward into the stored position.

    Front GuardFront Guard Installation (KAF620R9 RC/S9 SC) Install the front guard on the frame with theupper bolts (D = 10, L = 20) (2), lower bolts(D = 12, L = 75) (2) and nuts (2), and tightenthem securely.

  • 26 ASSEMBLY

    A. Front GuardB. Upper Bolts (D = 10, L = 20)C. Lower Bolts (D = 12, L = 75)D. Nuts (D = 12)

    Install the front guard cover on the front guardwith the screws (D = 6, L = 16) (4) and collars(L = 4) (4), and tighten the screws.

    A. Front Guard CoverB. Screws (D = 6, L = 16) and Collars (L =4)

    Front Guard Installation (KAF620RD RE/SD SE) Install the front guard on the frame with theupper bolts (D = 10, L = 20) (2), lower bolts(D = 12, L = 75) (2) and nuts (2), and tightenthem securely.

    A. Front GuardB. 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) Installa-tion Install the clip-nuts (5) on each left and rightside of the front cover and each lower fender.

    A. Clip-nuts (D = 6)

    Insert each left and right side hook portionof the front cover into each slot of the frontfender.

  • ASSEMBLY 27

    A. Hook Portion (Front Cover)B. Slot (Left Front Fender)

    Install each left and right front fender with thescrews 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 FenderB. 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 andCovers (Left and Right)Rear Fender Front Flaps and Covers(Left and Right) Installation Install each rear fender front left and right flapstay 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 StayB. Upper Bolts (D = 6, L = 20)C. Lower Bolt (D = 6, L = 14)

    Install each rear fender front left and right flapon the stay with the screw (D = 6, L = 16)(1), collar (L = 4) (1) and plastic rivet (1), andtighten them.

    A. Rear Fender Front Left FlapB. Screw (D = 6, L = 16) and Collar (L = 4)C. Plastic Rivet

    Remove the tapping screws (D = 6, L = 16)(2) and collar (L = 4) (2) from the frame. Insert the clip-nut (1) on the rear side cover. Install each rear left and right rear side coveron the 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 CoverB. 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

    For KAF620R9 RB/S9 SBmodel, installeach rear fender front left and right flap coverwith the screws (D = 6, L = 16) (2), collars (L =4) (2) and plastic rivets (2), and tighten them. For KAF620RC RE/SC SE model, installeach rear fender front left and right flap coverwith the screws (D = 6, L = 16) (1), tappingscrew (D = 6, L = 20) (1), collars (L = 4) (2)and plastic rivets (2), and tighten them.

    A. Rear Fender Front Left Flap CoverB. Screws (D = 6, L = 16) and Collars (L= 4)

    C. Plastic Rivets

    Install each front left and right side cover withthe screws (D = 6, L = 16) (2), collar (L = 4)(1) (L = 6) (1) and plastic rivets (2), and tightenthem.

    A. Front Left Side CoverB. Screws (D = 6, L = 16) and Collars (L= 4)

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

    D. Plastic Rivets

    Cargo Bed and Screen(Convertible)Cargo Bed and Screen Installation (4Passengers Mode) Lower the cargo bed.

    NOTETo lower the cargo bed, follow the reverseprocedure for raising. Be sure to restore theseat as before and put the latches on. Neverdrive the Mule without putting the latches tothe cargo bed.

    Swing open both front side panels of thecargo bed.

    A. Front Side Panel

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

  • ASSEMBLY 29

    A. Stopper PinB. Screen

    Insert both guide pins of the screen into thesockets at the rear side panels.

    A. ScreenB. Guide PinC. Socket

    Slide the stopper pins toward the outside atthe bottom of the screen to lock the screen.

    A. Stopper Pin

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

    A. Screws (D = 6, L = 14)B. BracketsC. Damper

    Insert both end projections of the front sidepanels into the dampers on the screen, andthen tighten the damper bracket screws.

    A. Front Side PanelsB. End ProjectionsC. Dampers

    Lower the rear seat assembly. Pull the rear seat stopper pin on the left sideand pull up the seat back.

    A. Stopper PinB. Rear Seat

    Hold the rear seat with both latches.

  • 30 ASSEMBLY

    Taillight Lead ConnectionRemove the taillight lead from the clamps onthe cargo bed and taillights.

    A. Clamps

    Route the taillight lead through the plasticclamp and connect it to the harness connec-tor at the dust boot, then cover the connectorwith the boot.

    A. Taillight LeadB. Plastic ClampC. ConnectorD. Dust Boot

    Reinstall the taillight lead and fasten it with theclamps.Latch Position InspectionThe rear seat must be latched securely on the

    hooks without rattling. If there is rattling or a loose fit, adjust the latchpositions for a snug fit.

    A. HookB. Latch LeverC. Mounting Bolts (D = 8, L = 20)D. Rear Seat

    Latch Position AdjustmentRelease the latch and loosen the mountingbolts (D = 8, L = 20). Reposition the latch to the suitable place bysliding it within the elliptical bolt holes. Retighten the mounting bolts.

    NOTEAdjustment must be made on both sides.Cargo Bed Assembly InspectionShut the tailgate completely.

    1. Cargo Bed2. Right Panel3. Tailgate4. Left Panel5. Bolts (D = 8, L = 20) and Nuts6. Push the panel with both hands.

    Measure the 2 dimensions [D] of the upperends of the left and right panels indicatedin the figure with the lock lever pins insertedwith a pair of vernier calipers (Make sure thatboth the right and the left lock lever pins aresecurely inserted).

  • ASSEMBLY 31

    Viewed from A:

    A. Left PanelB. Lock LeverC. TailgateD. 5 mm (0.2 in.) or less

    Furthermore, visually inspect the panels (bothright and left) for bend or warp. If they are warped and/or if the dimensions [D]of areas shown in the figure exceed 5mm (0.2in.), loosen the three mounting nuts (3, rightand left) at each lower end of the cargo bedpanel.Open the tailgate. Tighten all the mounting nuts while stronglypushing the rear upper ends of the panelswith both hands (both right and left) towardthe inside of cargo bed.Close the tailgate. If each dimension exceeds 5 mm (0.2 in.) af-ter measuring, repeat the procedures until thespecified dimensions are acquired.

    Converting Rear Seat and CargoBedThis vehicle can be converted to accommo-

    date more passengers and less cargo or fewerpassengers and more cargo.

    WARNINGIf passengers ride in the cargo bed, theycould be tossed about or thrown fromthe vehicle, causing serious injury ordeath. Never carry passengers in thecargo bed. Tilting the cargo bed whenit is loaded may cause the vehicle to tipover backwards, causing serious injuryor death. Never tilt the cargo bed whenit is loaded. Driving with the cargo bedtilted may be hazardous. Always lowerand latch the bed before driving.

    The seats and the cargo bed can be con-verted in the following way.Convert the Rear Seat and Cargo Bedfrom 4-person to 2-person

    1. Pull the rear seat stopper pin on the left side.

    A. Stopper PinB. Rear Seat

    2. Push the rear seat back forward.3. Release the latches on both sides.

    A. LatchB. Rear Seat Back (lowered position)

    4. Push the rear seat assembly forward into thestored position.

    A. Rear Seat (Stored position)B. Front Seat BackC. Warning Label

  • 32 ASSEMBLY

    5. Swing open the cargo bed side plates andfasten the latches on the both sides.

    A. Front Side PanelsB. Latch

    6. Slide the stopper pins at the bottom of theremovable screen to the inside.

    A. Stopper PinB. Screen

    7. Pull and remove the screen from the sock-ets, move forward and insert into the socketsat the end of the front side panels.

    A. ScreenB. Sockets

    8. Latch the stopper pins at the bottom of thescreen.

    Cargo Bed Latch Position InspectionThe cargo bed must be latched securely on

    the hooks without rattling. If there is rattling or looseness, adjust thelatch position.

    A. HookB. Latch and LeverC. Mounting Bolts (D = 8, L = 20)D. Cargo Bed

    Cargo Bed Latch Position AdjustmentRelease the latch and loosen the mountingbolts (D = 8, L = 20). Reposition the latch to the suitable place bysliding it within the elliptical bolt holes. Retighten the mounting bolts.

    NOTEAdjustment must be made on both sides.Convert the Rear Seat and Cargo Bedfrom 2-person to 4-person ModeReverse the procedure for 4-person to2-person mode conversion.

    NOTEWhen folding the cargo bed front side panels,be sure to insert the end projections into thedampers on the screen.

  • ASSEMBLY 33

    A. End ProjectionsB. Cargo Bed Front Side Panels (folded)

    French Labels for CanadianModels

    NOTEApply the French labels over the English la-bels on the unit when required.

    Wipe off any oil or grease from the Englishlabels. Refer to the following photographs inthe label locations. Peel each French label off the backing sheetand apply it over the English label.

    1. Off-Highway Utility Vehicle Warning(56070-0055)

    2. Front Cargo HoodWarning (56070-0058)

    3. Shifting Caution (56070-1211/56071-0129)4. General Warning (56071-0110)

    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)

    10. Refueling Warning (56071-7505)

    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

    13. Trailer-Towing Bracket Warning(56071-7512/0335)

    14. Hot Surfaces Warning (56070-1207)

    PreparationCharged Battery Service (USModel)Pre-filled, Pre-charged Battery

    The battery used in this Mule utility vehicle is apre-filled, pre-charged, sealed battery, eliminat-ing the need for dealers to prepare the batteryby filling it with electrolyte. However, dealersshould still check each batterys state of chargeperiodically to be sure it meets the minimum

    12.6 volt specification and charge it to 100%state of charge during Assembly & Preparation.The new battery is built to automotive indus-

    try standards and should hold a charge of 75%or above for approximately six months at 72-77 degrees Fahrenheit. Because the batterywill discharge at different rates based on vary-ing conditions, it is recommended that it bechecked every three months on any inventoryunit.Battery Charging Condition InspectionBattery 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 ParkingBrake Lever section). Remove the protective tapes on the batteryterminals and discard them.Measure the battery terminal voltage.

    NOTEMeasure with a digital voltmeter that can beread to at least one decimal place voltage.

    Battery Terminal VoltageStandard: 12.6 V or more

    If the reading is above the specification re-freshing charge is not required. Go on to thenext step.

    A. Voltmeter

    If the reading is below the specification re-freshing charge is required. See the BatteryRemoval and Refreshing Charge section.

  • PREPARATION 35

    Battery InstallationTurn the main switch OFF.Route the battery cables as shown, and firstconnect the red protective capped positivecable to the battery positive terminal (+), thenconnect the negative cable to the negativeterminal (). Put a light coat of grease on the terminals toprevent corrosion.

    A. Protective CapB. Positive Cable (+)C. Negative Cable ()D. Battery HolderE. Battery

    Cover the positive terminal (+) with its red pro-tective cap.Battery Removal Loosen the nuts to remove the battery holder. Remove the battery holder and take the bat-tery out of the battery case. Be careful thatany rubber dampers are not pulled out of po-sition.

    A. NutsB. Battery HolderC. Battery

    Battery SpecificationsBattery Capacity 12 V 14 AhBattery P/No. 26012-0107

    Refreshing Charge

    DANGERBatteries produce an explosive gas mix-ture of hydrogen and oxygen that cancause serious injury and burns if ignited.Keep the battery away from sparks andopen flames during charging. Whenusing a battery charger, connect thebattery to the charger before turning onthe charger. This procedure preventssparks at the battery terminals whichcould ignite any battery gases.

    NOTICEAlways remove the battery from thevehicle for charging. If the battery ischarged while still installed, batteryelectrolyte may spill and corrode theframe or other parts of the vehicle.Charging the battery at a rate higher thanspecified may ruin the battery. Chargingat a high rate causes excess heat whichcan warp the plates and cause internalshorting.Higher-than-normal charging rates alsocause the plates to shed active material.Deposits will accumulate, and can causeinternal shorting.If the temperature of the electrolyterises above 45C (113F) during charg-ing, reduce the charging rate to lowerthe temperature, and increase chargingtime proportionately.

    NOTENever attempt to charge a frozen battery.Allow it to warm up to room temperature be-fore charging.Never leave a battery on a trickle chargerlonger than 48 hours. Serious damage to thebattery will occur.

    WARNINGThis battery is sealed battery type.Never remove seal sheet or cap even atcharging. Never add water. Charge withcurrent and time as stated below.

  • 36 PREPARATION

    A. Seal Sheet or Cap

    Refer to the Battery Charging Time Table forthe charging.

    Determine battery condition after charging.Determine the condition of the battery 30 min-utes after completion of the charge by mea-suring the terminal voltage according to thetable below.

    Criteria Judgement12.6 V or higher Good

    12.0 12.6 V Charge insufficient Recharge

    12.0 V or lower Unserviceable Replace

    Battery InstallationTurn the main switch OFF.Check that the rubber dampers on the batteryholder and the battery case are properly inplace.

    A. Battery Case Damper

    Put the battery in the battery case. Reinstall the nuts, battery holder rod and bat-tery in the reverse of removal. Route the battery cables as shown, and firstconnect the red protective capped positivecable to the battery positive terminal (+), thenconnect the negative cable to the negativeterminal (). Put a light coat of grease on the terminals toprevent corrosion. Cover the positive terminal (+) with its red pro-tective cap.

    KAF620R9 RD/S9 SD

    A. Protective CapB. Positive Cable (+)C. Negative Cable ()D. Battery HolderE. Battery

  • PREPARATION 37

    KAF620RE/SE

    A. Protective CapB. Positive Cable (+)C. Negative Cable ()D. Battery HolderE. Battery

    Reinstall the battery cover (see ParkingBrake Lever section).

    Uncharged Battery Service (Otherthan US Model)Sealed Battery Type

    The battery used in this Mule utility vehicle isa sealed type. Follow the procedure for activat-ing a new battery to ensure the best possiblebattery performance.Activating the battery requires two steps,

    filling the battery with electrolyte, and charging.Read the Battery Safety label shown below andfollowing procedures carefully before batteryactivation.

    NOTICEIncorrect Battery Activation will reducebattery performance and service life. Besure to strictly follow the Battery Serviceinstructions in this Manual.

    Make sure to use the electrolyte packed in thecrate with the unit.Battery RemovalRemove the battery cover (see ParkingBrake Lever section). Loosen the nuts to remove the battery holder. Remove the battery holder and take the bat-tery out of the battery case. Be careful thatany rubber dampers are not pulled out of po-sition.

    A. NutsB. Battery HolderC. Battery

    Battery SpecificationsMake YuasaBattery Type YTX20L-BSBattery Capacity 12 V 18 AhElectrolyte Capacity 0.93 LBattery/Electrolyte Set P/No. 26012-3730

    Battery ActivationElectrolyte FillingMake sure that the model name of the elec-trolyte container matches the model name ofthe battery. These names must be the same.

    Battery Model NameKAF620R/S: YTX20L-BS

  • 38 PREPARATION

    A. Model Name of the ElectrolyteB. Model Name of the Battery

    NOTICEEach battery comeswith its own specificelectrolyte container; using the wrongcontainer may overfill the battery withincorrect electrolyte, which can shortenbattery life and deteriorate battery per-formance. Be sure to use the electrolytecontainer with the same model name asthe battery since the electrolyte volumeand specific gravity vary with the batterytype.

    NOTICEDo not remove the aluminum sealingsheet from the filler ports until just priorto use. Be sure to use the dedicatedelectrolyte container for correct elec-trolyte volume.

    DANGERSulfuric acid in battery electrolyte cancause severe burns. To prevent burns,wear protective clothing and safetyglasses when handling electrolyte. Ifthe electrolyte comes in contact withyour skin or eyes, wash the area withliberal amounts of water and seek medi-cal attention for more severe burns.

    Place the battery on a level surface.Check to see that the sealing sheet has nopeeling, tears, or holes in it. Remove the sealing sheet.

    NOTEThe battery is vacuum sealed. If the sealingsheet has leaked air into the battery, it mayrequire a longer initial charge.

    A. Sealing SheetB. Filler Ports

    Remove the electrolyte container from thevinyl bag. Detach the strip of caps from the containerand set aside, these will be used later to sealthe battery.

    NOTEDo not pierce or otherwise open the sealedcells of the electrolyte container. Do not at-tempt to separate individual cells.

    A. Strip of CapsB. Sealed Cells

    Place the electrolyte container upside downwith the six sealed cells into the filler portsof the battery. Hold the container level, pushdown to break the seals of all six cells. Youwill see air bubbles rising into each cell as theports fill.

    NOTEDo not tilt the electrolyte container.

  • PREPARATION 39

    Check the electrolyte flow. If no air bubbles are coming up from the fillerports, or if the container cells have not emp-tied completely, tap the container a few times.

    NOTEBe careful not to have the battery fall down.

    A. Air BubblesB. Tap the Container

    Keep the container in place. Dont removethe container from the battery, the battery re-quires all the electrolyte from the container forproper operation.

    NOTICERemoval of the container before it iscompletely empty can shorten the ser-vice life of the battery. Do not remove thecontainer until it is completely empty.

    After filling, let the battery sit for 20 60minutes with the electrolyte container kept inplace, which is required for the electrolyte tofully permeate into the plates.Make sure that the container cells have emp-tied completely, and remove the containerfrom the battery. Place the strip of caps loosely over the fillerports, press down firmly with both hands toseat the strip of caps into the battery (dontpound or hammer). When properly installed,the strip of caps will be level with the top ofthe battery.

    A. Strip of Caps

    NOTICEOnce the strip of caps is installed ontothe battery, never remove the caps, noradd water or electrolyte to the battery.

    NOTECharging the battery immediately after fillingcan shorten service life.

    Initial ChargeNewly activated sealed batteries require aninitial charge.Standard Charge: 1.8 A 5 10 hours

  • 40 PREPARATION

    If using a recommended battery charger, fol-low the chargers instructions for newly acti-vated sealed battery.

    Kawasaki-recommended chargers:Battery Mate 150-9OptiMate PRO 4-S/PRO S/PRO 2Yuasa MB-2040/2060Christie C10122S

    If the above chargers are not available, useequivalent one. Let battery sit 30 minutes after initial charge,then check voltage using a voltmeter. (Volt-age immediately after charging becomes tem-porarily high. For accurate measuring, let thebattery sit for given time.)

    NOTECharging rates will vary depending on howlong the battery has been stored, tempera-ture, and the type of charger used. If voltageis not at least 12.8 volts, repeat charging cy-cle.To ensure maximum battery life and customersatisfaction, it is recommended the battery beload tested at three times its amp-hour ratingfor 15 seconds.Re-check voltage and if less than 12.8 voltsrepeat the charging cycle and load test. If stillbelow 12.8 volts the battery is defective.

    Battery Installation

    NOTEThe procedure of the installation is the sameas the above Charged Battery Service (USModel).

    Turn the main switch OFF.Check that the rubber dampers on the batteryholder and the battery case are properly inplace.

    A. Battery Case DamperB. Battery Holder Damper

    Put the battery in the battery case. Reinstall the nuts, battery holder rod and bat-tery in the reverse of removal. Route the battery cables as shown, and firstconnect the red protective capped positivecable to the battery positive terminal (+), thenconnect the negative cable to the negativeterminal (). Put a light coat of grease on the terminals toprevent corrosion. Cover the positive terminal (+) with its red pro-tective cap.

    KAF620R9 RD/S9 SD

    A. Protective CapB. Positive Cable (+)C. Negative Cable ()D. Battery HolderE. Battery

    KAF620RE/SE

    A. Protective CapB. Positive Cable (+)C. Negative Cable ()D. Battery HolderE. Battery

    Reinstall the battery cover (see ParkingBrake Lever section).

  • PREPARATION 41

    Transmission OilTransmission Oil Level InspectionCheck oil level and drain plug tightness.Transmission Oil Drain Plug Torque:

    15 Nm (1.5 kgfm, 11 ftlb)

    A. Transmission CaseB. Drain Plug

    Park the vehicle on level ground. Lift the rear seat up and release the cargo bedlatches.Unscrew the oil filler plug, wipe its dipstick dry,and insert it into the filler opening but DONOTSCREW IT IN.

    A. Transmission CaseB. Oil Filler Plug

    NOTICEBe careful not to allow any dirt or foreignmaterials to enter the transmission case.

    Pull out the oil filler plug and check the oillevel. The oil level should be between the H(High) and L (Low) lines on the dipstick.

    A. Oil Filler PlugB. "H" (High) LineC. "L" (Low) Line

    If the oil level is too high, remove the excessoil, using a syringe or other suitable device,through the oil filler opening. If the oil level is too low, add enough oil toreach the correct level.When replacing the filler plug, be sure theO-ring is in place, and screw the plug in fingertight.

    NOTEUse the same type of oil that is already in thetransmission case.

    Transmission OilType: hypoid gear oilViscosity: SAE 90 [above 5C (41F)] or

    SAE 80 [below 5C (41F)]Capacity: 2.5 L (2.6 US qt)

    Front Final Gear Case OilFront Final Gear Case Oil Level Inspec-tionRemove the front final gear case guard byremoving the mounting bolts (D = 10, L = 16)and nuts (D = 10).

  • 42 PREPARATION

    A. Front Final Gear Case GuardB. Nuts (D = 10)

    A. Bolts (D = 10, L = 16)

    Park the vehicle on level ground.Remove the filler cap from the front final gearcase.

    A. Front Final Gear CaseB. Filler Cap

    NOTICEBe careful not to allow any dirt or for-eign materials to enter the front finalgear case.

    Check the oil level. The oil level should cometo the bottom of the filler opening. If it is low,add oil through the oil filler opening as neces-sary.

    A. Front Final Gear CaseB. Filler OpeningC. Bottom of Filler OpeningD. Drain Plug

    Reinstall the filler cap and tighten it to thespecified torque.

    Torque:29 Nm (3.0 kgfm, 22 ftlb)

    NOTEUse the same type of oil that is already in thegear case.

    Front Final Gear Case OilType: hypoid gear oil for LSD

    (Limited Slip Differentialgears)

    Viscosity: SAE 140 (GL-5) orSAE 90 (GL-6)

    Capacity: 0.40 L (0.42 US qt)

    Front Final Gear Case Oil Drain Plug Torque:20 Nm (2.0 kgfm, 14 ftlb)

    Reinstall the gear case guard.

  • PREPARATION 43

    Brake FluidBrake Fluid Level Inspection

    WARNINGWhen working with the disc brake, ob-serve the precautions listed below.Never reuse old brake fluid.Do not use fluid from a container thathas been left unsealed or that has beenopen for a long time.Do not mix two types and brands offluid for use in the brake. This lowersthe brake fluid boiling point and couldcause the brake to be ineffective. Itmay also cause the rubber brake partsto deteriorate.Dont leave the reservoir cap off forany length of time to avoid moisturecontamination of the fluid.Dont change the fluid in the rain orwhen a strong wind is blowing.Brake fluid quickly ruins painted sur-faces; any spilled fluid should be com-pletely wiped up immediately. If any of the brake line fittings or thebleed valve is opened at any time,the AIR MUST BE BLED FROM THEBRAKE LINE.

    With the vehicle on level ground, check that,through the inspection hole in the dashboard,the fluid level in the reservoir is between theupper (markedMAX) and lower (markedMIN)level lines.

    A. Inspection HoleB. Upper Level Line (MAX)C. Lower Level Line (MIN)

    If the fluid level is lower than the lower levelline, check for fluid leaks in the brake lines,and open the front cargo hood and fill thereservoir to the upper level line with D.O.T.3brake fluid. Pull the hood latch release knob and raise thehood.

    A. Hood Latch Release KnobB. Front Cargo Hood

    Remove the maintenance cover.

    A. Maintenance CoverB. Brake Fluid Reservoir

    Operate the brake pedal several times. If it feels spongy, there might be air in thebrake lines. Also check for fluid leakage around the fit-tings.Hood Closing Lower the hood. After the hood touches the damper boot, pushthe two parts of the hood to ensure the hoodis latched.

  • 44 PREPARATION

    A. BootB. Push the two parts.

    WARNINGAn open front cargo hood can distract orimpair visibility of the operator, causingloss of vehicle control and potential se-rious injury or death.Latch the hood securely before operat-ing the vehicle.

    Brake PedalBrake Pedal Free Play InspectionDepress the brake pedal lightly by hand. There should be 2 10 mm (0.08 0.40 in.)of free play. If it does not, adjust the brake pedal play.Brake Pedal Free Play:

    2 10 mm (0.08 0.40 in.)

    A. Brake PedalB. 2 10 mm (0.08 0.40 in.)

    Brake Pedal Free Play AdjustmentHave the brake pedal free play adjusted by an

    authorized Kawasaki dealer.

    Brake Light SwitchBrake Light Switch InspectionTurn the main switch to the ON position. Depress the brake pedal. The brake lightshould go on after about 10 mm (0.4 in.) ofpedal travel.

    A. Brake PedalB. 10 mm (0.4 in.)

    If it does not, check the bulb and, if necessary,adjust the brake light switch.Brake Light Switch AdjustmentHave the brake light switch adjusted by an

    authorized Kawasaki dealer.

    Steering Position AdjustmentThe steering wheel position can be adjusted

    to suit the operator. Loosen the upper and lower nuts on the steer-ing column bracket and move the steeringwheel up or down.

    A. Steering Column BracketB. Nuts

    Tighten the bolts and nuts.

  • PREPARATION 45

    Parking Brake LeverParking Brake Lever Travel InspectionRemove the two screws (D = 6, L = 16) andthe four plastic rivets, then remove the batterycover.

    A. Screws (D = 6, L = 16)B. Plastic RivetsC. Battery Cover

    Move the O-ring forward and pull the rubberboot up on the bottom.

    A. Parking Brake LeverB. O-ringC. Rubber Boot

    Pull the parking brake lever up and to the rear. After 8 to 12 clicks of lever travel, the vehicleshould not roll while parked.Parking Brake Travel: 8 12 Clicks

    A. 8 12 clicks

    If it rolls, adjust the parking brake lever.Parking Brake Lever Travel Adjustment Loosen the locknut (upper nut) on the middleof the parking brake lever, and turn the nutnext to the locknut until the brake lever willonly move 8 12 clicks upward.

    A. LocknutB. Nut

    Tighten the locknut securely. Reinstall the rubber boot making sure that theprojections on its lower edge are completelypushed into the holes in the bracket. Reinstall the battery cover with the screws (D= 6, L = 16) (2) and plastic rivets (4).

    Steering WheelSteering Wheel Free Play InspectionCheck steering wheel free play. Set the vehicles front tires straight ahead.Gently turn the steering wheel left and right.The steering wheel free play is the amount oftravel in the steering wheel, before the frontwheels begin to turn.

    Steering Wheel Free Play:0 20 mm (0 0.8 in.)

  • 46 PREPARATION

    A. 0 20 mm (0 0.8 in.)B. Gently turn.

    If the free play is incorrect, check and tightenthe steering wheel mounting nut and thesteering system parts, and adjust the steer-ing gear preload.Refer to the Steering Inspection and theSteering Gear Preload Adjustment proce-dures in the Service Manual.

    Tire PressureTire Air Pressure AdjustmentAdjust the pressures to the specified valuesin the front and rear, and make sure to tightenthe caps securely.

    Tire Air Pressure (when cold)Front: 69 kPa (0.7 kgf/cm, 10 psi)Rear: 167 kPa (1.7 kgf/cm, 24 psi)

    WARNINGOperating with unequally or improperlypressurized tires can adversely affectsteering or handling. Inflate both fronttires to the same pressure and both reartires to the same pressure.

    Fuel

    WARNINGGasoline is extremely flammable andcan be explosive under certain condi-tions, creating the potential for seriousburns. When filling the tank, turn theignition switch off. Do not smoke. Makesure the area is well ventilated and freefrom any source of flame or sparks; thisincludes any appliance with a pilot light.

    Fill the fuel tank with one gallon/or four liters ofunleaded gasoline. Use gasoline with a min-imum Antiknock Index rating in accordancewith the regulations of your country. Refer tothe following table.

    The antiknock index is an average of the Re-search Octane Number (RON) and the MotorOctane Number (MON), as shown in the table.For US and Canadian Models

    MinimumOctane Rating Method

    RatingAntiknock (RON + MON)Index 2

    87

    Close the fuel tank cap and check for anyleaks and correct them.

    CoolantCoolant Reservoir Tank Level CheckPark the vehicle on level ground. Lift the front cargo hood up. Check the coolant level through the coolantlevel gauge on the reserve tank. The coolantlevel should be between the F (Full) and L(Low) marks.

    NOTECheck the level when the engine is cold (roomor atmospheric temperature).

    If the coolant level is low, then unscrew thecap from the reserve tank and add coolantthrough the filler opening to the F (Full)mark.

    A. Reserve TankB. CapC. F (Full) MarkD. L (Low) Mark

    Install the cap. Close the front cargo hood.

  • PREPARATION 47

    Engine OilEngine Oil Level Inspection

    DANGERExhaust gas contains carbon monoxide,a colorless, odorless poisonous gas. In-haling carbon monoxide can cause seri-ous brain injury or death. DO NOT runthe engine in enclosed areas. Operateonly in a well-ventilated area.

    NOTEThis vehicles engine is filled with 10W-30 oilfrom the factory. DO NOT DRAIN and refillthe crankcase before use. Check oil level anddrain plug tightness.

    Engine Oil Drain Plug Torque:32 Nm (3.3 kgfm, 24 ftlb)

    A. Oil Drain Plug

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

    A. DipstickB. Groove MarkC. Rear Seat

    Wipe it dry, and insert it into the tube securelywith the indent upward. Pull out the dipstick and check that the enginehas oil.

    NOTEIt is necessary to match indent of the dipstickwith themark on the tube tomeasure a correctamount of oil.

    A. Dipstick TubeB. MarkC. IndentD. DipstickE. Oil Filler Cap

    Reinsert the dipstick until it bottoms into thetube securely.

    NOTICEIf the engine is run without oil, it will beseverely damaged.

  • 48 PREPARATION

    Start the engine and run it for several minutesat 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.

    A. DipstickB. "F" (Full) LineC. "L" (Low) Line

    If the oil level is too high, remove the excessoil, using a syringe or other suitable device. If the oil level is too low, unscrew the oil fillercap and add oil to reach the correct level. Reinsert the dipstick until it bottoms into thetube, and install the filler cap.

    Recommended Engine OilType: API SF, or SG class

    API SH or SJ with JASO MA,MA1 or MA2 class

    Viscosity: SAE 10W-40Capacity: 1.0 L (1.1 US qt)

    When filter is not removed.1.3 L (1.4 US qt)When filter is removed.

    NOTEDo not add any chemical additive to the oil.Oils fulfilling the above requirements are fullyformulated and provide adequate lubricationfor the engine.

    Although 10W-40 engine oil is the recom-mended oil for most conditions, the oil viscositymay need to be changed to accommodateatmospheric conditions in your riding area.

    Throttle PedalThrottle Pedal Free Play InspectionCheck that the throttle pedal has 5 10mm (0.2 0.4 in.) of free play and movessmoothly from full open to close.Throttle Pedal Free Play:

    5 10 mm (0.20 0.40 in.)

    A. Throttle PedalB. 5 10 mm (0.20 0.40 in.)

    Throttle Pedal Free Play Adjustment Lift the cargo bed and support it with the rod. Loosen and turn the throttle cable mountingnuts on the cable bracket until the properamount of throttle pedal play is obtained.

  • PREPARATION 49

    A. Mounting NutsB. Throttle Cable

    Tighten the mounting nuts securely.Throttle Pedal Stop Position AdjustmentThe full throttle pedal stop position can be ad-

    justed to prevent pulling the throttle cable morethan required. Loosen the locknut. Screw in the throttle pedal stop bolt. Depress the throttle pedal until the speed con-trol lever above the transmission case is in thefully opened position and hold it there. Turn the throttle pedal stop bolt until the bolthead lightly touches the bottom of the throttlepedal. Tighten the locknut securely.

    A. Throttle PedalB. LocknutC. Throttle Pedal Stop Bolt

    Idle SpeedIdle Speed InspectionStart the engine and warm it up thoroughly. Lift the cargo bed and support it with the rod.Use a suitable tachometer to measure the idleRPM.Idle Speed: 950 50 r/min (rpm)

    Idle Speed AdjustmentHave the idle speed adjusted by an autho-rized Kawasaki dealer.

    Headlight BeamThe headlight beams can be adjusted verti-

    cally. Turn the adjusting screw on the reverse sideof the headlight to adjust the headlight verti-cally.

    A. Adjusting Screw

    Wheel AlignmentToe-in is the amount that the front wheels

    are closer together in front than at the rear atthe axle height. When there is toe-in, the dis-tance A (Rear) is greater than B (Front) asshown. The purpose of toe-in is to preventthe front wheels from getting out of parallel atany time, and to prevent any slipping or scuff-ing action between the tires and the ground.If toe-in is incorrect, the front wheels will bedragged along the ground, scuffing and wear-ing 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 hubheight)

  • 50 PREPARATION

    Toe-in Adjustment Lift the front wheels off the ground. Apply a heavy coat of chalk near the center ofthe front tires.Using a needle nose scriber, make a thinmark near the center of the chalk coatingwhile turning the wheel. Set the wheels so that the marks on the tiresare at the front side and at the level of the axleheight.Ground the front wheels. Set the steering wheel straight ahead. At the level of the axle height, measure thedistance between the scribed lines with ameasure.

    Move the vehicle rearward until the marks onthe front tires are at the rear side and at thesame level as the axle.Measure the distance between the scribedlines.

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

    Toe-in of Front WheelsStandard: 0 20 mm (0 0.79 in.) at 1G

    If the length is out of specification adjust thetie-rod length. Loosen the locknuts [A] on each tie-rod andturn the adjusting rods [B] the same numberof turns and the same direction on both sidesto achieve the specified toe-in.

    NOTEThe toe-in will be near the specified range, ifthe length of the tie-rod distance between therod groove [A] and the locknut [B] is 43.5 mm(1.71 in.) [C] on both the left and right tie-rods.

    Check the toe-in again. 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

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  • 52 PREPARATION

    Fastener CheckThe torque values listed are for assembly andpreparation items only, see the appropriateService Manual for a more comprehensivelist. Check tightness of all fasteners that arein the table before retail delivery. Also checkto see that each cotter pin or circlip is in place.

  • PREPARATION 53

    TorqueNo. Fastener

    Nm kgfm ftlbRemarks

    Steering1 Tie-rod end locknuts (Left and Right) 49 5.0 36Frame2 Seat belt mounting bolts 34 3.5 253 Front bar mounting bolts (Upper) 44 4.5 334 Front bar mounting bolts (Lower) 98 10.0 725 Center bar mounting bolts and nuts 64 6.5 476 Joint bar mounting bolts 44 4.5 337 Rear bar mounting bolts and nuts (middle) 44 4.5 338 Rear bar mounting bolts and nuts (lower) 64 6.5 479 Front seat back mounting bolts 64 6.5 47Wheel10 Wheel nuts 137 14.0 101 SSuspension

    11 Rear shock absorber upper mounting nuts (Left andRight) 59 6.0 43

    12 Front suspension arm pivot bolts (Left and Right) 98 10.0 7213 Leaf spring front mounting bolts (Left and Right) 98 10.0 7214 Leaf spring rear mounting nuts (Left and Right) 59 6.0 43Engine15 Engine oil drain plug 32 3.3 2416 Front final gear case oil drain plug 20 2.0 1417 Transmission oil drain plug 15 1.5 11Cotter pin or Snap Pin18 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

  • 54 PREPARATION

    Standard Torque TableThis table relating tightening torque to thread

    diameter, lists the basic torque for bolts andnuts. Use this table only for the bolts and nutsnot listed above. All of the values are for usewith dry solvent-cleaned threads.General Fasteners:Threads Torquedia. mm Nm kgfm ftlb

    5 3.4 4.9 0.35 0.50 30 43 inlb6 5.9 7.8 0.60 0.80 52 69 inlb8 14 19 1.4 1.9 10.0 13.510 25 34 2.6 3.5 19.0 2512 44 61 4.5 6.2 33 4514 73 98 7.4 10.0 54 7216 115 155 11.5 16.0 83 11518 165 225 17.0 23.0 125 16520 225 325 23 33 165 240

    Test Ride ChecklistComplete the test ride checklist.Steering: Action is free from

    lock-to-lock.Suspension: Check operation.Engine: The starter works

    properly and enginestarts promptly. Goodthrottle response andreturn.

    Belt Drive TorqueConverter:

    Smooth operation.

    Differential: Smooth operation.Forward-ReverseShift:

    Smooth operation.

    Hi-Low Shift: Smooth operation.2WD-4WD Shift: Smooth operation.Brakes: Adequate, smooth

    stopping power. Donot 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 CoolantLeaks:Make a thorough visual check after the testride.

    PREPARATION IS COMPLETE.If any of the above items were found to oper-ate improperly, refer to the Kawasaki Mule 4010TRANS 4 4 Service Manual for repair and ad-justment procedures.

  • MODEL APPLICATIONYear Model Name2009 KAF620R9 MULE 4010 TRANS442009 KAF620S9 MULE 4010 TRANS442010 KAF620RA MULE 4010 TRANS442010 KAF620SA MULE 4010 TRANS442011 KAF620RB MULE 4010 TRANS442011 KAF620SB MULE 4010 TRANS442012 KAF620RC MULE 4010 TRANS442012 KAF620SC MULE 4010 TRANS442013 KAF620RD MULE 4010 TRANS442013 KAF620SD MULE 4010 TRANS442014 KAF620RE MULE 4010 TRANS442014 KAF620SE MULE 4010 TRANS44

    Part No. 99931-1495-03