Model:
MULE 4010 TRANS 4x4 Diesel
Product Name:
2009-2012 Kawasaki MULE 4010 TRANS 4x4 Diesel Service Repair Manual Instant Download
Chassis Codes Covered:
KAF950G9, KAF950GA, KAF950HA, KAF950GB, KAF950HB, KAF950GC
Generation:
First Generation (2009-2014)
Market Position:
The Kawasaki MULE 4010 TRANS 4x4 Diesel is a utility vehicle designed for demanding work environments, offering robust diesel power and enhanced off-road capability with its true 4x4 system and transformative bed.
Competitive Analysis:
Competes with other utility UTVs from brands like John Deere (Gator), Polaris (Ranger), and Kubota, positioning itself as a durable and powerful workhorse.
Key Features:
Diesel engine for torque and fuel efficiency, true 4x4 system, K-TRAC (Kawasaki Traction Control), Trans-Cab feature for passenger capacity, durable construction.
Manual Value Proposition:
This service manual empowers owners and technicians to maintain, diagnose, and repair their Kawasaki MULE 4010 TRANS 4x4 Diesel, saving time and money compared to professional dealer services.
Systems Covered:
General Information, Periodic Maintenance, Fuel System (DFI), Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Fuel System Detail:
DFI, fuel pump, injectors, fuel filter replacement, fuel tank service.
Electrical System Detail:
Battery, charging system (alternator), starter motor, lighting, ignition system (glow plugs), fuses, relays, wiring diagrams.
Procedures Included:
Detailed step-by-step repair instructions, diagnostic procedures, torque specifications, wiring diagrams, troubleshooting guides, component removal and installation, adjustment procedures, maintenance schedules
Engine Rebuild Procedures:
Detailed instructions for engine disassembly, inspection, component replacement (pistons, rings, bearings, valves), and reassembly.
Brake System Repair:
Front and rear brake caliper service, pad replacement, rotor inspection, hydraulic system bleeding, brake line routing.
Suspension Component Replacement:
Front struts, rear shocks, bushings, and ball joint service.
Troubleshooting Guide:
Systematic approach to diagnosing common problems with clear symptoms, probable causes, and recommended solutions.
Technical Depth:
Comprehensive; suitable for DIY enthusiasts and professional mechanics, covering routine maintenance to major overhauls.
Searchability:
Typically PDF files are searchable, allowing users to quickly find specific information.
Portability:
Can be saved to hard drive, burned to CD, or accessed on multiple devices.
Print Quality:
High Resolution, suitable for printing in great quality
Binding Type:
Digital Download (No physical binding)
Paper Type:
Not Applicable (Digital PDF)
Compatibility:
All PC-based Windows Operating Systems and Mac
Requirements:
Adobe PDF Reader, WinZip
Engine Manufacturer Model:
Kawasaki D782-B (3-cylinder, liquid-cooled diesel)
Displacement:
778 cc (47.5 cu in)
Engine Id Tag:
Engine model and serial number found on engine block (refer to manual for specific location).
Horsepower:
Approx. 17.8 HP (This is an approximate value for this engine, specific tuning may vary.)
Torque:
High torque output characteristic of diesel engines, ideal for towing and hauling.
Fuel Injection:
Indirect Injection (IDI) with DFI (Digital Fuel Injection) management
Cooling Type:
Liquid-cooled
Oil Type:
Refer to manual for specific diesel engine oil viscosity (e.g., SAE 10W-30 or 15W-40 diesel rated API CI-4 or higher)
Transmission Type:
Continuously Variable Transmission (CVT) with High/Low range and Reverse
Gear Ratios:
Refer to manual for specific CVT ratio ranges and final drive ratios.
Drive Modes:
2WD / 4WD selection, Locking Rear Differential
Trans Cab Feature:
Ability to convert from 2-passenger to 4-passenger configuration by folding the cargo bed.
Overall Length:
Approximately 124.4 inches (3160 mm)
Overall Width:
Approximately 61.5 inches (1562 mm)
Overall Height:
Approximately 75.8 inches (1925 mm)
Wheelbase:
Approximately 70.9 inches (1800 mm)
Ground Clearance:
Approximately 7.0 inches (178 mm)
Bed Length:
Approximately 47.1 inches (1196 mm) in 2-passenger mode
Bed Width:
Approximately 43.1 inches (1095 mm)
Bed Depth:
Approximately 11.0 inches (280 mm)
Curb Weight:
Approximately 1,400 - 1,500 lbs (635 - 680 kg) (Varies by configuration)
Towing Capacity:
1,200 lbs (544 kg)
Payload Capacity:
840 lbs (381 kg)
Front Track:
Approximately 53.3 inches (1354 mm)
Rear Track:
Approximately 53.1 inches (1348 mm)
Safety Ratings:
Not applicable in the same way as passenger vehicles. Focus is on ROPS (Roll-Over Protective Structure) and seat belts.
Active Safety Features:
Four-wheel disc brakes, engine braking through CVT.
Passive Safety Features:
Steel-tube frame with ROPS, seat belts for all passengers, grab handles.
Engine Oil Change:
Refer to manual (typically every 50-100 operating hours or annually)
Air Filter Inspection:
Refer to manual (frequent checks in dusty conditions)
Coolant Check:
Refer to manual (frequently, especially before operation)
Engine Oil Specification:
Diesel engine oil, API CI-4 or higher, SAE 10W-30 or 15W-40 (Verify with manual)
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water (Verify with manual)
Transmission Oil Type:
Refer to manual for CVT fluid specifications (proprietary or specific fluid type)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (Verify with manual)
Common Issues:
Potential for CVT belt wear with heavy use, occasional overheating if cooling system is neglected, common diesel engine maintenance needs (glow plugs, fuel filter).
Brand Heritage:
Kawasaki has a long-standing reputation for building rugged, reliable, and powerful recreational and utility vehicles, including the popular MULE line.
Model Evolution:
The MULE 4010 TRANS 4x4 Diesel built upon the successful MULE platform, introducing the innovative Trans-Cab system and a powerful diesel option for increased work capability and efficiency.
Production Years:
2009-2012 (for this specific manual coverage)
