2009–2012 Kawasaki MULE 4010 TRANS4x4 Diesel UTV Assembly & Preparation Manual (P/N 99931-1497-03)

Kawasaki's Assembly & Preparation Manual covers dealer setup of the 2009–2012 MULE 4010 TRANS4x4 Diesel before retail delivery. This is the May 2011 edition, P/N 99931-1497-03.

• Crate handling and parts checks: US and non-US uncrating procedures, tie-down illustrations, and illustrated parts inventories with fastener dimensions and part numbers.

• Chassis assembly: Installation of the steering wheel, center bar, front bar, rear bar, front seat back, rear seat, and front guard.

• Cargo bed and bodywork: Convertible cargo bed and screen installation, rear-seat conversion, latch adjustment, and fitting of front fenders, flaps, and covers.

• Battery preparation: Charge checks for the US battery and activation procedures for Canadian and European models, supported by charging tables and connection illustrations.

• Fluids and engine controls: Engine, transmission, and front final gear case oil checks, coolant inspection, throttle pedal free-play and stop adjustment, and idle-speed inspection.

• Brakes, steering, and lighting: Brake fluid, brake pedal, and brake light switch checks; parking brake lever, steering position, headlight beam, and toe-in adjustments.

• Delivery checks: Illustrated fastener inspection charts, component-specific and standard torque tables, and a test ride checklist covering drivetrain, chassis, and electrical operation.

This manual is suited to dealership setup technicians equipped for vehicle lifting, torque checks, and battery testing.

Dealer Assembly and Convertible Cargo Bed

The manual outlines the setup procedures required for dealer pre-sale preparation. The final test ride section directs repair and further adjustment work to a separate service manual.

Parts Check illustrations and tables identify the supplied components and their hardware. KAF950GC-specific entries distinguish revised fasteners and body-panel hardware from KAF950G9/GA/GB/HA/HB parts, helping technicians match the hardware to the vehicle before assembly.

Cargo bed conversion views explain rear-seat folding, screen relocation, and latch positioning. The assembly inspection also addresses side-panel alignment at the tailgate.

Regional equipment: European KAF950GA/GB/GC models have separate trailer hitch and reverse light installation instructions. Canadian models have French-label placement references.

Observe the manual's safety precautions for heavy components, the raised cargo bed, and battery electrolyte.

Battery Variants and Fluid Preparation

US models use the pre-filled, sealed East Penn 526 RMF battery. Canadian KAF950G9/GA/GB/GC and European KAF950G9/GA/GB models use the conventional 722 FMF battery with packaged electrolyte. The European KAF950GC section covers activation with electrolyte supplied separately by the dealership.

The Battery Charging Time Table relates terminal voltage to charging current and duration. Battery service warnings explain how excessive charging rates can warp the plates and cause internal shorts.

Fluid sections identify oil types and level-check methods for the engine, transmission, and front final gear case, along with coolant reservoir checks. The engine-oil section explains how filling too quickly or overfilling can send oil into the intake and cause hydraulic lock.

Brake Checks, Wheel Alignment, and Final Inspection

Brake pedal free play, brake light switch operation, and engine idle speed have inspection instructions. Their adjustments are assigned to an authorized Kawasaki dealer; steering gear preload adjustment is referred to the separate service manual.

The wheel-alignment section provides toe-in measurement drawings and tie-rod adjustment instructions. Caster and camber are built in and require no adjustment.

Fastener charts link numbered inspection photos to component-specific torque values. The Standard Torque Table applies to otherwise unlisted bolts and nuts with dry, solvent-cleaned threads.

The Test Ride Checklist covers belt-drive torque-converter and differential operation, along with forward-reverse, high-low, and 2WD-4WD shifting. It also calls for checks of steering, suspension, brakes, seat belts, speedometer, lights, unusual noises, and fluid leaks.

A Preview of Brake and Alignment Specifications

These brake and alignment values are a small sample of the preparation specifications in the manual.

Brake pedal free play is specified at 2–10 mm (0.08–0.40 in.) for inspection. Parking brake lever travel is specified at 8–12 clicks.

The standard front-wheel toe-in is 0–20 mm (0–0.79 in.) at 1G, with measurements taken at axle height.

PDF Text Search and Page Details

Text search and navigation: Main text and tables support PDF text search. Some illustration callouts are image-based, and the file has no embedded PDF bookmarks.

Supplied as one printable, English-language, 64-page PDF. The total includes 60 numbered pages—three intentionally blank—plus front and back covers and two unnumbered blank pages.