ATVWorks Tune Up Kit Instruction Manual

1. Introduction

This instruction manual provides essential information for the proper installation and maintenance of your ATVWorks Tune Up Kit for Kawasaki Mule 4000 and 4010 models (2011-2018). Regular tune-ups are crucial for maintaining engine performance, fuel efficiency, and extending the lifespan of your utility vehicle.

Please read this manual thoroughly before beginning any installation or maintenance procedures. For detailed vehicle-specific instructions, always refer to your Kawasaki Mule's official service manual.

2. Product Overview

The ATVWorks Tune Up Kit (Model PK4010B) is designed to provide the necessary components for a comprehensive engine tune-up on compatible Kawasaki Mule 4000 and 4010 utility vehicles manufactured between 2011 and 2018. This kit includes high-quality aftermarket parts built to meet or exceed OEM standards, ensuring reliable performance.

Figure 1: ATVWorks Tune Up Kit for Kawasaki Mule 4000/4010, displaying two air filters, one oil filter, one fuel strainer and filter, and two spark plugs.

3. Components Included

Your ATVWorks Tune Up Kit contains the following items:

• (1) Element Air Cleaner (OEM Equivalent: 11013-1290): Primary air filter element.
• (1) Air Filter (OEM Equivalent: 11013-1263): Secondary air filter element.
• (1) Oil Filter OF300 (OEM Equivalent: 49065-2071): Engine oil filter.
• (1) Fuel Filter FF340 (OEM Equivalent: 49019-0013): Fuel strainer and filter assembly.
• (2) Spark Plugs BPR2ES: Engine ignition spark plugs.

4. Setup and Installation

Important Safety Information: Always ensure the vehicle is turned off, cooled down, and the parking brake is engaged before performing any maintenance. Disconnect the battery's negative terminal to prevent accidental starting. Wear appropriate personal protective equipment (PPE) such as gloves and eye protection. If you are unsure about any step, consult a qualified mechanic or your vehicle's official service manual.

4.1. Air Filter Replacement

1. Locate the air filter housing, typically found near the engine.
2. Carefully open or unlatch the air filter housing cover.
3. Remove the old primary (11013-1290) and secondary (11013-1263) air filter elements. Note their orientation.
4. Clean the inside of the air filter housing to remove any dust or debris.
5. Install the new air filter elements, ensuring they are seated correctly.
6. Securely close the air filter housing cover.

4.2. Oil Filter Replacement

1. Warm up the engine slightly, then turn it off.
2. Place a drain pan beneath the engine oil drain plug.
3. Remove the oil drain plug and allow all old oil to drain completely. Reinstall and tighten the drain plug to the manufacturer's specifications.
4. Locate the old oil filter (49065-2071). Place the drain pan underneath it.
5. Using an oil filter wrench, carefully remove the old oil filter. Expect some oil to spill.
6. Apply a thin film of new engine oil to the rubber gasket of the new OF300 oil filter.
7. Hand-tighten the new oil filter until the gasket makes contact, then tighten an additional 1/2 to 3/4 turn as specified by the vehicle manufacturer. Do not overtighten.
8. Refill the engine with the recommended type and amount of new engine oil.
9. Start the engine and check for leaks around the filter and drain plug. Turn off the engine and recheck the oil level.

4.3. Fuel Strainer & Filter Replacement

1. Locate the fuel filter/strainer assembly (49019-0013), typically in the fuel line between the fuel tank and the engine.
2. Place a rag or small container underneath to catch any spilled fuel.
3. Carefully disconnect the fuel lines from both ends of the old filter. Be aware of residual fuel pressure.
4. Remove the old FF340 fuel filter.
5. Install the new fuel filter, ensuring the flow direction arrow (if present) points towards the engine.
6. Reconnect the fuel lines securely.
7. Turn the ignition key to the 'ON' position (without starting the engine) for a few seconds to allow the fuel pump to prime the system and check for leaks.

4.4. Spark Plug Replacement

1. Locate the spark plug wires and spark plugs on the engine.
2. Carefully disconnect one spark plug wire at a time to avoid mixing them up.
3. Using a spark plug socket, remove the old spark plug.
4. Inspect the new BPR2ES spark plug for correct gap. Adjust if necessary according to your vehicle's service manual.
5. Thread the new spark plug into the cylinder head by hand to prevent cross-threading.
6. Tighten the spark plug with a torque wrench to the manufacturer's specified torque. Do not overtighten.
7. Reconnect the spark plug wire firmly.
8. Repeat for the remaining spark plug(s).

5. Maintenance

Regular maintenance using this tune-up kit helps ensure the longevity and optimal performance of your Kawasaki Mule. Adhere to the maintenance schedule outlined in your vehicle's owner's manual. Typically, air filters, oil filters, fuel filters, and spark plugs require inspection and replacement at specific intervals, often based on operating hours or mileage.

• Air Filters: Inspect regularly, especially when operating in dusty conditions. Replace when dirty or damaged.
• Oil Filter: Replace with every oil change, typically every 50-100 operating hours or annually.
• Fuel Filter: Replace annually or as recommended by the manufacturer, or if fuel delivery issues arise.
• Spark Plugs: Inspect and replace as part of routine engine tune-ups, usually every 100-200 operating hours or every few years.

6. Troubleshooting

If you experience issues after installing the tune-up kit, consider the following common troubleshooting steps:

• Engine Misfire or Rough Idle: Check spark plug wires for proper connection. Ensure spark plugs are correctly gapped and tightened.
• Loss of Power: Verify air filters are clean and properly seated. Check fuel filter for correct installation and ensure no air leaks in the fuel lines.
• Fuel Leaks: Recheck all fuel line connections at the fuel filter for tightness.
• Oil Leaks: Ensure the oil filter is properly tightened and the oil drain plug is secure.
• Starting Difficulty: Confirm spark plug connections and fuel delivery.

If problems persist, consult your vehicle's service manual or seek professional assistance.

7. Specifications

8. Warranty and Support

For specific warranty information regarding your ATVWorks Tune Up Kit, please refer to the product packaging or contact the seller directly. ATVWorks stands by the quality of its aftermarket parts.

If you require technical assistance or have questions about the installation or compatibility of this kit, please contact ATVWorks customer support through the retailer where the product was purchased.