Owners Manual
Page 5
... fuel tank. A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which we all live, Kawasaki has incorporated crankcase emission (1), exhaust emission (2) and evaporative emission (3) control systems in a canister when the engine is engine modifications that consist of a fuel injection system and ignition system having optimum ignition timing characteristics. Instead, fuel vapors are led to this Mule utility vehicle...
... fuel tank. A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which we all live, Kawasaki has incorporated crankcase emission (1), exhaust emission (2) and evaporative emission (3) control systems in a canister when the engine is engine modifications that consist of a fuel injection system and ignition system having optimum ignition timing characteristics. Instead, fuel vapors are led to this Mule utility vehicle...
Owners Manual
Page 6
... performance while maintaining a low noise level. You should keep a maintenance record for the purposes of emission control prior to its sale or delivery to ensure compliance with effective intake and exhaust silencing systems. They are the acts listed below: Do not tamper with the original emission related parts: Fuel injection system and internal parts Magneto or electronic battery ignition system Spark plugs Fuel filter Air...
... performance while maintaining a low noise level. You should keep a maintenance record for the purposes of emission control prior to its sale or delivery to ensure compliance with effective intake and exhaust silencing systems. They are the acts listed below: Do not tamper with the original emission related parts: Fuel injection system and internal parts Magneto or electronic battery ignition system Spark plugs Fuel filter Air...
Owners Manual
Page 7
...Service Manual. The Service Manual contains detailed disassembly and maintenance information. No part of a new Kawasaki Mule. KAWASAKI HEAVY INDUSTRIES, LTD. For those who plan to do their Mule, a Service Manual is the result of Kawasaki's engineering expertise and a tradition of course, be considered a permanent part of your new Mule so that you can refer to change...this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. It is available for your Mule at the time of printing. Please read this manual. This manual ...
...Service Manual. The Service Manual contains detailed disassembly and maintenance information. No part of a new Kawasaki Mule. KAWASAKI HEAVY INDUSTRIES, LTD. For those who plan to do their Mule, a Service Manual is the result of Kawasaki's engineering expertise and a tradition of course, be considered a permanent part of your new Mule so that you can refer to change...this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. It is available for your Mule at the time of printing. Please read this manual. This manual ...
Owners Manual
Page 8
... DRIVING ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Light Switch ...Coolant Temperature Warning Light...Oil Pressure Warning Light...Fuel Injection Warning Light ...Parking Brake Warning Light...Power Steering Warning Light (KAF620M) ...Steering Wheel (KAF620M) ...Brake Pedal...Cargo Bed ...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Hour Meter ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift...
... DRIVING ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Light Switch ...Coolant Temperature Warning Light...Oil Pressure Warning Light...Fuel Injection Warning Light ...Parking Brake Warning Light...Power Steering Warning Light (KAF620M) ...Steering Wheel (KAF620M) ...Brake Pedal...Cargo Bed ...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Hour Meter ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift...
Owners Manual
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Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System (California model only) ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Tank Vent...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Power Steering System (KAF620M) ...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Seat Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System (KAF620M) ...Breaker...General Lubrication ...Cleaning ...Bolt and Nut ...
Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System (California model only) ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Tank Vent...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Power Steering System (KAF620M) ...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Seat Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System (KAF620M) ...Breaker...General Lubrication ...Cleaning ...Bolt and Nut ...
Owners Manual
Page 12
10 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance 47 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2 ft) 2 persons 3 005 ...; 1 310 × 288 mm (46.26 × 51.57 × 11.34 in.) OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 × 68.0 mm (2.99 × 2.68 in.) 10.3 : 1 Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio
10 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance 47 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2 ft) 2 persons 3 005 ...; 1 310 × 288 mm (46.26 × 51.57 × 11.34 in.) OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 × 68.0 mm (2.99 × 2.68 in.) 10.3 : 1 Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio
Owners Manual
Page 13
... 11 Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type 4WD gear, (P) 2WD gear 2-speed & reverse, automatic, (P)1-speed & reverse, automatic Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio: Forward Reverse Transmission Gear Ratio: Forward 3.9 ∼ 0.85 (Belt drive torque converter) 5.4 8.360 (High), (P) 8.360 (M) 17.212 (Low) 19.372, (P) 9.409 1.821 (High), (P) 1.821 (M) 3.750 (Low) Electric starter...
... 11 Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type 4WD gear, (P) 2WD gear 2-speed & reverse, automatic, (P)1-speed & reverse, automatic Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio: Forward Reverse Transmission Gear Ratio: Forward 3.9 ∼ 0.85 (Belt drive torque converter) 5.4 8.360 (High), (P) 8.360 (M) 17.212 (Low) 19.372, (P) 9.409 1.821 (High), (P) 1.821 (M) 3.750 (Low) Electric starter...
Owners Manual
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Parking Brake Warning Light 37. Differential Shift Lever 41. Right Glove Compartment 38. FI Warning Light 39. Oil Pressure Warning Light Brake Fluid Reserve Tank 42. 43. 44. 45. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever (KAF620M) 46. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. LOCATION OF PARTS 17 29. 30. 31. 32. 33. 34. 35. Power Steering Warning Light (KAF620M) 40.
Parking Brake Warning Light 37. Differential Shift Lever 41. Right Glove Compartment 38. FI Warning Light 39. Oil Pressure Warning Light Brake Fluid Reserve Tank 42. 43. 44. 45. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever (KAF620M) 46. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. LOCATION OF PARTS 17 29. 30. 31. 32. 33. 34. 35. Power Steering Warning Light (KAF620M) 40.
Owners Manual
Page 28
...) when pulling a trailer. Braking • Reduce distance is not overloaded and that extends beyond the rear of the cab frame. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. Make sure the cargo will void the utility vehicle warranty. This helps maintain stability by centralizing weight. They may affect vehicle handling in weight distribution, you...
...) when pulling a trailer. Braking • Reduce distance is not overloaded and that extends beyond the rear of the cab frame. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. Make sure the cargo will void the utility vehicle warranty. This helps maintain stability by centralizing weight. They may affect vehicle handling in weight distribution, you...
Owners Manual
Page 34
... steering wheel position can be adversely affected and will cause serious driving problems. If such components need service, see "Steering Wheel" section). żThe power steering system functions only when engine is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected. 32 GENERAL INFORMATION j Power Steering Warning Light (KAF620M) The power steering warning light will momentarily illuminate when the engine starts...
... steering wheel position can be adversely affected and will cause serious driving problems. If such components need service, see "Steering Wheel" section). żThe power steering system functions only when engine is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected. 32 GENERAL INFORMATION j Power Steering Warning Light (KAF620M) The power steering warning light will momentarily illuminate when the engine starts...
Owners Manual
Page 38
... industry specifications may cause the fuel to expand and overflow through the vents in unsatisfactory performance. Turn the ignition switch "OFF". 36 GENERAL INFORMATION j WARNING Gasoline is extremely flammable and can lead to severe engine damage. Make sure the area is an average of its resistance to the top. Never fill the tank completely to detonation or "knocking." The octane rating...
... industry specifications may cause the fuel to expand and overflow through the vents in unsatisfactory performance. Turn the ignition switch "OFF". 36 GENERAL INFORMATION j WARNING Gasoline is extremely flammable and can lead to severe engine damage. Make sure the area is an average of its resistance to the top. Never fill the tank completely to detonation or "knocking." The octane rating...
Owners Manual
Page 44
KAF620M only) or "R" (Reverse) position. Participating Kawasaki dealers can use the code to the starter can be used. Do not turn the ignition switch key to the "START" position with a starter lockout switch. Ask your key number here. żThe NOTE vehicle is in the "H" (High), "L" (Low; j START NOTICE Do not operate the starter continuously for the battery to recover power. Upon release, key will drop temporarily. Write your...
KAF620M only) or "R" (Reverse) position. Participating Kawasaki dealers can use the code to the starter can be used. Do not turn the ignition switch key to the "START" position with a starter lockout switch. Ask your key number here. żThe NOTE vehicle is in the "H" (High), "L" (Low; j START NOTICE Do not operate the starter continuously for the battery to recover power. Upon release, key will drop temporarily. Write your...
Owners Manual
Page 55
... areas. The time required is cold), no leaks. j WARNING Failure to a safe operating condition. Fuel ...Enough fuel in a well-ventilated area. Do not run the engine in the window. Inhaling carbon monoxide can cause serious brain injury or death. HOW TO OPERATE 53 HOW TO OPERATE Daily Safety Checks Check the following items each day before operation. Tires ...Air pressure (when cold): Front Rear 69 kPa...
... areas. The time required is cold), no leaks. j WARNING Failure to a safe operating condition. Fuel ...Enough fuel in a well-ventilated area. Do not run the engine in the window. Inhaling carbon monoxide can cause serious brain injury or death. HOW TO OPERATE 53 HOW TO OPERATE Daily Safety Checks Check the following items each day before operation. Tires ...Air pressure (when cold): Front Rear 69 kPa...
Owners Manual
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... .). Electrical Equipment ...All lights and horn work. Oil level between level lines (when engine is cold), no leaks. Coolant level between H and L lines, no leaks. 54 HOW TO OPERATE Front Final Gear Case ...Transmission Case Oil ...Coolant ...Throttle ...No oil leaks. Parking brake lever travel: 8 ∼ 12 clicks. Check for braking effectiveness (while test running). Brakes ...Check for dirt on or damage to rest position when released. Brake fluid level between level lines, no leaks. Throttle pedal...
... .). Electrical Equipment ...All lights and horn work. Oil level between level lines (when engine is cold), no leaks. Coolant level between H and L lines, no leaks. 54 HOW TO OPERATE Front Final Gear Case ...Transmission Case Oil ...Coolant ...Throttle ...No oil leaks. Parking brake lever travel: 8 ∼ 12 clicks. Check for braking effectiveness (while test running). Brakes ...Check for dirt on or damage to rest position when released. Brake fluid level between level lines, no leaks. Throttle pedal...
Owners Manual
Page 60
... parking brake. • Gradually increase engine speed by the vehicle's automatic transmission which releases the engine at very low speed to prevent it from stalling. the throttle pedal completely. • Release Press on • the throttle pedal. This is released completely and the engine speed drops near an idle, the vehicle has no engine braking. Employ the brakes to stop when carrying cargo or towing a trailer. Failure to allow more distance to control the vehicle's speed...
... parking brake. • Gradually increase engine speed by the vehicle's automatic transmission which releases the engine at very low speed to prevent it from stalling. the throttle pedal completely. • Release Press on • the throttle pedal. This is released completely and the engine speed drops near an idle, the vehicle has no engine braking. Employ the brakes to stop when carrying cargo or towing a trailer. Failure to allow more distance to control the vehicle's speed...
Owners Manual
Page 76
or 5,000 km (3,000 (600 miles) miles) of use of use D D j Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect Front final gear case oil and transmission case oil-change* 1 year • • D • • D •...
or 5,000 km (3,000 (600 miles) miles) of use of use D D j Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect Front final gear case oil and transmission case oil-change* 1 year • • D • • D •...
Owners Manual
Page 87
..., replace it with its gasket. If the gasket is a toxic substance. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) Transmission Case Oil Type API "GL-5" Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Transmission Case Oil Capacity KAF620M: 2.5 L (2.6 US qt) KAF620P: 2.2 L (2.3 US qt) j WARNING Oil on tires can make them with soap and water...
..., replace it with its gasket. If the gasket is a toxic substance. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) Transmission Case Oil Type API "GL-5" Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Transmission Case Oil Capacity KAF620M: 2.5 L (2.6 US qt) KAF620P: 2.2 L (2.3 US qt) j WARNING Oil on tires can make them with soap and water...
Owners Manual
Page 107
... brake light should be sure that the switch body does not turn during adjustment. MAINTENANCE AND ADJUSTMENT 105 Brake Light Switch When the brake pedal is hard to the "ON" position. Inspection • • Turn the ignition switch to adjust. Brake Pedal B. 10 mm (0.4 in.) it does not, check the bulb and, if necessary, • If adjust the brake light switch. The brake light switch should go on . Adjustment is best performed...
... brake light should be sure that the switch body does not turn during adjustment. MAINTENANCE AND ADJUSTMENT 105 Brake Light Switch When the brake pedal is hard to the "ON" position. Inspection • • Turn the ignition switch to adjust. Brake Pedal B. 10 mm (0.4 in.) it does not, check the bulb and, if necessary, • If adjust the brake light switch. The brake light switch should go on . Adjustment is best performed...
Owners Manual
Page 122
... general lubrication performed by an authorized Kawasaki dealer or perform it can ground out the spark. close opening - if water gets into the spark plug caps, it referring to be Careful Avoid spraying water with any great force near the following parts. Horn button - Power Steering System - Cleaning To prolong the life of the rear cab frame top) - Ignition switch - Front and rear brakes - cover with a plastic bag. cover the keyhole...
... general lubrication performed by an authorized Kawasaki dealer or perform it can ground out the spark. close opening - if water gets into the spark plug caps, it referring to be Careful Avoid spraying water with any great force near the following parts. Horn button - Power Steering System - Cleaning To prolong the life of the rear cab frame top) - Ignition switch - Front and rear brakes - cover with a plastic bag. cover the keyhole...
Owners Manual
Page 126
... • Spark plug wire not on spark plug • Spark plug dirty • Engine Stops fuel in tank • No Water in fuel • Air filter clogged or inlet blocked • Fuel tank cap vent clogged • Engine overheated • żToo much idling or low speed running (not enough żOverloaded żWrong spark plug żRadiator clogged żCoolant level too low air flow) Starter Motor Won't Turn Fuse failed (be sure to check for cause of failure) Battery leads...
... • Spark plug wire not on spark plug • Spark plug dirty • Engine Stops fuel in tank • No Water in fuel • Air filter clogged or inlet blocked • Fuel tank cap vent clogged • Engine overheated • żToo much idling or low speed running (not enough żOverloaded żWrong spark plug żRadiator clogged żCoolant level too low air flow) Starter Motor Won't Turn Fuse failed (be sure to check for cause of failure) Battery leads...