Owners Manual
Page 7
... your vehicle's controls, its features, capabilities, and limitations. No part of this Owner's Manual aboard your Mule, give it is the result of Kawasaki's engineering expertise and a tradition of manufacturing high-quality consumer products. All products are subject to do their Mule, a Service Manual is available for your Mule at the time of printing. Dec. 28, 2012. (1) For those who plan to change without...
... your vehicle's controls, its features, capabilities, and limitations. No part of this Owner's Manual aboard your Mule, give it is the result of Kawasaki's engineering expertise and a tradition of manufacturing high-quality consumer products. All products are subject to do their Mule, a Service Manual is available for your Mule at the time of printing. Dec. 28, 2012. (1) For those who plan to change without...
Owners Manual
Page 8
... 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 ...Tailgate ...Cargo Bed ...Fuel Tank ...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Fuel Gauge/Hour Meter...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF620M)...Differential Shift Lever ...Parking Brake Lever ...9 11 15...
... 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 ...Tailgate ...Cargo Bed ...Fuel Tank ...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Fuel Gauge/Hour Meter...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF620M)...Differential Shift Lever ...Parking Brake Lever ...9 11 15...
Owners Manual
Page 9
Front Final Gear Case Oil (KAF620M) ...Transmission Case Oil ...Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Pump Filter ...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) ...
Front Final Gear Case Oil (KAF620M) ...Transmission Case Oil ...Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Pump Filter ...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) ...
Owners Manual
Page 12
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio 47.0 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2 ... kg (1 336 lb) 1 175 × 1 310 × 290 mm (46.26 × 51.57 × 11.42 in.) OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76 × 68 mm (2.99 × 2.68 in.) 10.3 : 1 Front...
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio 47.0 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2 ... kg (1 336 lb) 1 175 × 1 310 × 290 mm (46.26 × 51.57 × 11.42 in.) OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76 × 68 mm (2.99 × 2.68 in.) 10.3 : 1 Front...
Owners Manual
Page 13
12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Viscosity Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio: Overall Drive Ratio: Front Rear Forward Reverse 4WD gear, (P) 2WD gear 2-speed & reverse, automatic (P) 1-speed & reverse, automatic 3.9 ∼ 0.85 (Belt drive torque converter) (M) 5.200 5.429 8.404 (High) (M) 17.303 (Low) 19.475, (P) 9.459 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection)...
12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Viscosity Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio: Overall Drive Ratio: Front Rear Forward Reverse 4WD gear, (P) 2WD gear 2-speed & reverse, automatic (P) 1-speed & reverse, automatic 3.9 ∼ 0.85 (Belt drive torque converter) (M) 5.200 5.429 8.404 (High) (M) 17.303 (Low) 19.475, (P) 9.459 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection)...
Owners Manual
Page 14
SPECIFICATIONS 13 Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Steering Caster Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 Front & Rear Front & Rear Steel tube, ladder type Assisted with Electric Power Steering (EPS) System (P) Manual (rack and pinion) 7.5° 35 mm (1.4 in.) 23 × 11.00-10 Tubeless 10 × 8.5 AT...
SPECIFICATIONS 13 Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Steering Caster Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 Front & Rear Front & Rear Steel tube, ladder type Assisted with Electric Power Steering (EPS) System (P) Manual (rack and pinion) 7.5° 35 mm (1.4 in.) 23 × 11.00-10 Tubeless 10 × 8.5 AT...
Owners Manual
Page 19
Differential Shift Lever 40. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever (KAF620M) 45. Power Steering Warning Light (KAF620M) 39. Oil Pressure Warning Light Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 35. Parking Brake Warning Light 36. 18 LOCATION OF PARTS 28. 29. 30. 31. 32. 33. 34. FI Warning Light 38. Brake Fluid Reserve Tank 41. 42. 43. 44. Right Glove Compartment 37.
Differential Shift Lever 40. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever (KAF620M) 45. Power Steering Warning Light (KAF620M) 39. Oil Pressure Warning Light Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 35. Parking Brake Warning Light 36. 18 LOCATION OF PARTS 28. 29. 30. 31. 32. 33. 34. FI Warning Light 38. Brake Fluid Reserve Tank 41. 42. 43. 44. Right Glove Compartment 37.
Owners Manual
Page 30
... genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of your vehicle may result in the cargo bed. speed when carrying cargo. Carrying cargo and pulling a trailer can make sure that the vehicle is not overloaded and that you are not designed to carry cargo or to your own safety and the safety of gravity. Cargo weight...
... genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of your vehicle may result in the cargo bed. speed when carrying cargo. Carrying cargo and pulling a trailer can make sure that the vehicle is not overloaded and that you are not designed to carry cargo or to your own safety and the safety of gravity. Cargo weight...
Owners Manual
Page 36
... or you install wireless equipment on when the engine NOTE starts, there may affect the ECU. The steering wheel position can be a problem with an electric power steering system. GENERAL INFORMATION 35 j Power Steering Warning Light (KAF620M) The power steering warning light will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer. The system does not require regular maintenance by users. Installing such equipment improperly may...
... or you install wireless equipment on when the engine NOTE starts, there may affect the ECU. The steering wheel position can be a problem with an electric power steering system. GENERAL INFORMATION 35 j Power Steering Warning Light (KAF620M) The power steering warning light will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer. The system does not require regular maintenance by users. Installing such equipment improperly may...
Owners Manual
Page 40
... of the U.S. Operating problems that result from entering the fuel tank. Turn the ignition switch to the top. Octane Rating Method Antiknock Index (RON + MON) 2 Minimum Rating 87 j NOTICE If engine "knocking" or "pinging" occurs, use of poor quality or nonrecommended fuel may not be explosive under warranty. GENERAL INFORMATION 39 NOTICE Always clean dirt/mud/debris/water from the fuel tank cap and surrounding area prior...
... of the U.S. Operating problems that result from entering the fuel tank. Turn the ignition switch to the top. Octane Rating Method Antiknock Index (RON + MON) 2 Minimum Rating 87 j NOTICE If engine "knocking" or "pinging" occurs, use of poor quality or nonrecommended fuel may not be explosive under warranty. GENERAL INFORMATION 39 NOTICE Always clean dirt/mud/debris/water from the fuel tank cap and surrounding area prior...
Owners Manual
Page 45
... NOTE vehicle is a three-position, key-operated switch. 44 GENERAL INFORMATION j Ignition Switch This is equipped with the engine running, or damage to the starter can be removed from operating when the gear shift lever is in "N" (neutral) position. START NOTICE Do not operate the starter continuously for the battery to recover power. "ON" position D. A. "START" position E. Fuel Gauge F. Fuel gauge works. Ignition Switch B. Electric starter is engaged by holding ignition switch key in this position, only when gear shift...
... NOTE vehicle is a three-position, key-operated switch. 44 GENERAL INFORMATION j Ignition Switch This is equipped with the engine running, or damage to the starter can be removed from operating when the gear shift lever is in "N" (neutral) position. START NOTICE Do not operate the starter continuously for the battery to recover power. "ON" position D. A. "START" position E. Fuel Gauge F. Fuel gauge works. Ignition Switch B. Electric starter is engaged by holding ignition switch key in this position, only when gear shift...
Owners Manual
Page 57
... refer to the Service Manual for the action required to return the vehicle to perform these checks will help ensure safe, reliable operation. If any imbedded stones or other foreign particles in the window. Do not run the engine in a well-ventilated area. Air Cleaner ...Check the restriction gauge for cuts, cracks, damage, or excessive wear. DANGER Exhaust gas contains carbon monoxide...
... refer to the Service Manual for the action required to return the vehicle to perform these checks will help ensure safe, reliable operation. If any imbedded stones or other foreign particles in the window. Do not run the engine in a well-ventilated area. Air Cleaner ...Check the restriction gauge for cuts, cracks, damage, or excessive wear. DANGER Exhaust gas contains carbon monoxide...
Owners Manual
Page 78
... km (3,000 (6,000 miles) (600 miles) miles) of use of use of use D 1 year D ○ Valve clearance-inspect Engine oil-change* Oil filter-replace* ○ Throttle pedal play-inspect Throttle link lever-inspect Spark arrester-clean D D 1 year 5 years (D) 2 years (D) D • D D j • • ○ Idle speed-adjust Radiator-clean* Water hoses and connections-inspect* Fuel hose-replace Coolant-change D ○ Evaporative emission control system-inspect* CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect...
... km (3,000 (6,000 miles) (600 miles) miles) of use of use of use D 1 year D ○ Valve clearance-inspect Engine oil-change* Oil filter-replace* ○ Throttle pedal play-inspect Throttle link lever-inspect Spark arrester-clean D D 1 year 5 years (D) 2 years (D) D • D D j • • ○ Idle speed-adjust Radiator-clean* Water hoses and connections-inspect* Fuel hose-replace Coolant-change D ○ Evaporative emission control system-inspect* CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect...
Owners Manual
Page 79
...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* Brake fluid-change Brake master cylinder cup and dust seal -replace Brake wheel cylinder assembly -replace Brake hose-replace 1 year 2 years (D) 2 years (D) 2 years (D) 4 years (D) D D D D D D • • Every 250 Every 500 hrs. 78 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service...
...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* Brake fluid-change Brake master cylinder cup and dust seal -replace Brake wheel cylinder assembly -replace Brake hose-replace 1 year 2 years (D) 2 years (D) 2 years (D) 4 years (D) D D D D D D • • Every 250 Every 500 hrs. 78 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service...
Owners Manual
Page 89
... a toxic substance. Transmission case oil is damaged, replace it with its gasket. Dispose of used oil properly. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. 88 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an accident and injury. Contact your local authorities for approved disposal methods or possible recycling. the oil has completely...
... a toxic substance. Transmission case oil is damaged, replace it with its gasket. Dispose of used oil properly. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. 88 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an accident and injury. Contact your local authorities for approved disposal methods or possible recycling. the oil has completely...
Owners Manual
Page 108
... authorized Kawasaki dealer inspect it does not, check the bulb and, if necessary, • If adjust the brake light switch. j WARNING Air in accordance with the Periodic Maintenance Chart. If brake lever travel . This may cause reduced braking performance or brake failure and result in .) Fluid Change it immediately. Brake Pedal B. 10 mm (0.4 in an accident. Inspection the ignition switch to the "ON" position. • Turn Depress the brake...
... authorized Kawasaki dealer inspect it does not, check the bulb and, if necessary, • If adjust the brake light switch. j WARNING Air in accordance with the Periodic Maintenance Chart. If brake lever travel . This may cause reduced braking performance or brake failure and result in .) Fluid Change it immediately. Brake Pedal B. 10 mm (0.4 in an accident. Inspection the ignition switch to the "ON" position. • Turn Depress the brake...
Owners Manual
Page 109
... not turn during adjustment. j Inspection • Pull the rubber boot up on the bottom. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the parking brake lever functions properly. A. Rubber Boot Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. Parking Brake Lever B. 108 MAINTENANCE AND ADJUSTMENT Adjustment is best performed by an authorized • Adjustment Kawasaki...
... not turn during adjustment. j Inspection • Pull the rubber boot up on the bottom. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the parking brake lever functions properly. A. Rubber Boot Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. Parking Brake Lever B. 108 MAINTENANCE AND ADJUSTMENT Adjustment is best performed by an authorized • Adjustment Kawasaki...
Owners Manual
Page 124
... fire. cover the keyhole with tape. • Ignition cleaner intake (middle of the rear ROPS top) • Air close opening - cover with sea water or exposed to cool, then remove any great force near the following parts. Allow the engine to salt air, or operated on rainy days, rough terrain, or in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Muffler rear...
... fire. cover the keyhole with tape. • Ignition cleaner intake (middle of the rear ROPS top) • Air close opening - cover with sea water or exposed to cool, then remove any great force near the following parts. Allow the engine to salt air, or operated on rainy days, rough terrain, or in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Muffler rear...
Owners Manual
Page 126
... fresh engine oil. • Put Empty the fuel from the fuel tank. • j WARNING Gasoline is well ventilated and free from the tire rubber. this procedure. Install the spark plugs. boards under certain conditions. Run the engine for approved disposal methods or possible recycling. If you do get into each cylinder. Turn the engine over the engine when performing this includes any appliance with the ignition switch key to keep...
... fresh engine oil. • Put Empty the fuel from the fuel tank. • j WARNING Gasoline is well ventilated and free from the tire rubber. this procedure. Install the spark plugs. boards under certain conditions. Run the engine for approved disposal methods or possible recycling. If you do get into each cylinder. Turn the engine over the engine when performing this includes any appliance with the ignition switch key to keep...
Owners Manual
Page 128
... • Coolant Cooling fan breaker functioned • Engine oil low • No Power Engine overheated Too much idling or low speed running (not enough air flow) Overloaded Wrong spark plug Radiator clogged Coolant level too low Coolant deteriorated Cooling fan breaker functioned Engine oil low Compression leakage Valve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel • running (not Power Steering Won't Work (KAF620M) functioned to prevent overheating. • ECU failed • Fuse Battery discharged •...
... • Coolant Cooling fan breaker functioned • Engine oil low • No Power Engine overheated Too much idling or low speed running (not enough air flow) Overloaded Wrong spark plug Radiator clogged Coolant level too low Coolant deteriorated Cooling fan breaker functioned Engine oil low Compression leakage Valve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel • running (not Power Steering Won't Work (KAF620M) functioned to prevent overheating. • ECU failed • Fuse Battery discharged •...