Owners Manual
Page 5
... the intake manifold. Exhaust Emission Control System The exhaust emission control system applied to the breather chamber through the inside of the breather chamber from the gases while passing through the crankcase. Instead, fuel vapors are routed into the running engine to be burned, or stored in the fuel system are led to this vehicle consists of a catalytic converter in the muffler (California model only...
... the intake manifold. Exhaust Emission Control System The exhaust emission control system applied to the breather chamber through the inside of the breather chamber from the gases while passing through the crankcase. Instead, fuel vapors are routed into the running engine to be burned, or stored in the fuel system are led to this vehicle consists of a catalytic converter in the muffler (California model only...
Owners Manual
Page 6
... emission related parts: Carburetor and internal parts Spark plug Magneto or electronic battery ignition system Fuel filter Air cleaner element the acts listed below: NOTE hoses • Fuel Fuel tank • Muffler and carbon canister (California model only) • Installation of these specified modifications only are not considered to be performed by any new vehicle for purposes of maintenance, repair, or replacement, of any device or element of...
... emission related parts: Carburetor and internal parts Spark plug Magneto or electronic battery ignition system Fuel filter Air cleaner element the acts listed below: NOTE hoses • Fuel Fuel tank • Muffler and carbon canister (California model only) • Installation of these specified modifications only are not considered to be performed by any new vehicle for purposes of maintenance, repair, or replacement, of any device or element of...
Owners Manual
Page 8
Please read this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. This manual should remain with the proper operation of...Kawasaki's engineering expertise and a tradition of printing. Keep this manual. Feb. 2009. (1). (C, Ke) For those who plan to do their Mule, a Service Manual is available for your purchase of a new Kawasaki Mule. All rights reserved. This publication includes the latest information available at all times...
Please read this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. This manual should remain with the proper operation of...Kawasaki's engineering expertise and a tradition of printing. Keep this manual. Feb. 2009. (1). (C, Ke) For those who plan to do their Mule, a Service Manual is available for your purchase of a new Kawasaki Mule. All rights reserved. This publication includes the latest information available at all times...
Owners Manual
Page 9
... ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Choke Knob...Engine Oil Temperature Warning Light (KAF400 A/C) ...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF400A/C)...Differential Shift Lever ...Parking Brake Lever...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch...
... ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Choke Knob...Engine Oil Temperature Warning Light (KAF400 A/C) ...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF400A/C)...Differential Shift Lever ...Parking Brake Lever...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch...
Owners Manual
Page 10
Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System (California model only) ...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ...Battery ...Fuse ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ......
Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System (California model only) ...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ...Battery ...Fuse ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ......
Owners Manual
Page 13
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Track: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) ENGINE Type Displacement (A/C) 29.7 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) (B) 27.9 N·m (2.8 kgf·m, 21.0 ft·lb) @2 ...lb) (C) 469 kg (1 034 lb) 1 044 × 900 × 245 mm (41.10 × 35.43 × 9.65 in.) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in)
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Track: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) ENGINE Type Displacement (A/C) 29.7 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) (B) 27.9 N·m (2.8 kgf·m, 21.0 ft·lb) @2 ...lb) (C) 469 kg (1 034 lb) 1 044 × 900 × 245 mm (41.10 × 35.43 × 9.65 in.) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in)
Owners Manual
Page 14
...; Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio: Forward Reverse 9.263 (High) (A/C) 13.706 (Low) 11.910 (A/C) 3.851 4.000 (A/C) Gear (2WD/4WD) (B) Gear (2WD) (A/C) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic 3.653 ∼ 0.794 (Belt drive torque converter) 82 × 76 mm (3,23 × 2.99 in.) (A/C) 8.6 : 1 (B) 8.3 : 1 Electric starter NIKKI 6C1026 Magneto...
...; Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio: Forward Reverse 9.263 (High) (A/C) 13.706 (Low) 11.910 (A/C) 3.851 4.000 (A/C) Gear (2WD/4WD) (B) Gear (2WD) (A/C) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic 3.653 ∼ 0.794 (Belt drive torque converter) 82 × 76 mm (3,23 × 2.99 in.) (A/C) 8.6 : 1 (B) 8.3 : 1 Electric starter NIKKI 6C1026 Magneto...
Owners Manual
Page 20
Accessory Connector 39. 40. 41. 42. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A/C) 37. Ignition Switch 38. 18 LOCATION OF PARTS 28. 29. 30. 31. Parking Brake Warning Light 33. 34. 35. 36. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32.
Accessory Connector 39. 40. 41. 42. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A/C) 37. Ignition Switch 38. 18 LOCATION OF PARTS 28. 29. 30. 31. Parking Brake Warning Light 33. 34. 35. 36. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32.
Owners Manual
Page 29
... affect vehicle handling in an unsafe operating condition. LOADING INFORMATION 27 LOADING INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your weight. Braking • Reduce distance is stopped) and adjust as possible (while the vehicle is increased. All cargo should be genuine Kawasaki components. Do not carry cargo on Kawasaki utility vehicles. NOTICE The front body work and fenders...
... affect vehicle handling in an unsafe operating condition. LOADING INFORMATION 27 LOADING INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your weight. Braking • Reduce distance is stopped) and adjust as possible (while the vehicle is increased. All cargo should be genuine Kawasaki components. Do not carry cargo on Kawasaki utility vehicles. NOTICE The front body work and fenders...
Owners Manual
Page 42
... of the starter to recover power. Do not turn the ignition switch key to the "START" position with the engine running, or damage to make any additional spare keys you need, using your original key as a master or using the key code on the tag with a starter lockout switch. Hour meter works. Participating Kawasaki dealers can use the code to the starter can be used. This switch prevents the electric starter from...
... of the starter to recover power. Do not turn the ignition switch key to the "START" position with the engine running, or damage to make any additional spare keys you need, using your original key as a master or using the key code on the tag with a starter lockout switch. Hour meter works. Participating Kawasaki dealers can use the code to the starter can be used. This switch prevents the electric starter from...
Owners Manual
Page 53
... particles in tread. Fuel ...Enough fuel in enclosed areas. The time required is cold), no leaks. Do not run the engine in tank, no leaks. Operate only in serious damage or an accident. Engine oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks before operation may result in a well-ventilated area. Tires ...Air pressure (when cold): KAF400A/C Front Rear 47 kPa (0.47...
... particles in tread. Fuel ...Enough fuel in enclosed areas. The time required is cold), no leaks. Do not run the engine in tank, no leaks. Operate only in serious damage or an accident. Engine oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks before operation may result in a well-ventilated area. Tires ...Air pressure (when cold): KAF400A/C Front Rear 47 kPa (0.47...
Owners Manual
Page 54
... Transmission Case Oil ...Oil level between H and L lines, no leaks. Parking brake lever travel: 8 ∼ 12 clicks. Steering ...Steering wheel free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Brake fluid level between level lines in .). Throttle pedal operates smoothly and returns to lights. Throttle ...Throttle pedal free play 0 ∼ 20 mm (0 ∼ 0.8 in .). Brakes ...Check for mud and other debris. Engine Cooling Fan Screen ...Check for braking effectiveness (while test running). j Electrical Equipment ...All lights and horn work. Brake...
... Transmission Case Oil ...Oil level between H and L lines, no leaks. Parking brake lever travel: 8 ∼ 12 clicks. Steering ...Steering wheel free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Brake fluid level between level lines in .). Throttle pedal operates smoothly and returns to lights. Throttle ...Throttle pedal free play 0 ∼ 20 mm (0 ∼ 0.8 in .). Brakes ...Check for mud and other debris. Engine Cooling Fan Screen ...Check for braking effectiveness (while test running). j Electrical Equipment ...All lights and horn work. Brake...
Owners Manual
Page 55
... system, start the engine with the choke that the throttle-linked choke system functions. Do not run the engine in a well-ventilated area. Operate only in enclosed areas. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the choke knob after the engine starts to warm up. żWhen engine is warm or air temperature...
... system, start the engine with the choke that the throttle-linked choke system functions. Do not run the engine in a well-ventilated area. Operate only in enclosed areas. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the choke knob after the engine starts to warm up. żWhen engine is warm or air temperature...
Owners Manual
Page 73
... use of use 4 years (D) ż Fuel hose-replace Evaporative emission control system-function (California model only)* j • • D • • D CHASSIS Steering-inspect 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 D • •...
... use of use 4 years (D) ż Fuel hose-replace Evaporative emission control system-function (California model only)* j • • D • • D CHASSIS Steering-inspect 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 D • •...
Owners Manual
Page 84
...°F) SAE 80 Transmission Case Oil Capacity KAF400A/C: 2.4 L (2.5 US qt) KAF400B: 2.2 L (2.3 US qt) j the cargo bed and support it to the "H" (High) line on tires can make them with a new one. 82 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can get extremely hot during oil draining. If the gasket is a toxic substance. Fill the transmission case up to the spec- • Install...
...°F) SAE 80 Transmission Case Oil Capacity KAF400A/C: 2.4 L (2.5 US qt) KAF400B: 2.2 L (2.3 US qt) j the cargo bed and support it to the "H" (High) line on tires can make them with a new one. 82 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can get extremely hot during oil draining. If the gasket is a toxic substance. Fill the transmission case up to the spec- • Install...
Owners Manual
Page 90
.... 88 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with the Periodic Maintenance Chart. j NOTICE The spark arrester must be properly maintained to provide adequate fire protection. Since the engine must be functioning properly to ensure its efficiency. Drain Plug the parking brake. • Apply In an open area away from combustible materials, • start the engine with the gear shift lever in...
.... 88 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with the Periodic Maintenance Chart. j NOTICE The spark arrester must be properly maintained to provide adequate fire protection. Since the engine must be functioning properly to ensure its efficiency. Drain Plug the parking brake. • Apply In an open area away from combustible materials, • start the engine with the gear shift lever in...
Owners Manual
Page 95
... adjustment. Quick Rivets (6 p.c.s.) E. A. Air Intake Ducts (2 p.c.s.) C. Clamps (6 p.c.s.) D. Choke Knob B. 0 ∼ 1 mm (0.00 ∼ 0.04 in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. The following procedure covers the idle speed adjustment. Cap MAINTENANCE AND ADJUSTMENT 93 Carburetor The idle speed adjustment should be performed in .) j Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the...
... adjustment. Quick Rivets (6 p.c.s.) E. A. Air Intake Ducts (2 p.c.s.) C. Clamps (6 p.c.s.) D. Choke Knob B. 0 ∼ 1 mm (0.00 ∼ 0.04 in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. The following procedure covers the idle speed adjustment. Cap MAINTENANCE AND ADJUSTMENT 93 Carburetor The idle speed adjustment should be performed in .) j Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the...
Owners Manual
Page 107
... switch body does not turn during adjustment. Brake Pedal B. 10 mm (0.4 in.) it does not, check the bulb and, if necessary, • If adjust the brake light switch. To avoid damaging the electrical connections inside the switch, be inspected in accordance with the Periodic Maintenance Chart. j A. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. The brake light switch...
... switch body does not turn during adjustment. Brake Pedal B. 10 mm (0.4 in.) it does not, check the bulb and, if necessary, • If adjust the brake light switch. To avoid damaging the electrical connections inside the switch, be inspected in accordance with the Periodic Maintenance Chart. j A. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. The brake light switch...
Owners Manual
Page 108
Brake Light Switch Adjusting Nut Lights sooner. If it does, adjust the parking brake lever. • Adjustment • Raise the seat. C. Lights later. A. 106 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. D. Parking Brake Lever the parking brake lever up and to the rear. • Pull After to 12 clicks of lever travel, the vehicle • should8 not roll while parked. In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. j Inspection A. B.
Brake Light Switch Adjusting Nut Lights sooner. If it does, adjust the parking brake lever. • Adjustment • Raise the seat. C. Lights later. A. 106 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. D. Parking Brake Lever the parking brake lever up and to the rear. • Pull After to 12 clicks of lever travel, the vehicle • should8 not roll while parked. In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. j Inspection A. B.
Owners Manual
Page 124
...;As an alternative to coat the cylinder walls. Run the engine for use . Contact your local authorities for approved disposal methods. Contact your local authorities for approved disposal methods or possible recycling. in a suitable container. (After a period of flame or sparks; 122 STORAGE STORAGE Preparation for use . Turn the engine over several times with a pilot light. Turn the ignition switch "OFF". WARNING j Motor oil is...
...;As an alternative to coat the cylinder walls. Run the engine for use . Contact your local authorities for approved disposal methods. Contact your local authorities for approved disposal methods or possible recycling. in a suitable container. (After a period of flame or sparks; 122 STORAGE STORAGE Preparation for use . Turn the engine over several times with a pilot light. Turn the ignition switch "OFF". WARNING j Motor oil is...