Owners Manual
Page 5
... optimum ignition timing characteristics. Evaporative Emission Control System (California model only) The evaporative emission control system for this Mule utility vehicle consists of low permeation fuel hoses and 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 compliance with a suitable air...
... optimum ignition timing characteristics. Evaporative Emission Control System (California model only) The evaporative emission control system for this Mule utility vehicle consists of low permeation fuel hoses and 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 compliance with a suitable air...
Owners Manual
Page 6
... internal parts Magneto or electronic battery ignition system Spark plugs Fuel filter Air cleaner element • • • • • PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product, Kawasaki has equipped it is carried out according to the instructions in this Owner's Manual at the end of this manual where an authorized Kawasaki dealer, or someone equally...
... internal parts Magneto or electronic battery ignition system Spark plugs Fuel filter Air cleaner element • • • • • PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product, Kawasaki has equipped it is carried out according to the instructions in this Owner's Manual at the end of this manual where an authorized Kawasaki dealer, or someone equally...
Owners Manual
Page 7
... in this manual. The Service Manual contains detailed disassembly and maintenance information. All rights reserved. Keep this Owner's Manual aboard your new Mule so that you can refer to change without our prior written permission. This publication includes the latest information available at all times so that you need information. Please read this Owner's Manual carefully before starting your Mule at the time of...
... in this manual. The Service Manual contains detailed disassembly and maintenance information. All rights reserved. Keep this Owner's Manual aboard your new Mule so that you can refer to change without our prior written permission. This publication includes the latest information available at all times so that you need information. Please read this Owner's Manual carefully before starting your Mule at the time of...
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...Steering Wheel...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 Lever ...Differential...
... 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...Steering Wheel...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 Lever ...Differential...
Owners Manual
Page 9
... Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...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...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam ...Battery ... 79...
... Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...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...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam ...Battery ... 79...
Owners Manual
Page 11
... off and make driving more comfortable and could increase the risk of injury, always keep arms and legs inside the cab frame while the vehicle is operated. approved helmet. It should wear the seat belts whenever the vehicle is in your vehicle. Use the Parking Brake Always apply the parking brake before starting the engine are: 1. 2. Wearing Seat Belt Both the operator and passengers should return to...
... off and make driving more comfortable and could increase the risk of injury, always keep arms and legs inside the cab frame while the vehicle is operated. approved helmet. It should wear the seat belts whenever the vehicle is in your vehicle. Use the Parking Brake Always apply the parking brake before starting the engine are: 1. 2. Wearing Seat Belt Both the operator and passengers should return to...
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: Ground Clearance Curb Mass Cargo Bed (L × W × H) Front Rear 3 305 mm (130.12 in.) 1 486 mm (58.50 in.) 1 925 mm (75.79 in.) 2 165 mm (85.24 ...287 mm (50.39 × 47.72 × 11.30 in.) Short bed mode 770 × 1 212 × 287 (30.31 × 47.72 × 11.30 in.) ENGINE Type Displacement Bore × Stroke OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 × 68.0 mm ...
10 SPECIFICATIONS 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) Front Rear 3 305 mm (130.12 in.) 1 486 mm (58.50 in.) 1 925 mm (75.79 in.) 2 165 mm (85.24 ...287 mm (50.39 × 47.72 × 11.30 in.) Short bed mode 770 × 1 212 × 287 (30.31 × 47.72 × 11.30 in.) ENGINE Type Displacement Bore × Stroke OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 × 68.0 mm ...
Owners Manual
Page 13
... 11 Compression Ratio 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 Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio: Forward Reverse Transmission Gear Ratio: Forward 4WD gear 2-speed & reverse, automatic, 3.9 ∼ 0.85 (Belt drive torque converter) 5.4 8.360 (High) 17.212 (Low) 19.372 1.821 (High) 10.3 : 1 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor...
... 11 Compression Ratio 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 Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio: Forward Reverse Transmission Gear Ratio: Forward 4WD gear 2-speed & reverse, automatic, 3.9 ∼ 0.85 (Belt drive torque converter) 5.4 8.360 (High) 17.212 (Low) 19.372 1.821 (High) 10.3 : 1 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor...
Owners Manual
Page 17
LOCATION OF PARTS 15 LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6. Belt Drive Torque Converter 17. Air Cleaner (Belt Drive Torque Converter) 16. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Latch 15. Handgrip Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. Battery 14.
LOCATION OF PARTS 15 LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6. Belt Drive Torque Converter 17. Air Cleaner (Belt Drive Torque Converter) 16. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Latch 15. Handgrip Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. Battery 14.
Owners Manual
Page 19
Power Steering Warning Light 41. FI Warning Light 40. Differential Shift Lever 42. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 37. Parking Brake Warning Light 38. Right Glove Compartment 39. LOCATION OF PARTS 17 30. 31. 32. 33. 34. 35. 36. Brake Fluid Reserve Tank 43. 44. 45. 46. 47.
Power Steering Warning Light 41. FI Warning Light 40. Differential Shift Lever 42. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 37. Parking Brake Warning Light 38. Right Glove Compartment 39. LOCATION OF PARTS 17 30. 31. 32. 33. 34. 35. 36. Brake Fluid Reserve Tank 43. 44. 45. 46. 47.
Owners Manual
Page 20
Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Warning (Pinching Fingers: both sides) Important Information (Tires/Max. 18 LOCATION OF LABELS LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Load) Warning (Cargo Bed) Warning (Refueling) Warning (Rear Seat Capacity) Warning (Cargo Bed) Warning (Trailer-Towing Bracket) Warning (Hot Surfaces) Important Engine Information Specification Information (Front Hood) Important Engine Information (California model only)
Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Warning (Pinching Fingers: both sides) Important Information (Tires/Max. 18 LOCATION OF LABELS LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Load) Warning (Cargo Bed) Warning (Refueling) Warning (Rear Seat Capacity) Warning (Cargo Bed) Warning (Trailer-Towing Bracket) Warning (Hot Surfaces) Important Engine Information Specification Information (Front Hood) Important Engine Information (California model only)
Owners Manual
Page 30
... or use on top of the vehicle. Braking • Reduce distance is moving. Cargo weight should be genuine Kawasaki components. Do not carry more than 16 km/h (10 mph) when pulling a trailer. We strongly recommend 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...
... or use on top of the vehicle. Braking • Reduce distance is moving. Cargo weight should be genuine Kawasaki components. Do not carry more than 16 km/h (10 mph) when pulling a trailer. We strongly recommend 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...
Owners Manual
Page 36
... setting of the steering will be adjusted to suit the operator (see an authorized Kawasaki dealer to the "Steering Wheel" section in order. If the warning light illuminates any other steering problems, refer to have the system checked. Steering Wheel This vehicle is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected...
... setting of the steering will be adjusted to suit the operator (see an authorized Kawasaki dealer to the "Steering Wheel" section in order. If the warning light illuminates any other steering problems, refer to have the system checked. Steering Wheel This vehicle is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected...
Owners Manual
Page 40
... the tank cap is filled completely to the top, heat may cause the fuel to detonation or "knocking." The Antiknock Index is a measure of a gasoline is posted on service station pumps in the U.S.A. The octane rating of its resistance to expand and overflow through the vents in unsatisfactory performance. Gasoline quality is certified to severe engine damage. 38 GENERAL INFORMATION j WARNING...
... the tank cap is filled completely to the top, heat may cause the fuel to detonation or "knocking." The Antiknock Index is a measure of a gasoline is posted on service station pumps in the U.S.A. The octane rating of its resistance to expand and overflow through the vents in unsatisfactory performance. Gasoline quality is certified to severe engine damage. 38 GENERAL INFORMATION j WARNING...
Owners Manual
Page 57
... to the Service Manual for the action required to return the vehicle to perform these checks will help ensure safe, reliable operation. Do not run the engine in a well-ventilated area. If any imbedded stones or other foreign particles in the window. Air Cleaner ...Check the restriction gauge for cuts, cracks, damage, or excessive wear. j WARNING Failure to a safe operating condition. Engine oil ...Oil level...
... to the Service Manual for the action required to return the vehicle to perform these checks will help ensure safe, reliable operation. Do not run the engine in a well-ventilated area. If any imbedded stones or other foreign particles in the window. Air Cleaner ...Check the restriction gauge for cuts, cracks, damage, or excessive wear. j WARNING Failure to a safe operating condition. Engine oil ...Oil level...
Owners Manual
Page 62
the parking brake. • Release increase engine speed by the vehicle's automatic transmission which releases the engine at very low speed to stop when carrying cargo or towing a trailer. Always allow for increased braking distance may result in accident and injury. Braking j żPractice starting and stopping (using the brakes) until you are familiar with the controls. This is released completely and the engine speed drops near an idle, the vehicle has no engine braking. Employ...
the parking brake. • Release increase engine speed by the vehicle's automatic transmission which releases the engine at very low speed to stop when carrying cargo or towing a trailer. Always allow for increased braking distance may result in accident and injury. Braking j żPractice starting and stopping (using the brakes) until you are familiar with the controls. This is released completely and the engine speed drops near an idle, the vehicle has no engine braking. Employ...
Owners Manual
Page 85
... 5,000 km (3,000 (600 miles) miles) of use of use 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 Front final gear case oil and transmission case oil-change* 1 year D j • D • D •...
... 5,000 km (3,000 (600 miles) miles) of use of use 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 Front final gear case oil and transmission case oil-change* 1 year D j • D • D •...
Owners Manual
Page 97
...;C (41°F) SAE 80 Transmission Case Oil Capacity 2.5 L (2.6 US qt) j WARNING Oil on the dipstick with soap and water. Contact your local authorities for approved disposal methods or possible recycling. If the gasket is a toxic substance. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. MAINTENANCE AND ADJUSTMENT 95 WARNING The exhaust system can cause an...
...;C (41°F) SAE 80 Transmission Case Oil Capacity 2.5 L (2.6 US qt) j WARNING Oil on the dipstick with soap and water. Contact your local authorities for approved disposal methods or possible recycling. If the gasket is a toxic substance. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. MAINTENANCE AND ADJUSTMENT 95 WARNING The exhaust system can cause an...
Owners Manual
Page 117
... damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. The brake light should be sure that the switch body does not turn during adjustment. Depress the brake pedal. Inspection • • Turn the ignition switch to adjust. The brake light switch should go on . MAINTENANCE AND ADJUSTMENT 115 Brake Light Switch When the brake pedal is...
... damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. The brake light should be sure that the switch body does not turn during adjustment. Depress the brake pedal. Inspection • • Turn the ignition switch to adjust. The brake light switch should go on . MAINTENANCE AND ADJUSTMENT 115 Brake Light Switch When the brake pedal is...
Owners Manual
Page 134
... taken to keep water off the following places. Under the rear seat - Power Steering System - Preparation for this happens the vehicle will not work effectively until they may cause malfunction. • • • cover with tape. Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the spark. close opening - if water gets into the ignition coils or into the...
... taken to keep water off the following places. Under the rear seat - Power Steering System - Preparation for this happens the vehicle will not work effectively until they may cause malfunction. • • • cover with tape. Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the spark. close opening - if water gets into the ignition coils or into the...