Owners Manual
Page 5
... chamber through the inside of low permeation fuel hoses and fuel tank. Exhaust Emission Control System The exhaust emission control system applied to this vehicle consists of the breather chamber from the gases while passing through the crankcase. Instead, fuel vapors are not vented into the running engine to the intake manifold. A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process...
... chamber through the inside of low permeation fuel hoses and fuel tank. Exhaust Emission Control System The exhaust emission control system applied to this vehicle consists of the breather chamber from the gases while passing through the crankcase. Instead, fuel vapors are not vented into the running engine to the intake manifold. A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process...
Owners Manual
Page 8
... Mule, a Service Manual is available for your vehicle's controls, its features, capabilities, and limitations. This manual should be considered a permanent part of the Mule and should , of course, be competent mechanics and possess the special tools described in this Owner's Manual carefully before starting your new Mule so that you will be thoroughly familiar with the Mule when it is the result of Kawasaki's engineering...
... Mule, a Service Manual is available for your vehicle's controls, its features, capabilities, and limitations. This manual should be considered a permanent part of the Mule and should , of course, be competent mechanics and possess the special tools described in this Owner's Manual carefully before starting your new Mule so that you will be thoroughly familiar with the Mule when it is the result of Kawasaki's engineering...
Owners Manual
Page 9
... 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 ...Keys ...Hour Meter ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever ...Differential Shift Lever ...Parking Brake Lever...Seat ...9 11 15 16 19 27 29 29 29 30 31 32 32 33 33 34 34 36 39 39 40 42 42 43 44 45 45 46 46 47 48 Seat Belts ...Throttle Pedal ...Trailer Hitch...
... 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 ...Keys ...Hour Meter ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever ...Differential Shift Lever ...Parking Brake Lever...Seat ...9 11 15 16 19 27 29 29 29 30 31 32 32 33 33 34 34 36 39 39 40 42 42 43 44 45 45 46 46 47 48 Seat Belts ...Throttle Pedal ...Trailer Hitch...
Owners Manual
Page 10
... ...Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System ...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...Seat Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System...Breaker ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING...
... ...Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System ...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...Seat Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System...Breaker ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING...
Owners Manual
Page 13
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 Starting System Cylinder Numbering Method 47 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2... 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...
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 Starting System Cylinder Numbering Method 47 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2... 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...
Owners Manual
Page 15
... Differentials, SAE 85 W-140, SAE90 or SAE140 0.4 L (0.4 US qt) API GL-5 Hypoid gear oil, SAE 90 [above 5°C (41°F)] SAE 80 [below 5°C (41°F)] 2.5 L (2.6 US qt) Steel tube, ladder type Assisted with Electrical Power Steering (EPS) System 7.5° 35 mm (1.4 in.) Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Steering Castor Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light...
... Differentials, SAE 85 W-140, SAE90 or SAE140 0.4 L (0.4 US qt) API GL-5 Hypoid gear oil, SAE 90 [above 5°C (41°F)] SAE 80 [below 5°C (41°F)] 2.5 L (2.6 US qt) Steel tube, ladder type Assisted with Electrical Power Steering (EPS) System 7.5° 35 mm (1.4 in.) Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Steering Castor Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light...
Owners Manual
Page 20
FI Warning Light 39. Parking Brake Warning Light 37. Differential Shift Lever 41. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Power Steering Warning Light 40. Right Glove Compartment 38. Brake Fluid Reserve Tank 42. 43. 44. 45. 46.
FI Warning Light 39. Parking Brake Warning Light 37. Differential Shift Lever 41. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Power Steering Warning Light 40. Right Glove Compartment 38. Brake Fluid Reserve Tank 42. 43. 44. 45. 46.
Owners Manual
Page 21
Load) Warning (Cargo Bed) Warning (Cargo Bed) Warning (Hot Surfaces) Warning (Towing Bracket/Trailer) Warning (Refueling) Important Engine Information Specification (Under the seat) Information (Front Hood) Important Emission Information Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Important Information (Tires/Max. LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Load) Warning (Cargo Bed) Warning (Cargo Bed) Warning (Hot Surfaces) Warning (Towing Bracket/Trailer) Warning (Refueling) Important Engine Information Specification (Under the seat) Information (Front Hood) Important Emission Information Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Important Information (Tires/Max. LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Owners Manual
Page 29
... in weight and changes in an unsafe operating condition. Because any vehicle is moving. Do not operate this vehicle faster than 363 kg (800 lb) in carrying cargo. We strongly recommend that extends beyond the rear of the vehicle. LOADING INFORMATION 27 LOADING INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your own safety and the safety...
... in weight and changes in an unsafe operating condition. Because any vehicle is moving. Do not operate this vehicle faster than 363 kg (800 lb) in carrying cargo. We strongly recommend that extends beyond the rear of the vehicle. LOADING INFORMATION 27 LOADING INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your own safety and the safety...
Owners Manual
Page 35
... 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. Stop driving immediately and see an authorized Kawasaki dealer to suit the operator (see an authorized Kawasaki dealer. GENERAL INFORMATION 33 j Power Steering Warning Light The power steering warning light will cause serious driving problems. If such components need service, see "Steering Wheel...
... 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. Stop driving immediately and see an authorized Kawasaki dealer to suit the operator (see an authorized Kawasaki dealer. GENERAL INFORMATION 33 j Power Steering Warning Light The power steering warning light will cause serious driving problems. If such components need service, see "Steering Wheel...
Owners Manual
Page 39
... vehicle is certified to operate on service station pumps in unleaded gasoline by the U.S. Octane Rating Method Antiknock Index (RON + MON) 2 Minimum Rating 87 j NOTICE If engine "knocking" or "pinging" occurs, use in the U.S.A. Fuels of flame or sparks; Operating problems that result from any appliance with a minimum Antiknock Index of a strategy to reduce exhaust emissions. The types and volume of fuel oxygenates...
... vehicle is certified to operate on service station pumps in unleaded gasoline by the U.S. Octane Rating Method Antiknock Index (RON + MON) 2 Minimum Rating 87 j NOTICE If engine "knocking" or "pinging" occurs, use in the U.S.A. Fuels of flame or sparks; Operating problems that result from any appliance with a minimum Antiknock Index of a strategy to reduce exhaust emissions. The types and volume of fuel oxygenates...
Owners Manual
Page 45
... battery power will return to the starter can result. j Keys This UV has a key, which is in "N" (neutral) position. In the event you lose your keys, you purchased your key number here. All electrical circuits off . Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is stamped on the key itself. Do not turn the ignition switch key to the "START" position with the engine running...
... battery power will return to the starter can result. j Keys This UV has a key, which is in "N" (neutral) position. In the event you lose your keys, you purchased your key number here. All electrical circuits off . Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is stamped on the key itself. Do not turn the ignition switch key to the "START" position with the engine running...
Owners Manual
Page 57
... fuel in enclosed areas. Check for any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to perform these checks will help ensure safe, reliable operation. Always perform daily safety checks before operation. Do not run the engine in tank, no leaks. Air...
... fuel in enclosed areas. Check for any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to perform these checks will help ensure safe, reliable operation. Always perform daily safety checks before operation. Do not run the engine in tank, no leaks. Air...
Owners Manual
Page 58
... between level lines, no leaks. Throttle pedal free play 2 a 10 mm (0.1 a 0.4 in .). Brake fluid level between H and L lines, no leaks. Steering ...Steering wheel free play , rough spots, or strange noises. Brakes ...Check for dirt on or damage to rest position when released. 56 HOW TO OPERATE Front Final Gear Case ...Transmission Case Oil ...Coolant ...Throttle ...No oil leaks. Parking brake lever travel: 8 a 12 clicks. Electrical Equipment ...All lights and horn work. Action smooth without...
... between level lines, no leaks. Throttle pedal free play 2 a 10 mm (0.1 a 0.4 in .). Brake fluid level between H and L lines, no leaks. Steering ...Steering wheel free play , rough spots, or strange noises. Brakes ...Check for dirt on or damage to rest position when released. 56 HOW TO OPERATE Front Final Gear Case ...Transmission Case Oil ...Coolant ...Throttle ...No oil leaks. Parking brake lever travel: 8 a 12 clicks. Electrical Equipment ...All lights and horn work. Action smooth without...
Owners Manual
Page 59
... the engine starts. żThe vehicle is in the switch. • Turn theignition ignition switch key to the "START" posi• tion to recover. j NOTICE Do not operate the electric starter continuously for battery power to activate the electric starter. This switch prevents the electric starter from operating when the gear shift lever is equipped with a starter lockout switch. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear switch key in...
... the engine starts. żThe vehicle is in the switch. • Turn theignition ignition switch key to the "START" posi• tion to recover. j NOTICE Do not operate the electric starter continuously for battery power to activate the electric starter. This switch prevents the electric starter from operating when the gear shift lever is equipped with a starter lockout switch. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear switch key in...
Owners Manual
Page 78
.... 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 • •...
.... 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 • •...
Owners Manual
Page 89
... plug. If the gasket is a toxic substance. When draining or filling the transmission case, be careful that no oil gets on the tires or rims. Clean off any oil that inadvertently gets on the dipstick with a new one. MAINTENANCE AND ADJUSTMENT 87 WARNING The exhaust system can get extremely hot during oil draining. To avoid a serious burn, never touch a hot muffler or exhaust...
... plug. If the gasket is a toxic substance. When draining or filling the transmission case, be careful that no oil gets on the tires or rims. Clean off any oil that inadvertently gets on the dipstick with a new one. MAINTENANCE AND ADJUSTMENT 87 WARNING The exhaust system can get extremely hot during oil draining. To avoid a serious burn, never touch a hot muffler or exhaust...
Owners Manual
Page 109
... • • Turn the ignition switch to adjust. j A. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. The brake light should be sure that the switch body does not turn during adjustment. Depress the brake pedal. The brake light switch should go on . NOTICE To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary...
... • • Turn the ignition switch to adjust. j A. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. The brake light should be sure that the switch body does not turn during adjustment. Depress the brake pedal. The brake light switch should go on . NOTICE To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary...
Owners Manual
Page 124
.... Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the spark. Front and rear brakes - When this vehicle. if water gets into the actuator or is sprayed over the ECU, they will not operate properly and the affected parts must be taken to be wiped dry. Under the seat - Ignition switch - if water gets into the spark plug caps...
.... Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the spark. Front and rear brakes - When this vehicle. if water gets into the actuator or is sprayed over the ECU, they will not operate properly and the affected parts must be taken to be wiped dry. Under the seat - Ignition switch - if water gets into the spark plug caps...
Owners Manual
Page 128
...; Fuel tank vent clogged • Spark plug wire not on spark plug • • Spark plug dirty Engine Stops fuel in tank • No Water in fuel • Air filter clogged or intake 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...
...; Fuel tank vent clogged • Spark plug wire not on spark plug • • Spark plug dirty Engine Stops fuel in tank • No Water in fuel • Air filter clogged or intake 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...