Owners Manual
Page 5
... with a suitable air cleaner and exhaust system. Evaporative Emission Control System The evaporative emission control system for this engine family is engine modifications that consist of a catalytic converter in the muffler (California model only), a modified carburetor and ignition system having optimum ignition timing characteristics. Instead, fuel vapors are routed into the atmosphere. The blow-by gases are not vented into the running engine to the breather...
... with a suitable air cleaner and exhaust system. Evaporative Emission Control System The evaporative emission control system for this engine family is engine modifications that consist of a catalytic converter in the muffler (California model only), a modified carburetor and ignition system having optimum ignition timing characteristics. Instead, fuel vapors are routed into the atmosphere. The blow-by gases are not vented into the running engine to the breather...
Owners Manual
Page 6
..., contact Kawasaki Motors Corp., U.S.A. If you in this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. at your own expense. NOTE żWhen properly performed, these optional parts may be emissions system "tampering" and vehicle performance is generally unchanged as verification of this Owner's Manual at the following repair recommendations specified in the appropriate Kawasaki Service Manual. Kawasaki will...
..., contact Kawasaki Motors Corp., U.S.A. If you in this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. at your own expense. NOTE żWhen properly performed, these optional parts may be emissions system "tampering" and vehicle performance is generally unchanged as verification of this Owner's Manual at the following repair recommendations specified in the appropriate Kawasaki Service Manual. Kawasaki will...
Owners Manual
Page 7
... intake and exhaust silencing systems. They are Do not tamper with the original emission related parts: Carburetor and internal parts Spark plug Magneto or electronic battery ignition system Fuel filter the acts listed below: cleaner element • Air Fuel hoses • Fuel tank • Muffler and carbon canister (California model only) • PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product, Kawasaki...
... intake and exhaust silencing systems. They are Do not tamper with the original emission related parts: Carburetor and internal parts Spark plug Magneto or electronic battery ignition system Fuel filter the acts listed below: cleaner element • Air Fuel hoses • Fuel tank • Muffler and carbon canister (California model only) • PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product, Kawasaki...
Owners Manual
Page 8
... of Kawasaki's engineering expertise and a tradition of a new Kawasaki Mule. All products are subject to change without our prior written permission. Jan. 2010. (1). (M, Ke) This publication includes the latest information available at all times so that you can refer to do their Mule, a Service Manual is sold. No part of printing. Please read this Owner's Manual carefully before starting your new Mule so...
... of Kawasaki's engineering expertise and a tradition of a new Kawasaki Mule. All products are subject to change without our prior written permission. Jan. 2010. (1). (M, Ke) This publication includes the latest information available at all times so that you can refer to do their Mule, a Service Manual is sold. No part of printing. Please read this Owner's Manual carefully before starting your new Mule so...
Owners Manual
Page 9
... DRIVING ...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...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Keys ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever ...Differential Shift Lever ...Parking Brake Lever ...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch Bracket...
... DRIVING ...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...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Keys ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever ...Differential Shift Lever ...Parking Brake Lever ...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch Bracket...
Owners Manual
Page 10
Spark Plug ...Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System ...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...YOUR WARRANTY/OWNER SATISFACTION ...
Spark Plug ...Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System ...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...YOUR WARRANTY/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 Tread: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System 30 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) 3.6 m...; 900 × 245 mm (41.10 × 35.43 × 9.65 in.) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in.) 82.0 × 76.0 mm (3.23 × 2.99 in...
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System 30 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) 3.6 m...; 900 × 245 mm (41.10 × 35.43 × 9.65 in.) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in.) 82.0 × 76.0 mm (3.23 × 2.99 in...
Owners Manual
Page 18
Seat Belts Cargo Bed Grille (Front Bumper) Air Cleaner Intake Parking Brake Air Cleaner (Carburetor) 13. 14. 15. 16. 17. 16 LOCATION OF PARTS LOCATION OF PARTS 1. 2. 3. 4. 5. 6. Battery Suspensions Carburetor Latch Handle Tail Gate Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Seat 7. 8. 9. 10. 11. 12.
Seat Belts Cargo Bed Grille (Front Bumper) Air Cleaner Intake Parking Brake Air Cleaner (Carburetor) 13. 14. 15. 16. 17. 16 LOCATION OF PARTS LOCATION OF PARTS 1. 2. 3. 4. 5. 6. Battery Suspensions Carburetor Latch Handle Tail Gate Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Seat 7. 8. 9. 10. 11. 12.
Owners Manual
Page 20
Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Light Switch Brake Fluid Level 41. Brake Light Switch 42. Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40. 18 LOCATION OF PARTS 28. 29. 30. 31.
Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Light Switch Brake Fluid Level 41. Brake Light Switch 42. Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40. 18 LOCATION OF PARTS 28. 29. 30. 31.
Owners Manual
Page 30
... been spe- • • cially designed for your weight. NOTICE The front body work and fenders are personally responsible for use on top of the cab frame. Because any vehicle is sensitive to steer and may break. Before you operate it, make sure that extends beyond the rear of accessories. Use extreme caution when climbing and descending hills, and traversing...
... been spe- • • cially designed for your weight. NOTICE The front body work and fenders are personally responsible for use on top of the cab frame. Because any vehicle is sensitive to steer and may break. Before you operate it, make sure that extends beyond the rear of accessories. Use extreme caution when climbing and descending hills, and traversing...
Owners Manual
Page 42
...) position. Key B. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is in a safe place. Key Number Write your key number, contact the dealer where START NOTICE Do not operate the starter continuously for the battery to "ON" position. NOTE żThe vehicle is equipped with the engine running, or damage to have a duplicate made. Upon release, key will...
...) position. Key B. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is in a safe place. Key Number Write your key number, contact the dealer where START NOTICE Do not operate the starter continuously for the battery to "ON" position. NOTE żThe vehicle is equipped with the engine running, or damage to have a duplicate made. Upon release, key will...
Owners Manual
Page 54
... Final Gear Case ...No oil leaks Transmission Case Oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks will help ensure safe, reliable operation. j WARNING Failure to perform 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 a safe operating condition. Always perform daily safety...
... Final Gear Case ...No oil leaks Transmission Case Oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks will help ensure safe, reliable operation. j WARNING Failure to perform 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 a safe operating condition. Always perform daily safety...
Owners Manual
Page 56
.... Push down the throttle pedal slightly. the parking brake. • Apply the gear shift lever in the "N" (Neutral) position. • Put • Put the ignition key in the ignition switch to the start po• Turn sition to activate the electric starter. A. Throttle-linked Choke Stroke the key in the switch. Release the choke knob when the engine has started and push in the carburetor starts to close. ż...
.... Push down the throttle pedal slightly. the parking brake. • Apply the gear shift lever in the "N" (Neutral) position. • Put • Put the ignition key in the ignition switch to the start po• Turn sition to activate the electric starter. A. Throttle-linked Choke Stroke the key in the switch. Release the choke knob when the engine has started and push in the carburetor starts to close. ż...
Owners Manual
Page 65
... reduces converter performance when the engine is cold. the capability of engine excessively accelerates reaction in motion. This can ignite a fire, resulting in an area where flammable materials such as grasses or dry leaves may contact with muffler or exhaust pipe. Under these conditions unburned air/fuel mixture flowing out of the catalytic converter. Never use leaded • gasoline. Do not idle or park your vehicle in...
... reduces converter performance when the engine is cold. the capability of engine excessively accelerates reaction in motion. This can ignite a fire, resulting in an area where flammable materials such as grasses or dry leaves may contact with muffler or exhaust pipe. Under these conditions unburned air/fuel mixture flowing out of the catalytic converter. Never use leaded • gasoline. Do not idle or park your vehicle in...
Owners Manual
Page 75
... km (3 000 (600 mile) mile) of use of use 4 years (D) Fuel hose-replace ż j Evaporative emission control system-function* • • 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...
... km (3 000 (600 mile) mile) of use of use 4 years (D) Fuel hose-replace ż j Evaporative emission control system-function* • • 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...
Owners Manual
Page 86
...-5 Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Transmission Case Oil Capacity 2.4 L (2.5 US qt) j • Install the filler plug and dipstick. Fill the transmission case up to the spec- • ified torque. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) WARNING Oil on the dipstick with its gasket. the oil has completely...
...-5 Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Transmission Case Oil Capacity 2.4 L (2.5 US qt) j • Install the filler plug and dipstick. Fill the transmission case up to the spec- • ified torque. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) WARNING Oil on the dipstick with its gasket. the oil has completely...
Owners Manual
Page 98
... run the engine in a well-ventilated area. A. j Idle Speed Adjustment the parking brake. • Apply Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and the 6 quick rivets. the gear shift lever in the "N" (Neutral) position. • Put Start • the engine, and warm it with the Periodic Maintenance Chart or whenever the idle speed is changed. the cover plate on the idle...
... run the engine in a well-ventilated area. A. j Idle Speed Adjustment the parking brake. • Apply Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and the 6 quick rivets. the gear shift lever in the "N" (Neutral) position. • Put Start • the engine, and warm it with the Periodic Maintenance Chart or whenever the idle speed is changed. the cover plate on the idle...
Owners Manual
Page 108
... ignition switch to the "ON" position. • Turn the brake pedal. Adjustment light • Brake pedal. Brake Light Switch When the brake pedal is depressed, the brake light goes on after about 10 mm (0.4 in.) of pedal travel is located above the brake Inspection j Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. This may cause reduced braking performance...
... ignition switch to the "ON" position. • Turn the brake pedal. Adjustment light • Brake pedal. Brake Light Switch When the brake pedal is depressed, the brake light goes on after about 10 mm (0.4 in.) of pedal travel is located above the brake Inspection j Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. This may cause reduced braking performance...
Owners Manual
Page 109
A. Lights later. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. Brake Light Switch B. B. C. D. MAINTENANCE AND ADJUSTMENT 107 j A. Brake Light Switch Adjusting Nut Lights sooner. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut.
A. Lights later. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. Brake Light Switch B. B. C. D. MAINTENANCE AND ADJUSTMENT 107 j A. Brake Light Switch Adjusting Nut Lights sooner. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut.
Owners Manual
Page 125
... an alternative to draining the fuel system, a fuel stabilizer, such as Kawasaki K-Kare Fogging Oil (part number K61030-002), directly into each cylinder. in a suitable container. (After a period of used . the spark plug and spray fogging oil, such • Remove as STA-BIL, may contain poisonous substances. Turn the engine over several times with a pilot light. Dispose of flame or sparks, including any appliance with the ignition switch key...
... an alternative to draining the fuel system, a fuel stabilizer, such as Kawasaki K-Kare Fogging Oil (part number K61030-002), directly into each cylinder. in a suitable container. (After a period of used . the spark plug and spray fogging oil, such • Remove as STA-BIL, may contain poisonous substances. Turn the engine over several times with a pilot light. Dispose of flame or sparks, including any appliance with the ignition switch key...