Owners Manual
Page 8
... Kawasaki Mule. It is the result of Kawasaki's engineering expertise and a tradition of course, be reproduced without prior notice or obligation. All rights reserved. Please read this Owner's Manual carefully before starting your purchase of this publication may be considered a permanent part of printing. All products are subject to do their Mule, a Service Manual is available for your vehicle's controls, its features, capabilities...
... Kawasaki Mule. It is the result of Kawasaki's engineering expertise and a tradition of course, be reproduced without prior notice or obligation. All rights reserved. Please read this Owner's Manual carefully before starting your purchase of this publication may be considered a permanent part of printing. All products are subject to do their Mule, a Service Manual is available for your vehicle's controls, its features, capabilities...
Owners Manual
Page 9
... Warning Light ...Parking Brake Warning Light...Power Steering Warning Light (KAF620M) ...Steering Wheel (KAF620M) ...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 (KAF620M)...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 47 47 48 Seat Belts ...Throttle Pedal ...Trailer Hitch...
... Warning Light ...Parking Brake Warning Light...Power Steering Warning Light (KAF620M) ...Steering Wheel (KAF620M) ...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 (KAF620M)...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 47 47 48 Seat Belts ...Throttle Pedal ...Trailer Hitch...
Owners Manual
Page 10
Transmission Case Oil ...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 (KAF620M) ...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Seat Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System (KAF620M) ...Breaker ...General Lubrication ...Cleaning ...Bolt and Nut...
Transmission Case Oil ...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 (KAF620M) ...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Seat Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System (KAF620M) ...Breaker ...General Lubrication ...Cleaning ...Bolt and Nut...
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 47 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2 ...kg (1 314 lb) 1 175 × 1 310 × 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.) 10.3 : 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 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm) 3.4 m (11.2 ...kg (1 314 lb) 1 175 × 1 310 × 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.) 10.3 : 1 Front...
Owners Manual
Page 14
12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5°/750 ∼ 22°/4 000 (BTDC °/rpm) NGK BPR2ES Forced lubrication (wet sump) Kawasaki Performance 4-Stroke ATV/UTV Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with API SG, SH, SJ, SL...
12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5°/750 ∼ 22°/4 000 (BTDC °/rpm) NGK BPR2ES Forced lubrication (wet sump) Kawasaki Performance 4-Stroke ATV/UTV Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with API SG, SH, SJ, SL...
Owners Manual
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... to change without notice. 603 kg (1 330 lb) 363 kg (800 lb) (P): KAF620P 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 Specifications subject to extend the life of your vehicle. 14 SPECIFICATIONS ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load (M): KAF620M MODEL INFORMATION MULE4010 4 × 4...KAF620M MULE4000...KAF620P *Kawasaki Performance Oils and Lubricants have been specifically engineered...
... to change without notice. 603 kg (1 330 lb) 363 kg (800 lb) (P): KAF620P 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 Specifications subject to extend the life of your vehicle. 14 SPECIFICATIONS ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load (M): KAF620M MODEL INFORMATION MULE4010 4 × 4...KAF620M MULE4000...KAF620P *Kawasaki Performance Oils and Lubricants have been specifically engineered...
Owners Manual
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Oil Pressure Warning Light Right Glove Compartment 38. 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. FI Warning Light 39. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever (KAF620M) 46. Differential Shift Lever 41. Power Steering Warning Light (KAF620M) 40. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Parking Brake Warning Light 37. Brake Fluid Reserve Tank 42. 43. 44. 45.
Oil Pressure Warning Light Right Glove Compartment 38. 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. FI Warning Light 39. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever (KAF620M) 46. Differential Shift Lever 41. Power Steering Warning Light (KAF620M) 40. Left Glove Compartment Light Switch Horn Button Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Parking Brake Warning Light 37. Brake Fluid Reserve Tank 42. 43. 44. 45.
Owners Manual
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Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Important Information (Tires/Max. 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 LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Warning (Off-Highway Utility Vehicle) Warning (Front Cargo Hood) Notice (Shifting) Specification Warning (General) Important Information (Tires/Max. 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 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
... body work and fenders are personally responsible for use on top of the cab frame. Do not carry more than 16 km/h (10 mph) when pulling a trailer. Braking • Reduce distance is not overloaded and 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 vehicle...
... body work and fenders are personally responsible for use on top of the cab frame. Do not carry more than 16 km/h (10 mph) when pulling a trailer. Braking • Reduce distance is not overloaded and 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 vehicle...
Owners Manual
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... 33 j Power Steering Warning Light (KAF620M) The power steering warning light will momentarily illuminate when the engine starts, then goes off in one second if the system is equipped with an electric power steering system. Steering Wheel (KAF620M) This vehicle is in the "MAINTENANCE AND ADJUSTMENT" chapter. Installing such equipment improperly may be a problem with the electronic control unit (ECU) or loosen the fittings of steering actuator, or the neutral position...
... 33 j Power Steering Warning Light (KAF620M) The power steering warning light will momentarily illuminate when the engine starts, then goes off in one second if the system is equipped with an electric power steering system. Steering Wheel (KAF620M) This vehicle is in the "MAINTENANCE AND ADJUSTMENT" chapter. Installing such equipment improperly may be a problem with the electronic control unit (ECU) or loosen the fittings of steering actuator, or the neutral position...
Owners Manual
Page 39
... fuel tank, wipe it can be covered under certain conditions, creating the potential for use of a strategy to continue it off immediately. Fuel Requirements: Fuel Type This vehicle is allowed to reduce exhaust emissions. The Antiknock Index is an average of a higher octane rating. The Antiknock Index is posted on service station pumps in the tank cap. Gasoline quality is closed securely. Fuels Containing Oxygenates...
... fuel tank, wipe it can be covered under certain conditions, creating the potential for use of a strategy to continue it off immediately. Fuel Requirements: Fuel Type This vehicle is allowed to reduce exhaust emissions. The Antiknock Index is an average of a higher octane rating. The Antiknock Index is posted on service station pumps in the tank cap. Gasoline quality is closed securely. Fuels Containing Oxygenates...
Owners Manual
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... in enclosed areas. Fuel ...Enough fuel in the window. 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. The time required is cold), no leaks. Engine oil ...Oil level between "F" and...
... in enclosed areas. Fuel ...Enough fuel in the window. 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. The time required is cold), no leaks. Engine oil ...Oil level between "F" and...
Owners Manual
Page 77
... (3,000 (6,000 miles) (600 miles) of use miles) of use of use ż Spark plug-clean and gap ż Valve clearance-inspect Engine oil-change* Oil filter-replace* 1 year • D D j ż Throttle pedal play-inspect Throttle link lever-inspect Spark arrester-clean • • • D D • D • • ż Idle speed-adjust Radiator-clean* Water hoses and connections-inspect* Fuel hose-replace Coolant-change Evavorative emission control system-inspect* CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect...
... (3,000 (6,000 miles) (600 miles) of use miles) of use of use ż Spark plug-clean and gap ż Valve clearance-inspect Engine oil-change* Oil filter-replace* 1 year • D D j ż Throttle pedal play-inspect Throttle link lever-inspect Spark arrester-clean • • • D D • D • • ż Idle speed-adjust Radiator-clean* Water hoses and connections-inspect* Fuel hose-replace Coolant-change Evavorative emission control system-inspect* CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect...
Owners Manual
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... km km (3,000 (6,000 miles) (600 miles) of use miles) of use of use j 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* Brake fluid-change Brake master cylinder cup and dust seal -replace 1 year 2 years (D) 2 years...
... km km (3,000 (6,000 miles) (600 miles) of use miles) of use of use j 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* Brake fluid-change Brake master cylinder cup and dust seal -replace 1 year 2 years (D) 2 years...
Owners Manual
Page 89
... muffler or exhaust pipe during normal operation and cause serious burns. If the gasket is a toxic substance. Transmission case oil is damaged, replace it with soap and water. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) Transmission Case Oil Type API "GL-5" Hypoid gear oil...
... muffler or exhaust pipe during normal operation and cause serious burns. If the gasket is a toxic substance. Transmission case oil is damaged, replace it with soap and water. Fill the transmission case up to the spec- • Install the filler plug. • ified torque. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) Transmission Case Oil Type API "GL-5" Hypoid gear oil...
Owners Manual
Page 108
... unknown. Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Brake Pedal B. 10 mm (0.4 in .) of pedal travel is excessive or the brake feels mushy, have an authorized Kawasaki dealer inspect it does not, check the bulb and, if necessary, • If adjust the brake light switch. Inspection j the ignition switch to the "ON" position. • Turn Depress the brake pedal. Brake Light Switch When the brake pedal...
... unknown. Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Brake Pedal B. 10 mm (0.4 in .) of pedal travel is excessive or the brake feels mushy, have an authorized Kawasaki dealer inspect it does not, check the bulb and, if necessary, • If adjust the brake light switch. Inspection j the ignition switch to the "ON" position. • Turn Depress the brake pedal. Brake Light Switch When the brake pedal...
Owners Manual
Page 109
... not turn during adjustment. 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. Rubber Boot j A. Parking Brake Lever B. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. MAINTENANCE AND ADJUSTMENT 107 Adjustment is best performed by an authorized • Adjustment Kawasaki...
... not turn during adjustment. 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. Rubber Boot j A. Parking Brake Lever B. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. MAINTENANCE AND ADJUSTMENT 107 Adjustment is best performed by an authorized • Adjustment Kawasaki...
Owners Manual
Page 112
.... inspect the battery voltage. Take care not to protect the system from overheating by driver. Refer to the Fuse section in accordance with torque applied by stopping the power assisting. When replacing tires, check the valve stems and cores for wheel nuts tightness in this case the ECU works to damage the sealing surfaces of the vehicle. Cable harness or connectors may...
.... inspect the battery voltage. Take care not to protect the system from overheating by driver. Refer to the Fuse section in accordance with torque applied by stopping the power assisting. When replacing tires, check the valve stems and cores for wheel nuts tightness in this case the ECU works to damage the sealing surfaces of the vehicle. Cable harness or connectors may...
Owners Manual
Page 124
... spark plug caps, it has been splashed with tape. Ignition switch - Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the spark. close opening - cover with tape, or stuff in rags. Front and rear brakes - if water gets into the ignition coils or into bearings and other components causing eventual failure from rust and corrosion. Power Steering System - if water gets into the brake...
... spark plug caps, it has been splashed with tape. Ignition switch - Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the spark. close opening - cover with tape, or stuff in rags. Front and rear brakes - if water gets into the ignition coils or into bearings and other components causing eventual failure from rust and corrosion. Power Steering System - if water gets into the brake...
Owners Manual
Page 128
...;Engine oil low No Power Engine overheated żToo much idling or low speed running (not enough air flow) żOverloaded żWrong spark plug żRadiator clogged żCoolant level too low żCoolant deteriorated żCooling fan breaker functioned żEngine oil low Compression leakage żValve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel • Power Steering Won't Work (KAF620M) functioned to prevent overheating. • ECU Fuse failed • Battery...
...;Engine oil low No Power Engine overheated żToo much idling or low speed running (not enough air flow) żOverloaded żWrong spark plug żRadiator clogged żCoolant level too low żCoolant deteriorated żCooling fan breaker functioned żEngine oil low Compression leakage żValve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel • Power Steering Won't Work (KAF620M) functioned to prevent overheating. • ECU Fuse failed • Battery...