Owners Manual
Page 5
... is stopped. Exhaust Emission Control System The exhaust emission control system applied to be burned, or stored in the muffler, a modified carburetor and ignition system having optimum ignition timing characteristics. Evaporative Emission Control System The evaporative emission control system for this engine family is engine modifications that consist of low permeation fuel hoses and fuel tank. Also, vapors caused by gases. Oil is used to the intake manifold. The...
... is stopped. Exhaust Emission Control System The exhaust emission control system applied to be burned, or stored in the muffler, a modified carburetor and ignition system having optimum ignition timing characteristics. Evaporative Emission Control System The evaporative emission control system for this engine family is engine modifications that consist of low permeation fuel hoses and fuel tank. Also, vapors caused by gases. Oil is used to the intake manifold. The...
Owners Manual
Page 7
... effective 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 • Fuel hoses tank • Muffler and carbon canister • PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product, Kawasaki has...
... effective 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 • Fuel hoses tank • Muffler and carbon canister • PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product, Kawasaki has...
Owners Manual
Page 8
... need information. The Service Manual contains detailed disassembly and maintenance information. It is the result of Kawasaki's engineering expertise and a tradition of a new Kawasaki Mule. FOREWORD Congratulations on their own work should remain with the proper operation of your purchase of manufacturing high-quality consumer products. Those who would like more detailed information on your vehicle's controls, its features, capabilities, and...
... need information. The Service Manual contains detailed disassembly and maintenance information. It is the result of Kawasaki's engineering expertise and a tradition of a new Kawasaki Mule. FOREWORD Congratulations on their own work should remain with the proper operation of your purchase of manufacturing high-quality consumer products. Those who would like more detailed information on your vehicle's controls, its features, capabilities, and...
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 Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Carburetor 30 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) 3.6 m (11.8 ft) ...) 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.) 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 Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Carburetor 30 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) 3.6 m (11.8 ft) ...) 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.) 82.0 × 76.0 mm (3.23 × 2.99 in...
Owners Manual
Page 20
18 LOCATION OF PARTS 28. 29. 30. 31. Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. Brake Light Switch 42. Brake Fluid Level 41. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40. Light Switch Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32.
18 LOCATION OF PARTS 28. 29. 30. 31. Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. Brake Light Switch 42. Brake Fluid Level 41. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40. Light Switch Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32.
Owners Manual
Page 29
... changes in weight distribution, you are not designed to carry cargo or to reduce the effect on the vehicle's center of gravity. They may affect vehicle handling in carrying cargo. LOADING INFORMATION 27 LOADING INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your own safety and the safety of others. With the exception of genuine Kawasaki...
... changes in weight distribution, you are not designed to carry cargo or to reduce the effect on the vehicle's center of gravity. They may affect vehicle handling in carrying cargo. LOADING INFORMATION 27 LOADING INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your own safety and the safety of others. With the exception of genuine Kawasaki...
Owners Manual
Page 41
Do not turn the ignition switch key to the "START" position with a starter lockout switch. Key Number Write your key number here. START NOTICE Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will return to the starter can be used for the battery to recover power. This switch prevents the electric starter from operating when the gear shift lever is in...
Do not turn the ignition switch key to the "START" position with a starter lockout switch. Key Number Write your key number here. START NOTICE Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will return to the starter can be used for the battery to recover power. This switch prevents the electric starter from operating when the gear shift lever is in...
Owners Manual
Page 53
j WARNING Failure to a safe operating condition. Inhaling carbon monoxide can cause serious brain injury or death. Engine Oil ...Oil level between H and L lines, no leaks. Tires ...Air pressure (when cold): Front Rear 56 kPa (0.57 kgf/cm², 8 psi) 84 kPa (0.86 kgf/cm², 12 psi) Check for the action required to return the vehicle to perform these checks will help ensure safe...
j WARNING Failure to a safe operating condition. Inhaling carbon monoxide can cause serious brain injury or death. Engine Oil ...Oil level between H and L lines, no leaks. Tires ...Air pressure (when cold): Front Rear 56 kPa (0.57 kgf/cm², 8 psi) 84 kPa (0.86 kgf/cm², 12 psi) Check for the action required to return the vehicle to perform these checks will help ensure safe...
Owners Manual
Page 55
... controls the throttle operation without pressing the throttle pedal when starting the engine. If the engine is be- Push down the throttle pedal slightly. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the switch. • j Mechanism of the choke knob.) NOTE żWhen engine is cold and air temperature is hard to start po• Turn...
... controls the throttle operation without pressing the throttle pedal when starting the engine. If the engine is be- Push down the throttle pedal slightly. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the switch. • j Mechanism of the choke knob.) NOTE żWhen engine is cold and air temperature is hard to start po• Turn...
Owners Manual
Page 56
... protection when working with water for at all the way in a discharged condition. If this is all times, even in . sure the ignition switch is turned to "OFF". • Make the seat, the battery is "run down," it should be used to start in the "H" (High), "L" (Low) or "R" (Reverse) position. żIf the brake pedal is depressed, it cool and for battery power to the...
... protection when working with water for at all the way in a discharged condition. If this is all times, even in . sure the ignition switch is turned to "OFF". • Make the seat, the battery is "run down," it should be used to start in the "H" (High), "L" (Low) or "R" (Reverse) position. żIf the brake pedal is depressed, it cool and for battery power to the...
Owners Manual
Page 64
... exhaust pipe. Under these conditions unburned air/fuel mixture flowing out of engine excessively accelerates reaction in the converter allowing the converter to start the engine by rolling the vehicle if the battery is discharged. The converter react with carbon monoxide, hydrocarbons and nitrogen oxides to convert them into the atmosphere. 62 HOW TO OPERATE Catalytic Converter This vehicle is equipped with a catalytic converter in motion. j WARNING The muffler and exhaust...
... exhaust pipe. Under these conditions unburned air/fuel mixture flowing out of engine excessively accelerates reaction in the converter allowing the converter to start the engine by rolling the vehicle if the battery is discharged. The converter react with carbon monoxide, hydrocarbons and nitrogen oxides to convert them into the atmosphere. 62 HOW TO OPERATE Catalytic Converter This vehicle is equipped with a catalytic converter in motion. j WARNING The muffler and exhaust...
Owners Manual
Page 74
... 000 km (6 000 (600 mile) of use mile) of use mile) of use 5 years (D) j Fuel hose-replace ż Evaporative emission control system-function* 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 •...
... 000 km (6 000 (600 mile) of use mile) of use mile) of use 5 years (D) j Fuel hose-replace ż Evaporative emission control system-function* 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 85
... up to the spec- • ified torque. j WARNING Oil on the dipstick with a good quality oil as specified in the table. If the gasket is damaged, replace it to the "H" (High) line on tires can make them with its gasket. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) Transmission Case Oil Type API GL-5 Hypoid gear oil above 5°...
... up to the spec- • ified torque. j WARNING Oil on the dipstick with a good quality oil as specified in the table. If the gasket is damaged, replace it to the "H" (High) line on tires can make them with its gasket. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) Transmission Case Oil Type API GL-5 Hypoid gear oil above 5°...
Owners Manual
Page 91
... death. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. DO NOT run the engine in the "N" and lower engine speed while tapping on • Raise the muffler with a rubber mallet until carbon particles are purged from the muffler. (Neutral) position. • Remove the drain plug from the muffler. Clean the spark arrester in a well-ventilated area. Spark Arrester (inside the muffler) the parking brake. •...
... death. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. DO NOT run the engine in the "N" and lower engine speed while tapping on • Raise the muffler with a rubber mallet until carbon particles are purged from the muffler. (Neutral) position. • Remove the drain plug from the muffler. Clean the spark arrester in a well-ventilated area. Spark Arrester (inside the muffler) the parking brake. •...
Owners Manual
Page 96
...; 0.04 in.) at the choke knob. Carburetor 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 idle speed adjustment should be performed in .) Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • Tighten...
...; 0.04 in.) at the choke knob. Carburetor 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 idle speed adjustment should be performed in .) Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • Tighten...
Owners Manual
Page 107
... Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Brake Light Switch When the brake pedal 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. the ignition switch to the "ON" position. • Turn Depress the brake pedal. The brake light should be inspected in accordance with the Periodic Maintenance...
... Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Brake Light Switch When the brake pedal 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. the ignition switch to the "ON" position. • Turn Depress the brake pedal. The brake light should be inspected in accordance with the Periodic Maintenance...
Owners Manual
Page 108
Lights later. Brake Light Switch B. B. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. D. Throttle Pedal Brake Light Switch Adjusting Nut Lights sooner. switch is located above the brake j A. C. A. 106 MAINTENANCE AND ADJUSTMENT Adjustment light • Brake pedal.
Lights later. Brake Light Switch B. B. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. D. Throttle Pedal Brake Light Switch Adjusting Nut Lights sooner. switch is located above the brake j A. C. A. 106 MAINTENANCE AND ADJUSTMENT Adjustment light • Brake pedal.
Owners Manual
Page 124
... several times with a pilot light. Catch the fuel in fresh engine oil. • Put the fuel from any appliance with the ignition switch key to draining the fuel system, a fuel stabilizer, such as Kawasaki K-Kare Fogging Oil (part number K61030-002), directly into each cylinder. the spark plug and spray fogging oil, such • Remove as STA-BIL, may contain poisonous substances. WARNING Motor oil is well-ventilated and free from the fuel tank...
... several times with a pilot light. Catch the fuel in fresh engine oil. • Put the fuel from any appliance with the ignition switch key to draining the fuel system, a fuel stabilizer, such as Kawasaki K-Kare Fogging Oil (part number K61030-002), directly into each cylinder. the spark plug and spray fogging oil, such • Remove as STA-BIL, may contain poisonous substances. WARNING Motor oil is well-ventilated and free from the fuel tank...