Owners Manual
Page 5
... permeation fuel hoses and fuel tank. Instead, fuel vapors are not vented into the running engine to the intake manifold. Evaporative Emission Control System The evaporative emission control system for this engine family is used to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of exhaust pollutants entering the atmosphere. 3. High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of a catalytic converter in the fuel system...
... permeation fuel hoses and fuel tank. Instead, fuel vapors are not vented into the running engine to the intake manifold. Evaporative Emission Control System The evaporative emission control system for this engine family is used to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of exhaust pollutants entering the atmosphere. 3. High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of a catalytic converter in the fuel system...
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
... the result of Kawasaki's engineering expertise and a tradition of manufacturing high-quality consumer products. FOREWORD Congratulations on their own work should, of course, be reproduced without prior notice or obligation. Please read this Owner's Manual aboard your vehicle's controls, its features, capabilities, and limitations. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. No part...
... the result of Kawasaki's engineering expertise and a tradition of manufacturing high-quality consumer products. FOREWORD Congratulations on their own work should, of course, be reproduced without prior notice or obligation. Please read this Owner's Manual aboard your vehicle's controls, its features, capabilities, and limitations. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. No part...
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
Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. 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. Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. Brake Fluid Level 41. Light Switch Brake Light Switch 42.
Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. 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. Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. Brake Fluid Level 41. Light Switch Brake Light Switch 42.
Owners Manual
Page 29
... LOADING INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your weight. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of the cab frame. NOTICE The front body work and fenders are personally responsible for use on top of accessories. speed when carrying cargo. Do not operate this vehicle faster...
... LOADING INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your weight. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of the cab frame. NOTICE The front body work and fenders are personally responsible for use on top of accessories. speed when carrying cargo. Do not operate this vehicle faster...
Owners Manual
Page 41
... battery to "ON" position. Upon release, key will drop temporarily. This switch prevents the electric starter from operating when the gear shift lever is used . START NOTICE Do not operate the starter continuously for the ignition switch, and one spare key. All electrical equipment can result. NOTE żThe vehicle is stamped on the key itself. Key Number Write your key number here. Do not turn the ignition switch key to the "START...
... battery to "ON" position. Upon release, key will drop temporarily. This switch prevents the electric starter from operating when the gear shift lever is used . START NOTICE Do not operate the starter continuously for the ignition switch, and one spare key. All electrical equipment can result. NOTE żThe vehicle is stamped on the key itself. Key Number Write your key number here. Do not turn the ignition switch key to the "START...
Owners Manual
Page 53
... in tank, no leaks. Front 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, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for cuts, cracks, damage, or excessive wear. The time required is cold), no leaks. j WARNING Failure to a safe operating condition. Always perform daily safety checks...
... in tank, no leaks. Front 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, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for cuts, cracks, damage, or excessive wear. The time required is cold), no leaks. j WARNING Failure to a safe operating condition. Always perform daily safety checks...
Owners Manual
Page 55
... knob.) NOTE żWhen engine is cold and air temperature is be- If the engine is hard to start po• Turn sition to the start , use the choke. Ordinary Choke Stroke C. Repeat until engine starts. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the choke knob after the engine starts to warm up. ż...
... knob.) NOTE żWhen engine is cold and air temperature is be- If the engine is hard to start po• Turn sition to the start , use the choke. Ordinary Choke Stroke C. Repeat until engine starts. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the choke knob after the engine starts to warm up. ż...
Owners Manual
Page 56
... certain conditions. Then crank the engine over with a starter lockout switch. sure the ignition switch is turned to "OFF". • Make the seat, the battery is all flames and sparks (cigarettes) away from operating when the gear shift lever is in the "H" (High), "L" (Low) or "R" (Reverse) position. żIf the brake pedal is depressed, it cool and for battery power to the positive (+) terminal of battery acid...
... certain conditions. Then crank the engine over with a starter lockout switch. sure the ignition switch is turned to "OFF". • Make the seat, the battery is all flames and sparks (cigarettes) away from operating when the gear shift lever is in the "H" (High), "L" (Low) or "R" (Reverse) position. żIf the brake pedal is depressed, it cool and for battery power to the positive (+) terminal of battery acid...
Owners Manual
Page 64
... exhaust pipe. Do not idle or park your vehicle in motion. j WARNING The muffler and exhaust pipe are very hot while the engine is equipped with carbon monoxide, hydrocarbons and nitrogen oxides to convert them into the atmosphere. This can ignite a fire, resulting in much cleaner exhaust gases to start the engine by rolling the vehicle if the battery is discharged. For proper operation of the catalytic converter...
... exhaust pipe. Do not idle or park your vehicle in motion. j WARNING The muffler and exhaust pipe are very hot while the engine is equipped with carbon monoxide, hydrocarbons and nitrogen oxides to convert them into the atmosphere. This can ignite a fire, resulting in much cleaner exhaust gases to start the engine by rolling the vehicle if the battery is discharged. For proper operation of the catalytic converter...
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
... careful that no oil gets on the tires or rims. Clean off any oil that inadvertently gets on the dipstick with the hook. • Lift • Remove the filler plug. MAINTENANCE AND ADJUSTMENT 83 WARNING The exhaust system can get extremely hot during oil draining. Fill the transmission case up to the spec- • ified torque. Tightening Torque Drain Plug: 15 N·m (1.5 kgf...
... careful that no oil gets on the tires or rims. Clean off any oil that inadvertently gets on the dipstick with the hook. • Lift • Remove the filler plug. MAINTENANCE AND ADJUSTMENT 83 WARNING The exhaust system can get extremely hot during oil draining. Fill the transmission case up to the spec- • ified torque. Tightening Torque Drain Plug: 15 N·m (1.5 kgf...
Owners Manual
Page 91
... the drain plug from the muffler. MAINTENANCE AND ADJUSTMENT 89 Spark Arrester This vehicle is equipped with the Periodic Maintenance Chart. Drain Plugs B. Spark Arrester (inside the muffler) the parking brake. • Apply In an open area away from combustible materials, • start the engine with the gear shift lever in accordance with a spark arrester approved for off-highway use by the U.S. DO NOT run the engine in...
... the drain plug from the muffler. MAINTENANCE AND ADJUSTMENT 89 Spark Arrester This vehicle is equipped with the Periodic Maintenance Chart. Drain Plugs B. Spark Arrester (inside the muffler) the parking brake. • Apply In an open area away from combustible materials, • start the engine with the gear shift lever in accordance with a spark arrester approved for off-highway use by the U.S. DO NOT run the engine in...
Owners Manual
Page 96
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. A. Guard Plate B. Clamps (6 p.c.s.) D. Quick Rivets (6 p.c.s.) E. A. Cap proper amount of play is 0 ∼ 1 mm (0.00 ∼ • 0.04 in .) Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable...
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. A. Guard Plate B. Clamps (6 p.c.s.) D. Quick Rivets (6 p.c.s.) E. A. Cap proper amount of play is 0 ∼ 1 mm (0.00 ∼ • 0.04 in .) Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable...
Owners Manual
Page 107
... brake light switch. Brake Pedal B. 10 mm (0.4 in brake line can make the brake feel mushy or soft. The brake light switch should • go on . If brake lever travel is depressed, the brake light goes on after about 10 mm (0.4 in.) of pedal travel. Inspection Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. j A. MAINTENANCE AND ADJUSTMENT 105 WARNING Air in .) it immediately. This may cause reduced braking performance...
... brake light switch. Brake Pedal B. 10 mm (0.4 in brake line can make the brake feel mushy or soft. The brake light switch should • go on . If brake lever travel is depressed, the brake light goes on after about 10 mm (0.4 in.) of pedal travel. Inspection Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. j A. MAINTENANCE AND ADJUSTMENT 105 WARNING Air in .) it immediately. This may cause reduced braking performance...
Owners Manual
Page 108
B. D. Lights later. Brake Light Switch B. adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. switch is located above the brake j A. C. 106 MAINTENANCE AND ADJUSTMENT Adjustment light • Brake pedal. Throttle Pedal Brake Light Switch Adjusting Nut Lights sooner. A. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.
B. D. Lights later. Brake Light Switch B. adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. switch is located above the brake j A. C. 106 MAINTENANCE AND ADJUSTMENT Adjustment light • Brake pedal. Throttle Pedal Brake Light Switch Adjusting Nut Lights sooner. A. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.
Owners Manual
Page 124
... . WARNING Motor oil is extremely flammable and can be used oil properly. Install the spark plugs. Do not smoke. Turn the engine over 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 warm the oil, shut it off and drain the engine oil. • • WARNING Gasoline is well-ventilated and free from the fuel tank, and...
... . WARNING Motor oil is extremely flammable and can be used oil properly. Install the spark plugs. Do not smoke. Turn the engine over 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 warm the oil, shut it off and drain the engine oil. • • WARNING Gasoline is well-ventilated and free from the fuel tank, and...