Owners Manual
Page 8
... possess the special tools described in this Owner's Manual aboard your Mule, give it whenever you need information. For those who plan to do their Mule, a Service Manual is available for your Mule at the time of printing. FOREWORD Congratulations on their own work should remain with the proper operation of your vehicle's controls, its features, capabilities, and limitations. All rights reserved...
... possess the special tools described in this Owner's Manual aboard your Mule, give it whenever you need information. For those who plan to do their Mule, a Service Manual is available for your Mule at the time of printing. FOREWORD Congratulations on their own work should remain with the proper operation of your vehicle's controls, its features, capabilities, and limitations. All rights reserved...
Owners Manual
Page 9
... Warning Light ...Parking Brake Warning Light...Power Steering Warning Light (KAF620M) ...Steering Wheel (KAF620M) ...Brake Pedal...Cargo Bed ...Fuel Tank ...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Fuel Gauge/Hour Meter...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF620M)...Differential Shift Lever ...Parking Brake Lever...Seat ...Seat Belts ...9 11 15 16 19 27 29 29 29 30 31 32 32 33 33 34 34 36 39 40 41 42 43 44 45 45 46 47 47 48 49 Throttle Pedal ...Trailer Hitch...
... Warning Light ...Parking Brake Warning Light...Power Steering Warning Light (KAF620M) ...Steering Wheel (KAF620M) ...Brake Pedal...Cargo Bed ...Fuel Tank ...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Fuel Gauge/Hour Meter...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF620M)...Differential Shift Lever ...Parking Brake Lever...Seat ...Seat Belts ...9 11 15 16 19 27 29 29 29 30 31 32 32 33 33 34 34 36 39 40 41 42 43 44 45 45 46 47 47 48 49 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 Pump Filter ...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 ...
Cooling System ...Spark Plugs ...Valve Clearance ...Engine Air Cleaner ...Evaporative Emission Control System ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Pump Filter ...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 12
... keep arms and legs inside the ROPS while the vehicle is very flammable. Use only the recommended tires for proper operation. Operating in the event of flame or sparks. Wearing Seat Belt Both the operator and passenger should return to preserve nature and the environment. Use the Parking Brake Always apply the parking brake before starting the engine are: 1. 2. In these conditions, Kawasaki recommends that...
... keep arms and legs inside the ROPS while the vehicle is very flammable. Use only the recommended tires for proper operation. Operating in the event of flame or sparks. Wearing Seat Belt Both the operator and passenger should return to preserve nature and the environment. Use the Parking Brake Always apply the parking brake before starting the engine are: 1. 2. In these conditions, Kawasaki recommends that...
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 (1 336 lb) 1 175 × 1 310 × 290 mm (46.26 × 51.57 × 11.42 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 (1 336 lb) 1 175 × 1 310 × 290 mm (46.26 × 51.57 × 11.42 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
... SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Viscosity Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio: Overall Drive Ratio: Front Rear Forward Reverse 4WD gear, (P) 2WD gear 2-speed & reverse, automatic (P) 1-speed & reverse, automatic 3.9 a 0.85 (Belt drive torque converter) (M) 5.200 5.429 (M) 8.404 (High), (P) 8.404 (M) 17.303 (Low) (M) 19.475, (P) 9.459 Electric starter Front to rear, 1-2 1-2 FI (Fuel...
... SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Viscosity Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio: Overall Drive Ratio: Front Rear Forward Reverse 4WD gear, (P) 2WD gear 2-speed & reverse, automatic (P) 1-speed & reverse, automatic 3.9 a 0.85 (Belt drive torque converter) (M) 5.200 5.429 (M) 8.404 (High), (P) 8.404 (M) 17.303 (Low) (M) 19.475, (P) 9.459 Electric starter Front to rear, 1-2 1-2 FI (Fuel...
Owners Manual
Page 15
SPECIFICATIONS 13 Transmission Gear Ratio: Forward Reverse 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 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 Front & Rear Front & Rear Steel tube, ladder type Assisted with Electric Power Steering (EPS) System (P) Manual (rack and pinion) 7.5° 35 mm (1.4 in.) 23 × 11.00-10 Tubeless 10 × 8.5 24...
SPECIFICATIONS 13 Transmission Gear Ratio: Forward Reverse 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 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 Front & Rear Front & Rear Steel tube, ladder type Assisted with Electric Power Steering (EPS) System (P) Manual (rack and pinion) 7.5° 35 mm (1.4 in.) 23 × 11.00-10 Tubeless 10 × 8.5 24...
Owners Manual
Page 20
Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 35. Power Steering Warning Light (KAF620M) 39. Parking Brake Warning Light 36. Oil Pressure Warning Light 18 LOCATION OF PARTS 28. 29. 30. 31. 32. 33. 34. FI Warning Light 38. Brake Fluid Reserve Tank 41. 42. 43. 44. Differential Shift Lever 40. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever (KAF620M) 45. Right Glove Compartment 37.
Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 35. Power Steering Warning Light (KAF620M) 39. Parking Brake Warning Light 36. Oil Pressure Warning Light 18 LOCATION OF PARTS 28. 29. 30. 31. 32. 33. 34. FI Warning Light 38. Brake Fluid Reserve Tank 41. 42. 43. 44. Differential Shift Lever 40. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever (KAF620M) 45. Right Glove Compartment 37.
Owners Manual
Page 29
... cargo will void the utility vehicle warranty. Because any vehicle is sensitive to steer and may affect vehicle handling in the cargo bed. The following general guidelines have been prepared to support your vehicle may break. In selecting and using accessories, and in an unsafe operating condition. Cargo should be genuine Kawasaki components. NOTICE The front body work and fenders are personally responsible for...
... cargo will void the utility vehicle warranty. Because any vehicle is sensitive to steer and may affect vehicle handling in the cargo bed. The following general guidelines have been prepared to support your vehicle may break. In selecting and using accessories, and in an unsafe operating condition. Cargo should be genuine Kawasaki components. NOTICE The front body work and fenders are personally responsible for...
Owners Manual
Page 35
... a problem with an electric power steering system. Installing such equipment improperly may be adjusted to have the system checked. A. GENERAL INFORMATION 33 j Power Steering Warning Light (KAF620M) The power steering warning light will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer. Steering Wheel (KAF620M) This vehicle is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has...
... a problem with an electric power steering system. Installing such equipment improperly may be adjusted to have the system checked. A. GENERAL INFORMATION 33 j Power Steering Warning Light (KAF620M) The power steering warning light will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer. Steering Wheel (KAF620M) This vehicle is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has...
Owners Manual
Page 39
... industry specifications may result in areas of fuel and cause fuel pump and/or engine damage. Environmental Protection Agency include a broad WARNING Gasoline is filled completely to reduce exhaust emissions. Fuels of fuel oxygenates approved for serious burns. this condition is well-ventilated and free from any appliance with a pilot light. If the tank is extremely flammable and can lead to "OFF". Octane Rating...
... industry specifications may result in areas of fuel and cause fuel pump and/or engine damage. Environmental Protection Agency include a broad WARNING Gasoline is filled completely to reduce exhaust emissions. Fuels of fuel oxygenates approved for serious burns. this condition is well-ventilated and free from any appliance with a pilot light. If the tank is extremely flammable and can lead to "OFF". Octane Rating...
Owners Manual
Page 44
... ON Engine off . Fuel gauge works. Electric starter is engaged by holding ignition switch key in "N" (neutral) position. Upon release, key will drop temporarily. Do not turn the ignition switch key to the "START" position with a starter lockout switch. "ON" position D. Wait 15 seconds between each operation of the starter to recover power. "OFF" position C. Hour Meter NOTE żThe vehicle is in this position, only when gear shift lever is equipped with the engine running...
... ON Engine off . Fuel gauge works. Electric starter is engaged by holding ignition switch key in "N" (neutral) position. Upon release, key will drop temporarily. Do not turn the ignition switch key to the "START" position with a starter lockout switch. "ON" position D. Wait 15 seconds between each operation of the starter to recover power. "OFF" position C. Hour Meter NOTE żThe vehicle is in this position, only when gear shift lever is equipped with the engine running...
Owners Manual
Page 56
... the window. Fuel ...Enough fuel in tread. 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 cuts, cracks, damage, or excessive wear. The time required is cold), no leaks. Do not run the engine in serious damage or an accident. j WARNING Failure to a safe operating condition. Engine oil ...Oil...
... the window. Fuel ...Enough fuel in tread. 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 cuts, cracks, damage, or excessive wear. The time required is cold), no leaks. Do not run the engine in serious damage or an accident. j WARNING Failure to a safe operating condition. Engine oil ...Oil...
Owners Manual
Page 77
... 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 1 year 5 years (D) 2 years (D) • D • D • D ż Evaporative emission control system-inspect* CHASSIS Steering-inspect Steering and axle shaft joint...
... 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 1 year 5 years (D) 2 years (D) • D • D • D ż Evaporative emission control system-inspect* CHASSIS Steering-inspect Steering and axle shaft joint...
Owners Manual
Page 78
... 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
...°F) SAE 80 Transmission Case Oil Capacity KAF620M: 2.5 L (2.6 US qt) KAF620P: 2.2 L (2.3 US qt) j WARNING Oil on tires can make them with the rod. • Lift • Remove the filler plug. Tighten it 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 pipe during normal operation...
...°F) SAE 80 Transmission Case Oil Capacity KAF620M: 2.5 L (2.6 US qt) KAF620P: 2.2 L (2.3 US qt) j WARNING Oil on tires can make them with the rod. • Lift • Remove the filler plug. Tighten it 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 pipe during normal operation...
Owners Manual
Page 108
... the bulb and, if necessary, • If adjust the brake light switch. A. Inspection j the ignition switch to the "ON" position. • Turn the brake pedal. WARNING Air in an accident. Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. the brake forcefully for a few seconds and • Apply check for use in the brake lowers the brake fluid boiling point and could reduce brake effectiveness. If brake lever travel . The brake light switch...
... the bulb and, if necessary, • If adjust the brake light switch. A. Inspection j the ignition switch to the "ON" position. • Turn the brake pedal. WARNING Air in an accident. Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. the brake forcefully for a few seconds and • Apply check for use in the brake lowers the brake fluid boiling point and could reduce brake effectiveness. If brake lever travel . The brake light switch...
Owners Manual
Page 109
... Maintenance Chart, check that the switch body does not turn during adjustment. Parking Brake Lever B. j A. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the parking brake lever functions properly. MAINTENANCE AND ADJUSTMENT 107 Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is hard to adjust. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked...
... Maintenance Chart, check that the switch body does not turn during adjustment. Parking Brake Lever B. j A. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the parking brake lever functions properly. MAINTENANCE AND ADJUSTMENT 107 Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is hard to adjust. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked...
Owners Manual
Page 124
... water gets into the brake drums, they have collected, park the vehicle outside and stop the engine. Air cleaner intake (middle of the rear ROPS top) close opening - Front and rear brakes - Do not park or store the vehicle in rags. Ignition switch - After Washing • • • the plastic bag and tape, and open the • Remove air cleaner intake. Some soaps are not recommended. Muffler rear...
... water gets into the brake drums, they have collected, park the vehicle outside and stop the engine. Air cleaner intake (middle of the rear ROPS top) close opening - Front and rear brakes - Do not park or store the vehicle in rags. Ignition switch - After Washing • • • the plastic bag and tape, and open the • Remove air cleaner intake. Some soaps are not recommended. Muffler rear...
Owners Manual
Page 128
... • Engine oil low • running (not Power Steering Won't Work (KAF620M) functioned to prevent overheating. • ECU Fuse failed • Battery discharged • Cable harness/connectors disconnected • No Power Engine overheated Too much idling or low speed running (not enough air flow) Overloaded Wrong spark plug Radiator clogged Coolant level too low Coolant deteriorated Cooling fan breaker functioned Engine oil low Compression leakage Valve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel •
... • Engine oil low • running (not Power Steering Won't Work (KAF620M) functioned to prevent overheating. • ECU Fuse failed • Battery discharged • Cable harness/connectors disconnected • No Power Engine overheated Too much idling or low speed running (not enough air flow) Overloaded Wrong spark plug Radiator clogged Coolant level too low Coolant deteriorated Cooling fan breaker functioned Engine oil low Compression leakage Valve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel •