Owners Manual
Page 5
... to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of low permeation fuel hoses and fuel tank. EMISSION CONTROL INFORMATION To protect the environment in which contributes to the bottom of a catalytic converter in the muffler, a modified carburetor and ignition system having optimum ignition timing characteristics. Crankcase Emission Control System A sealed-type crankcase emission control system is led to this vehicle consists of...
... to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of low permeation fuel hoses and fuel tank. EMISSION CONTROL INFORMATION To protect the environment in which contributes to the bottom of a catalytic converter in the muffler, a modified carburetor and ignition system having optimum ignition timing characteristics. Crankcase Emission Control System A sealed-type crankcase emission control system is led to this vehicle consists of...
Owners Manual
Page 6
... atmosphere makes the air/fuel mixture richer reducing performance and increasing fuel usage. You should also retain copies of this maintenance. Kawasaki Motors Corp., U.S.A P.O. When the vehicle is a problem with the applicable standards. Have the carburetor adjusted by the Periodic Maintenance Chart are unable to resolve any problem after consulting with your vehicle will work orders, bills, etc., as verification of maintenance work closely with...
... atmosphere makes the air/fuel mixture richer reducing performance and increasing fuel usage. You should also retain copies of this maintenance. Kawasaki Motors Corp., U.S.A P.O. When the vehicle is a problem with the applicable standards. Have the carburetor adjusted by the Periodic Maintenance Chart are unable to resolve any problem after consulting with your vehicle will work orders, bills, etc., as verification of maintenance work closely with...
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 hoses • Fuel tank • Fuel • 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 hoses • Fuel tank • Fuel • 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
... to change without our prior written permission. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. All products are subject to it is the result of Kawasaki's engineering expertise and a tradition of this manual. Motorcycle & Engine Company © 2012 Kawasaki Heavy Industries, Ltd. Keep this Owner's Manual aboard your vehicle's controls, its features, capabilities, and limitations. The Service Manual contains...
... to change without our prior written permission. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. All products are subject to it is the result of Kawasaki's engineering expertise and a tradition of this manual. Motorcycle & Engine Company © 2012 Kawasaki Heavy Industries, Ltd. Keep this Owner's Manual aboard your vehicle's controls, its features, capabilities, and limitations. The Service Manual contains...
Owners Manual
Page 9
...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 (KAF400A)...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 (KAF400A) ...Differential Shift Lever ...Parking Brake Lever...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch...
...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 (KAF400A)...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 (KAF400A) ...Differential Shift Lever ...Parking Brake Lever...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch...
Owners Manual
Page 10
Cooling Fan ...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 ...
Cooling Fan ...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 ...
Owners Manual
Page 14
NGK BPR5ES Forced lubrication (wet sump) 12 SPECIFICATIONS ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Viscosity Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio: Front Rear (A) 3.852 4.000 (A) Gear (2WD/4WD) (B) Gear (2WD) (A) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic 3.653 ∼ 0.794 (Belt drive torque converter) API SG, SH, SJ, SL, or SM with JASO MA...
NGK BPR5ES Forced lubrication (wet sump) 12 SPECIFICATIONS ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Viscosity Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio: Front Rear (A) 3.852 4.000 (A) Gear (2WD/4WD) (B) Gear (2WD) (A) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic 3.653 ∼ 0.794 (Belt drive torque converter) API SG, SH, SJ, SL, or SM with JASO MA...
Owners Manual
Page 20
Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A) 37. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Accessory Connector 39. 40. 41. 42. Ignition Switch 38. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Parking Brake Warning Light 33. 34. 35. 36. 18 LOCATION OF PARTS 28. 29. 30. 31.
Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A) 37. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Accessory Connector 39. 40. 41. 42. Ignition Switch 38. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Parking Brake Warning Light 33. 34. 35. 36. 18 LOCATION OF PARTS 28. 29. 30. 31.
Owners Manual
Page 30
.... They may affect vehicle handling in carrying cargo. The following general guidelines have followed these instructions. Carrying cargo and pulling a trailer can make your weight. Cargo weight should be securely anchored. Cargo should be genuine Kawasaki components. • • NOTICE The front body work and fenders are personally responsible for use on top of the ROPS. speed when carrying cargo...
.... They may affect vehicle handling in carrying cargo. The following general guidelines have followed these instructions. Carrying cargo and pulling a trailer can make your weight. Cargo weight should be securely anchored. Cargo should be genuine Kawasaki components. • • NOTICE The front body work and fenders are personally responsible for use on top of the ROPS. speed when carrying cargo...
Owners Manual
Page 35
... on the dashboard, to the left on (pulled out) after the engine has warmed up using the choke and throttle until the idle speed is left of the steering wheel, provides a rich mixture for detailed information. WARNING Overloading or improper use of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering the bed. Driving with the...
... on the dashboard, to the left on (pulled out) after the engine has warmed up using the choke and throttle until the idle speed is left of the steering wheel, provides a rich mixture for detailed information. WARNING Overloading or improper use of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering the bed. Driving with the...
Owners Manual
Page 43
... turn the ignition switch key to the "START" position with the key is a key number, which is used . j Keys This UV has a key, which is in a safe place. This switch prevents the electric starter from operating when the gear shift lever is stamped on the key itself. If you will need the key number to recover power. GENERAL INFORMATION 41 OFF ON Engine off . All electrical circuits off . Upon release, key...
... turn the ignition switch key to the "START" position with the key is a key number, which is used . j Keys This UV has a key, which is in a safe place. This switch prevents the electric starter from operating when the gear shift lever is stamped on the key itself. If you will need the key number to recover power. GENERAL INFORMATION 41 OFF ON Engine off . All electrical circuits off . Upon release, key...
Owners Manual
Page 55
... or other foreign particles in tread. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Engine oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks will help ensure safe, reliable operation. The time required is cold), no leaks. Fuel ...Enough fuel in serious damage or an accident. Tires ...Air pressure (when cold): KAF400A Front Rear 47 kPa (0.47 kgf/cm²...
... or other foreign particles in tread. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Engine oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks will help ensure safe, reliable operation. The time required is cold), no leaks. Fuel ...Enough fuel in serious damage or an accident. Tires ...Air pressure (when cold): KAF400A Front Rear 47 kPa (0.47 kgf/cm²...
Owners Manual
Page 77
... km of use of use 5 years (D) Fuel hose-replace ż Evaporative emission control system-function* • • D • • D j 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 D • •...
... km of use of use 5 years (D) Fuel hose-replace ż Evaporative emission control system-function* • • D • • D j 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 D • •...
Owners Manual
Page 82
... meets or exceeds warranty and service requirements and can help to the oil. NOTE *Kawasaki Performance Oils and Lubricants have been specifically engineered for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. żReplace any chemical additive to extend the life of your vehicle. Although 10W-40 engine oil is the recommended oil for your Kawasaki. the engine up to...
... meets or exceeds warranty and service requirements and can help to the oil. NOTE *Kawasaki Performance Oils and Lubricants have been specifically engineered for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. żReplace any chemical additive to extend the life of your vehicle. Although 10W-40 engine oil is the recommended oil for your Kawasaki. the engine up to...
Owners Manual
Page 88
... Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) 86 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an accident and injury. To avoid a serious burn, never touch a hot muffler or exhaust pipe during normal operation and cause serious burns. When draining or filling the transmission case, be careful that no oil gets on the tires or rims...
... Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) 86 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an accident and injury. To avoid a serious burn, never touch a hot muffler or exhaust pipe during normal operation and cause serious burns. When draining or filling the transmission case, be careful that no oil gets on the tires or rims...
Owners Manual
Page 94
.... Spark Arrester (inside the muffler) the parking brake. • Apply an open area away from the muffler. 92 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with a rubber mallet until carbon particles are purged from the muffler. • Remove the drain plug from combustible materials, • In start the engine with the gear shift lever in accordance with the Periodic Maintenance Chart. Raise and lower engine speed...
.... Spark Arrester (inside the muffler) the parking brake. • Apply an open area away from the muffler. 92 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with a rubber mallet until carbon particles are purged from the muffler. • Remove the drain plug from combustible materials, • In start the engine with the gear shift lever in accordance with the Periodic Maintenance Chart. Raise and lower engine speed...
Owners Manual
Page 99
... be performed in .) j Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • proper amount of play. A. Guard Plate B. Choke Knob B. 0 ∼ 1 mm (0.00 ∼ 0.04 in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. Air Intake Ducts (2 p.c.s.) C. Clamps (6 p.c.s.) D. Idle Speed Adjustment the parking brake. • Apply Raise the seat...
... be performed in .) j Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • proper amount of play. A. Guard Plate B. Choke Knob B. 0 ∼ 1 mm (0.00 ∼ 0.04 in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. Air Intake Ducts (2 p.c.s.) C. Clamps (6 p.c.s.) D. Idle Speed Adjustment the parking brake. • Apply Raise the seat...
Owners Manual
Page 110
... brake light switch. The brake light should be inspected in .) it immediately. Adjustment light • Brake pedal. 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. A. If brake lever travel . switch is located above the brake the ignition switch to the "ON" position. • Turn the brake pedal. The brake light switch should • Depress go on . 108 MAINTENANCE AND ADJUSTMENT WARNING Air...
... brake light switch. The brake light should be inspected in .) it immediately. Adjustment light • Brake pedal. 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. A. If brake lever travel . switch is located above the brake the ignition switch to the "ON" position. • Turn the brake pedal. The brake light switch should • Depress go on . 108 MAINTENANCE AND ADJUSTMENT WARNING Air...
Owners Manual
Page 111
B. C. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. A. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. Brake Light Switch Adjusting Nut Lights sooner. D. Brake Light Switch B. Lights later. MAINTENANCE AND ADJUSTMENT 109 j A.
B. C. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. A. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. Brake Light Switch Adjusting Nut Lights sooner. D. Brake Light Switch B. Lights later. MAINTENANCE AND ADJUSTMENT 109 j A.
Owners Manual
Page 125
... Kawasaki dealer or perform it has been splashed with sea water or exposed to inspecting for this vehicle. cover with tape. Do not park or store the vehicle in an enclosed space prior to salt air, or operated on rainy days, rough terrain, or in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Allow the engine to the Service Manual...
... Kawasaki dealer or perform it has been splashed with sea water or exposed to inspecting for this vehicle. cover with tape. Do not park or store the vehicle in an enclosed space prior to salt air, or operated on rainy days, rough terrain, or in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Allow the engine to the Service Manual...