Owners Manual
Page 5
... intake manifold. A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) and evaporative emission (3) control systems in compliance with a suitable air cleaner and exhaust system. Evaporative Emission Control System The evaporative emission control system for this engine family is engine modifications that consist of a catalytic converter...
... intake manifold. A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) and evaporative emission (3) control systems in compliance with a suitable air cleaner and exhaust system. Evaporative Emission Control System The evaporative emission control system for this engine family is engine modifications that consist of a catalytic converter...
Owners Manual
Page 6
... your vehicle will continue to resolve any warranty issues. If you will work orders, bills, etc., as verification of this maintenance. P.O. High Altitude Performance Adjustment Information The original carburetor settings for this vehicle are best for your vehicle. As the owner of vehicles operated at the following address: Consumer Services Kawasaki Motors Corp., U.S.A. When the vehicle is a problem with the emission control system within the warranty period...
... your vehicle will continue to resolve any warranty issues. If you will work orders, bills, etc., as verification of this maintenance. P.O. High Altitude Performance Adjustment Information The original carburetor settings for this vehicle are best for your vehicle. As the owner of vehicles operated at the following address: Consumer Services Kawasaki Motors Corp., U.S.A. When the vehicle is a problem with the emission control system within the warranty period...
Owners Manual
Page 8
... special tools described in the Service Manual. FOREWORD Congratulations on their own work should remain with the proper operation of your purchase of a new Kawasaki Mule. For those who plan to change without our prior written permission. Those who would like more detailed information on your vehicle's controls, its features, capabilities, and limitations. This manual should be considered a permanent part...
... special tools described in the Service Manual. FOREWORD Congratulations on their own work should remain with the proper operation of your purchase of a new Kawasaki Mule. For those who plan to change without our prior written permission. Those who would like more detailed information on your vehicle's controls, its features, capabilities, and limitations. This manual should be considered a permanent 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 11
... on floor, and hands on public roads is especially important for a list of these checks are 16 years or older with your new Kawasaki vehicle, so drive carefully, safely, and exercise good judgement. Habitual performance of items to this Owner's Manual. Off-Highway Use Only This vehicle is designed and equipped to the Daily Safety Checks section for inexperienced drivers. Even...
... on floor, and hands on public roads is especially important for a list of these checks are 16 years or older with your new Kawasaki vehicle, so drive carefully, safely, and exercise good judgement. Habitual performance of items to this Owner's Manual. Off-Highway Use Only This vehicle is designed and equipped to the Daily Safety Checks section for inexperienced drivers. Even...
Owners Manual
Page 12
..., 3. Check the throttle pedal for replacement. Gasoline is in the event of an accident. Also, to reduce chance of a sudden stop or collision. Apply the parking brake, Put the gear shift lever in case of injury, always keep arms and legs inside the ROPS while the vehicle is very flammable. Respect private property. Before Starting the Engine Three "musts" before...
..., 3. Check the throttle pedal for replacement. Gasoline is in the event of an accident. Also, to reduce chance of a sudden stop or collision. Apply the parking brake, Put the gear shift lever in case of injury, always keep arms and legs inside the ROPS while the vehicle is very flammable. Respect private property. Before Starting the Engine Three "musts" before...
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
Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40. Brake Fluid Level 41. Light Switch Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. 18 LOCATION OF PARTS 28. 29. 30. 31. 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. Brake Fluid Level 41. Light Switch Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. 18 LOCATION OF PARTS 28. 29. 30. 31. Brake Light Switch 42. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32.
Owners Manual
Page 29
... lb) in the cargo bed. Avoid carrying cargo that extends beyond the rear of accessories. Do not carry more than 16 km/h (10 mph) when pulling a trailer. Cargo should be securely anchored. Make sure the cargo will void the utility vehicle warranty. NOTICE The front body work and fenders are personally responsible for use on Kawasaki utility vehicles. speed when carrying cargo. This...
... lb) in the cargo bed. Avoid carrying cargo that extends beyond the rear of accessories. Do not carry more than 16 km/h (10 mph) when pulling a trailer. Cargo should be securely anchored. Make sure the cargo will void the utility vehicle warranty. NOTICE The front body work and fenders are personally responsible for use on Kawasaki utility vehicles. speed when carrying cargo. This...
Owners Manual
Page 41
... OFF ON Engine off . Do not turn the ignition switch key to the "START" position with a starter lockout switch. 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 used . Key B. START NOTICE Do not operate the starter continuously for the battery to recover power. Hour meter works. NOTE żThe vehicle is equipped with the engine running, or damage...
... OFF ON Engine off . Do not turn the ignition switch key to the "START" position with a starter lockout switch. 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 used . Key B. START NOTICE Do not operate the starter continuously for the battery to recover power. Hour meter works. NOTE żThe vehicle is equipped with the engine running, or damage...
Owners Manual
Page 53
... are found during these checks before operation may result in tank, no leaks. j WARNING Failure to perform these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to a safe operating condition. Engine Oil ...Oil level between H and L lines, no leaks. The time required is cold), no leaks. Tires ...Air pressure (when cold): Front Rear 56 kPa (0.56 kgf/cm², 8 psi) 84 kPa (0.84...
... are found during these checks before operation may result in tank, no leaks. j WARNING Failure to perform these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to a safe operating condition. Engine Oil ...Oil level between H and L lines, no leaks. The time required is cold), no leaks. Tires ...Air pressure (when cold): Front Rear 56 kPa (0.56 kgf/cm², 8 psi) 84 kPa (0.84...
Owners Manual
Page 75
... 000 km (6 000 (600 mile) of use mile) of use mile) of use 5 years (D) 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) 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 80
... *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 ·lb) żDo not add any damaged gaskets with high quality engine oil as specified in the • table. Start the engine and check for both the engine and the clutch. Consistent use of these products meets or exceeds warranty and service...
... *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 ·lb) żDo not add any damaged gaskets with high quality engine oil as specified in the • table. Start the engine and check for both the engine and the clutch. Consistent use of these products meets or exceeds warranty and service...
Owners Manual
Page 86
... dipstick with the hook. • Lift • Remove the filler plug. 84 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an accident and injury. WARNING Oil on tires can make them with soap and water. Transmission Case Oil Type API GL-5 Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Transmission Case Oil Capacity 2.4 L (2.5 US qt) j • Install the...
... dipstick with the hook. • Lift • Remove the filler plug. 84 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an accident and injury. WARNING Oil on tires can make them with soap and water. Transmission Case Oil Type API GL-5 Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Transmission Case Oil Capacity 2.4 L (2.5 US qt) j • Install the...
Owners Manual
Page 92
... Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Forest Service. Drain Plugs B. Clean the spark arrester in accordance with a rubber mallet until carbon particles are purged from the muffler. (Neutral) position. • Remove the drain plug from combustible materials, • start the engine with the gear shift lever in the "N" and lower engine speed while tapping on • Raise the muffler with the Periodic Maintenance Chart...
... Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Forest Service. Drain Plugs B. Clean the spark arrester in accordance with a rubber mallet until carbon particles are purged from the muffler. (Neutral) position. • Remove the drain plug from combustible materials, • start the engine with the gear shift lever in the "N" and lower engine speed while tapping on • Raise the muffler with the Periodic Maintenance Chart...
Owners Manual
Page 97
... 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. Quick Rivets (6 p.c.s.) E. 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. Clamps (6 p.c.s.) D. The idle speed adjustment should be performed in .) Adjustment and turn the choke cable mounting...
... 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. Quick Rivets (6 p.c.s.) E. 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. Clamps (6 p.c.s.) D. The idle speed adjustment should be performed in .) Adjustment and turn the choke cable mounting...
Owners Manual
Page 107
... ignition switch to the "ON" position. • Turn the brake pedal. Brake Pedal B. 10 mm (0.4 in.) it immediately. 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 brake light should be inspected in .) of pedal travel. MAINTENANCE AND ADJUSTMENT 105 WARNING Air...
... ignition switch to the "ON" position. • Turn the brake pedal. Brake Pedal B. 10 mm (0.4 in.) it immediately. 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 brake light should be inspected in .) of pedal travel. MAINTENANCE AND ADJUSTMENT 105 WARNING Air...
Owners Manual
Page 108
106 MAINTENANCE AND ADJUSTMENT Adjustment light • Brake pedal. C. switch is located above the brake j A. B. D. Throttle Pedal Brake Light Switch Adjusting Nut Lights sooner. A. Brake Light Switch B. Lights later. 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.
106 MAINTENANCE AND ADJUSTMENT Adjustment light • Brake pedal. C. switch is located above the brake j A. B. D. Throttle Pedal Brake Light Switch Adjusting Nut Lights sooner. A. Brake Light Switch B. Lights later. 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.
Owners Manual
Page 122
... to the Service Manual for this vehicle. When operating the vehicle in conditions that allow debris or flammable material to cool, then remove any collected debris. cover the keyhole with a plastic bag. Allow the engine to collect in rags. • • • Air cleaner intake (middle of fire. cover with tape. Preparation for build-up of debris or flammable materials. j WARNING Build-up...
... to the Service Manual for this vehicle. When operating the vehicle in conditions that allow debris or flammable material to cool, then remove any collected debris. cover the keyhole with a plastic bag. Allow the engine to collect in rags. • • • Air cleaner intake (middle of fire. cover with tape. Preparation for build-up of debris or flammable materials. j WARNING Build-up...