Owners Manual
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... are subject to change without our prior written permission. Motorcycle & Engine Company © 2012 Kawasaki Heavy Industries, Ltd. Dec. 28, 2012. (1) The Service Manual contains detailed disassembly and maintenance information. Keep this Owner's Manual aboard your Mule at the time of this publication may... it the proper care and maintenance described in this manual. Those who would like more detailed information on your purchase of your vehicle's controls, its features, capabilities, and limitations. FOREWORD Congratulations on their own work should, of course, be considered...
... are subject to change without our prior written permission. Motorcycle & Engine Company © 2012 Kawasaki Heavy Industries, Ltd. Dec. 28, 2012. (1) The Service Manual contains detailed disassembly and maintenance information. Keep this Owner's Manual aboard your Mule at the time of this publication may... it the proper care and maintenance described in this manual. Those who would like more detailed information on your purchase of your vehicle's controls, its features, capabilities, and limitations. FOREWORD Congratulations on their own work should, of course, be considered...
Owners Manual
Page 8
......GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Light Switch ...Coolant Temperature Warning Light...Oil Pressure Warning Light...Fuel Injection Warning Light ...Parking Brake Warning Light...Power Steering Warning Light...Steering Wheel...Brake Pedal...Converting Rear Seat and Cargo Bed...From 4-person to 2-person...From 2-person to 4-person Mode...Cargo Bed ...Tailgate ...Loading Cargo Bed ...Raising & Lowering the Cargo Bed ...Fuel Tank...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Fuel Gauge/Hour Meter...Shift Levers ...9 11...
......GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Light Switch ...Coolant Temperature Warning Light...Oil Pressure Warning Light...Fuel Injection Warning Light ...Parking Brake Warning Light...Power Steering Warning Light...Steering Wheel...Brake Pedal...Converting Rear Seat and Cargo Bed...From 4-person to 2-person...From 2-person to 4-person Mode...Cargo Bed ...Tailgate ...Loading Cargo Bed ...Raising & Lowering the Cargo Bed ...Fuel Tank...Glove Compartment ...Front Cargo Compartment ...Horn Button ...Ignition Switch ...Keys ...Fuel Gauge/Hour Meter...Shift Levers ...9 11...
Owners Manual
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...Maintenance Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...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...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam...Battery...
...Maintenance Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...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...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam...Battery...
Owners Manual
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... wear the seat belt properly and reach all -terrain vehicle; Passenger(s) should be able to sit with back against seat, feet flat on floor, and hands on the floor while gripping the handhold. BASIC SAFE DRIVING 9 BASIC SAFE DRIVING Knowing and following these rules for safe operation will help to insure safer, more reliable usage. Refer to this Owner's Manual. Even drugs...
... wear the seat belt properly and reach all -terrain vehicle; Passenger(s) should be able to sit with back against seat, feet flat on floor, and hands on the floor while gripping the handhold. BASIC SAFE DRIVING 9 BASIC SAFE DRIVING Knowing and following these rules for safe operation will help to insure safer, more reliable usage. Refer to this Owner's Manual. Even drugs...
Owners Manual
Page 11
..., eye protection, and protective clothing. Tire Air Pressure Tire inflation and type can reduce the risk of the vehicle for any reason. Check the throttle pedal for replacement. Use the Parking Brake Always apply the parking brake before starting the engine are: 1. 2. Obey Local Laws Know and obey all laws and regulations governing the use of off and make driving more comfortable and could increase...
..., eye protection, and protective clothing. Tire Air Pressure Tire inflation and type can reduce the risk of the vehicle for any reason. Check the throttle pedal for replacement. Use the Parking Brake Always apply the parking brake before starting the engine are: 1. 2. Obey Local Laws Know and obey all laws and regulations governing the use of off and make driving more comfortable and could increase...
Owners Manual
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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) Front Rear 3 265 mm (128.54 in.) 1 485 mm (58.46 in.) 1 925 mm (75.79 in.) 2 165 mm (85.24...39 × 47.64 × 11.22 in.) Short bed mode 770 × 1 210 × 285 mm (30.31 × 47.64 × 11.22 in.) ENGINE Type Displacement Bore × Stroke Compression Ratio OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 ×...
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) Front Rear 3 265 mm (128.54 in.) 1 485 mm (58.46 in.) 1 925 mm (75.79 in.) 2 165 mm (85.24...39 × 47.64 × 11.22 in.) Short bed mode 770 × 1 210 × 285 mm (30.31 × 47.64 × 11.22 in.) ENGINE Type Displacement Bore × Stroke Compression Ratio OHV, 2-cylinder, 4-stroke, liquid-cooled 617 cm³ (37.6 cu in.) 76.0 ×...
Owners Manual
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12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Grade 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 2-speed & reverse, automatic 3.9 ∼ 0.85 (Belt drive torque converter) 5.200 5.429 8.404 (High) 17.303 (Low) 19.475 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5° BTDC @750 r/min (rpm...
12 SPECIFICATIONS Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Grade 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 2-speed & reverse, automatic 3.9 ∼ 0.85 (Belt drive torque converter) 5.200 5.429 8.404 (High) 17.303 (Low) 19.475 Electric starter Front to rear, 1-2 1-2 FI (Fuel Injection) Magneto and transistor 5° BTDC @750 r/min (rpm...
Owners Manual
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... 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 7.5° 35 mm (1.4 in.) 23 × 11.00-10 Tubeless 10 × 8.5 AT 24 L (6.3 US gal) 1.821 (High) 3.750 (Low) 4.220 API GL-5 or API GL-6 Hypoid gear oil for Limited Slip Differentials...
... 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 7.5° 35 mm (1.4 in.) 23 × 11.00-10 Tubeless 10 × 8.5 AT 24 L (6.3 US gal) 1.821 (High) 3.750 (Low) 4.220 API GL-5 or API GL-6 Hypoid gear oil for Limited Slip Differentials...
Owners Manual
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Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Battery 14. Latch 15. Belt Drive Torque Converter 17. Headlights ROPS Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. Air Cleaner (Belt Drive Torque Converter) 16. Handgrip 16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6.
Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13. Battery 14. Latch 15. Belt Drive Torque Converter 17. Headlights ROPS Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. Air Cleaner (Belt Drive Torque Converter) 16. Handgrip 16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6.
Owners Manual
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Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Right Glove Compartment 38. Differential Shift Lever 41. Brake Fluid Reserve Tank 42. 43. 44. 45. 46. 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. FI Warning Light 39. Power Steering Warning Light 40. Parking Brake Warning Light 37. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light
Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Right Glove Compartment 38. Differential Shift Lever 41. Brake Fluid Reserve Tank 42. 43. 44. 45. 46. 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. FI Warning Light 39. Power Steering Warning Light 40. Parking Brake Warning Light 37. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light
Owners Manual
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Load) Warning (Cargo Bed) Warning (Refueling) Warning (Rear Seat Capacity) Warning (Cargo Bed) Specification 20 LOCATION OF LABELS 6. 7. 8. 9. 10. 11. 15. Warning (Pinching Fingers: both sides) Important Information (Tires/Max.
Load) Warning (Cargo Bed) Warning (Refueling) Warning (Rear Seat Capacity) Warning (Cargo Bed) Specification 20 LOCATION OF LABELS 6. 7. 8. 9. 10. 11. 15. Warning (Pinching Fingers: both sides) Important Information (Tires/Max.
Owners Manual
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... on the vehicle's center of the vehicle. speed when carrying cargo. Cargo weight should be genuine Kawasaki components. Avoid carrying cargo that all parts and accessories you have followed these instructions. Cargo should be carried as low as possible to your vehicle be securely anchored. We strongly recommend that extends beyond the rear of gravity. Carrying cargo and pulling a trailer can...
... on the vehicle's center of the vehicle. speed when carrying cargo. Cargo weight should be genuine Kawasaki components. Avoid carrying cargo that all parts and accessories you have followed these instructions. Cargo should be carried as low as possible to your vehicle be securely anchored. We strongly recommend that extends beyond the rear of gravity. Carrying cargo and pulling a trailer can...
Owners Manual
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If the warning light illuminates any other steering problems, refer to the "Steering Wheel" section in order. A. Power Steering Warning Light NOTE ○If the warning light does not go on board, contact an authorized dealer. Steering Wheel This vehicle is running. ○If you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected. Do not tamper with the electronic control unit...
If the warning light illuminates any other steering problems, refer to the "Steering Wheel" section in order. A. Power Steering Warning Light NOTE ○If the warning light does not go on board, contact an authorized dealer. Steering Wheel This vehicle is running. ○If you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected. Do not tamper with the electronic control unit...
Owners Manual
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.... Upon release, key will drop temporarily. Do not turn the ignition switch key to the "START" position with a starter lockout switch. "START" position E. The key can result. Fuel gauge works. Wait 15 seconds between each operation of the starter to let it is in this position, only when gear shift lever is a three-position, key-operated switch. "OFF" position C. A. Hour Meter ○The NOTE vehicle is equipped with the engine running, or...
.... Upon release, key will drop temporarily. Do not turn the ignition switch key to the "START" position with a starter lockout switch. "START" position E. The key can result. Fuel gauge works. Wait 15 seconds between each operation of the starter to let it is in this position, only when gear shift lever is a three-position, key-operated switch. "OFF" position C. A. Hour Meter ○The NOTE vehicle is equipped with the engine running, or...
Owners Manual
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... areas. The time required is cold), no leaks. Always perform daily checks before operation may result in the window. Do not run the engine in a well-ventilated area. Engine oil ...Oil level between "F" and "L" lines on the dipstick (when engine is minimal, and habitual performance of these checks before operation. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. j WARNING Failure to a safe operating condition. Inhaling...
... areas. The time required is cold), no leaks. Always perform daily checks before operation may result in the window. Do not run the engine in a well-ventilated area. Engine oil ...Oil level between "F" and "L" lines on the dipstick (when engine is minimal, and habitual performance of these checks before operation. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. j WARNING Failure to a safe operating condition. Inhaling...
Owners Manual
Page 86
... OPERATION 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 Front final gear case oil and transmission case oil-change* 1 year D • D • D j D D D D D or 1,000 km (600 miles) of use Regular Service Every...
... OPERATION 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 Front final gear case oil and transmission case oil-change* 1 year D • D • D j D D D D D or 1,000 km (600 miles) of use Regular Service Every...
Owners Manual
Page 98
...°F) SAE 80 Transmission Case Oil Capacity 2.5 L (2.6 US qt) j WARNING Oil on them slippery which can cause an accident and injury. the oil has completely drained out, install the • After drain plug with its gasket. MAINTENANCE AND ADJUSTMENT 97 WARNING The exhaust system can make them with a new one. To avoid a serious burn, never touch a hot muffler or exhaust pipe during normal...
...°F) SAE 80 Transmission Case Oil Capacity 2.5 L (2.6 US qt) j WARNING Oil on them slippery which can cause an accident and injury. the oil has completely drained out, install the • After drain plug with its gasket. MAINTENANCE AND ADJUSTMENT 97 WARNING The exhaust system can make them with a new one. To avoid a serious burn, never touch a hot muffler or exhaust pipe during normal...
Owners Manual
Page 118
...; Turn the ignition switch to adjust. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. NOTICE To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. j A. Depress the brake pedal. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is...
...; Turn the ignition switch to adjust. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. NOTICE To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. j A. Depress the brake pedal. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is...
Owners Manual
Page 135
if water gets into the brake drums, they will not work effectively until they may leave a residue or cause spotting. Water may be wiped dry. Ignition switch - Under the rear seat - Do not park or store the vehicle in and around the vehicle chassis, engine, and exhaust can ground out the spark. cover the keyhole with sea water or exposed to salt air, or operated on rainy days, rough...
if water gets into the brake drums, they will not work effectively until they may leave a residue or cause spotting. Water may be wiped dry. Ignition switch - Under the rear seat - Do not park or store the vehicle in and around the vehicle chassis, engine, and exhaust can ground out the spark. cover the keyhole with sea water or exposed to salt air, or operated on rainy days, rough...
Owners Manual
Page 139
...; Coolant Cooling fan breaker functioned • Engine oil low • 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 • running (not Power Steering Won't Work functioned to prevent overheating. • ECU failed • Fuse Battery discharged • Cable harness...
...; Coolant Cooling fan breaker functioned • Engine oil low • 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 • running (not Power Steering Won't Work functioned to prevent overheating. • ECU failed • Fuse Battery discharged • Cable harness...