Owners Manual
Page 4
... lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of exhaust pollutants entering the atmosphere. 3. Also, vapors caused by fuel evaporation in a canister when the engine is engine modifications that consist of a catalytic converter in compliance with a suitable air cleaner and exhaust system. Instead, fuel vapors are not vented into the running engine to the intake manifold. The blow-by gases. Evaporative Emission Control System...
... lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of exhaust pollutants entering the atmosphere. 3. Also, vapors caused by fuel evaporation in a canister when the engine is engine modifications that consist of a catalytic converter in compliance with a suitable air cleaner and exhaust system. Instead, fuel vapors are not vented into the running engine to the intake manifold. The blow-by gases. Evaporative Emission Control System...
Owners Manual
Page 5
... air/fuel mixture richer reducing performance and increasing fuel usage. This Owner's Manual contains those maintenance recommendations for inspection and diagnosis. If there is carried out according to ensure that the recommended maintenance is a problem with the dealership management and need to take it and any maintenance records to resolve any warranty issues. Maintenance and Warranty Proper maintenance is used at the following address: Consumer Services...
... air/fuel mixture richer reducing performance and increasing fuel usage. This Owner's Manual contains those maintenance recommendations for inspection and diagnosis. If there is carried out according to ensure that the recommended maintenance is a problem with the dealership management and need to take it and any maintenance records to resolve any warranty issues. Maintenance and Warranty Proper maintenance is used at the following address: Consumer Services...
Owners Manual
Page 7
... read this Owner's Manual carefully before starting your new Mule so that you need information. Those who would like more detailed information on your vehicle's controls, its features, capabilities, and limitations. All rights reserved. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. Dec. 3, 2012. (1) For those who plan to do their Mule, a Service Manual is sold...
... read this Owner's Manual carefully before starting your new Mule so that you need information. Those who would like more detailed information on your vehicle's controls, its features, capabilities, and limitations. All rights reserved. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. Dec. 3, 2012. (1) For those who plan to do their Mule, a Service Manual is sold...
Owners Manual
Page 8
... DRIVING ...SPECIFICATIONS...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Tailgate ...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...
... DRIVING ...SPECIFICATIONS...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Tailgate ...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...
Owners Manual
Page 9
Front Final Gear Case Oil (KAF400A)...Transmission Case Oil ...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...
Front Final Gear Case Oil (KAF400A)...Transmission Case Oil ...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...
Owners Manual
Page 13
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 19
Ignition Switch 38. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A) 37. 18 LOCATION OF PARTS 28. 29. 30. 31. Parking Brake Warning Light 33. 34. 35. 36. Accessory Connector 39. 40. 41. 42. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32.
Ignition Switch 38. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A) 37. 18 LOCATION OF PARTS 28. 29. 30. 31. Parking Brake Warning Light 33. 34. 35. 36. Accessory Connector 39. 40. 41. 42. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32.
Owners Manual
Page 30
... genuine Kawasaki components. Do not carry cargo on the vehicle's center of gravity. Cargo should be securely anchored. Because any vehicle is sensitive to increases in weight and changes in weight distribution, you are not designed to carry cargo or to side. Do not carry more than 16 km/h (10 mph) when pulling a trailer. NOTICE The front body work and fenders...
... genuine Kawasaki components. Do not carry cargo on the vehicle's center of gravity. Cargo should be securely anchored. Because any vehicle is sensitive to increases in weight and changes in weight distribution, you are not designed to carry cargo or to side. Do not carry more than 16 km/h (10 mph) when pulling a trailer. NOTICE The front body work and fenders...
Owners Manual
Page 35
... provided in handling which j WARNING Choke Knob The choke knob located on (pulled out) after tilting. Driving with the cargo bed tilted may cause serious injury or death. Warm the engine up using the choke and throttle until the idle speed is left of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering the bed.
... provided in handling which j WARNING Choke Knob The choke knob located on (pulled out) after tilting. Driving with the cargo bed tilted may cause serious injury or death. Warm the engine up using the choke and throttle until the idle speed is left of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering the bed.
Owners Manual
Page 43
.... ○The vehicle is in this position, only when gear shift lever is stamped on the key itself. This switch prevents the electric starter from operating when the gear shift lever is equipped with the engine running, or damage to the starter can be used for the battery to the "START" position with a starter lockout switch. All electrical circuits off . Do not turn the ignition switch key to recover power. Key B. j Keys This UV...
.... ○The vehicle is in this position, only when gear shift lever is stamped on the key itself. This switch prevents the electric starter from operating when the gear shift lever is equipped with the engine running, or damage to the starter can be used for the battery to the "START" position with a starter lockout switch. All electrical circuits off . Do not turn the ignition switch key to recover power. Key B. j Keys This UV...
Owners Manual
Page 55
... or death. j WARNING Failure to a safe operating condition. Engine 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 the action required to return the vehicle to perform these checks before operation. Front Final Gear Case ...No oil leaks (KAF400A). 54 HOW...
... or death. j WARNING Failure to a safe operating condition. Engine 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 the action required to return the vehicle to perform these checks before operation. Front Final Gear Case ...No oil leaks (KAF400A). 54 HOW...
Owners Manual
Page 77
or 5 000 km of use of use j ○ 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 • D • D D D D D D D • Every 250 or...
or 5 000 km of use of use j ○ 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 • D • D D D D D D D • Every 250 or...
Owners Manual
Page 85
... to the bottom thread of used oil properly. 84 MAINTENANCE AND ADJUSTMENT WARNING Oil on them slippery which can make them with soap and water. Drain Plug the vehicle level, place an oil pan beneath the • With gear case. • Remove the filler cap and drain plug. WARNING Gear case oil is damaged, replace it with a high quality oil as specified in the table. When...
... to the bottom thread of used oil properly. 84 MAINTENANCE AND ADJUSTMENT WARNING Oil on them slippery which can make them with soap and water. Drain Plug the vehicle level, place an oil pan beneath the • With gear case. • Remove the filler cap and drain plug. WARNING Gear case oil is damaged, replace it with a high quality oil as specified in the table. When...
Owners Manual
Page 88
...°F) SAE 80 Transmission Case Oil Capacity KAF400A: 2.4 L (2.5 US qt) KAF400B: 2.2 L (2.3 US qt) j WARNING Oil on them slippery which can make them with a new one. Fill the transmission case up to the spec- • Install the filler plug and dipstick. • ified torque. the cargo bed and support it with soap and water. If the gasket is damaged, replace it with its...
...°F) SAE 80 Transmission Case Oil Capacity KAF400A: 2.4 L (2.5 US qt) KAF400B: 2.2 L (2.3 US qt) j WARNING Oil on them slippery which can make them with a new one. Fill the transmission case up to the spec- • Install the filler plug and dipstick. • ified torque. the cargo bed and support it with soap and water. If the gasket is damaged, replace it with its...
Owners Manual
Page 94
... ensure its efficiency. Drain Plug B. Operate only in enclosed areas. MAINTENANCE AND ADJUSTMENT 93 Spark Arrester This vehicle is equipped with the gear shift lever in the "N" • (Neutral) position. j Spark Arrester Cleaning WARNING The muffler can cause serious brain injury or death. DO NOT run the engine in a well-ventilated area. NOTICE The spark arrester must be running during normal operation and cause...
... ensure its efficiency. Drain Plug B. Operate only in enclosed areas. MAINTENANCE AND ADJUSTMENT 93 Spark Arrester This vehicle is equipped with the gear shift lever in the "N" • (Neutral) position. j Spark Arrester Cleaning WARNING The muffler can cause serious brain injury or death. DO NOT run the engine in a well-ventilated area. NOTICE The spark arrester must be running during normal operation and cause...
Owners Manual
Page 99
... performed in .) Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • Tighten the nuts after adjustment. Cap A. Quick Rivets (6 p.c.s.) E. 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. Air Intake Ducts (2 p.c.s.) C. The following procedure covers the idle speed...
... performed in .) Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • Tighten the nuts after adjustment. Cap A. Quick Rivets (6 p.c.s.) E. 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. Air Intake Ducts (2 p.c.s.) C. The following procedure covers the idle speed...
Owners Manual
Page 110
... (0.4 in .) of pedal travel 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. Brake Light Switch When the brake pedal is located above the brake Inspection Have the brake fluid changed by an authorized Kawasaki dealer. Adjustment light • Brake pedal. j A. MAINTENANCE AND ADJUSTMENT 109 WARNING Air in an accident.
... (0.4 in .) of pedal travel 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. Brake Light Switch When the brake pedal is located above the brake Inspection Have the brake fluid changed by an authorized Kawasaki dealer. Adjustment light • Brake pedal. j A. MAINTENANCE AND ADJUSTMENT 109 WARNING Air in an accident.
Owners Manual
Page 111
B. D. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. C. Brake Light Switch B. Lights later. A. Brake Light Switch Adjusting Nut Lights sooner. 110 MAINTENANCE AND ADJUSTMENT j A.
B. D. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. C. Brake Light Switch B. Lights later. A. Brake Light Switch Adjusting Nut Lights sooner. 110 MAINTENANCE AND ADJUSTMENT j A.
Owners Manual
Page 125
... and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Ignition switch - cover with tape, or stuff in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of your vehicle, wash it down immediately after it referring to inspecting for this vehicle. Air cleaner intake (middle of the rear ROPS top) close opening - 124 MAINTENANCE AND ADJUSTMENT...
... and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Ignition switch - cover with tape, or stuff in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of your vehicle, wash it down immediately after it referring to inspecting for this vehicle. Air cleaner intake (middle of the rear ROPS top) close opening - 124 MAINTENANCE AND ADJUSTMENT...
Owners Manual
Page 130
...; Engine flooded or intake blocked • Fuel tank vent clogged • Spark plug wire not on spark plug • Spark plug dirty • Engine Stops fuel in tank • No Water in fuel • Fuel filter • Choke leftclogged on too long • Air filter clogged or intake blocked • Fuel tank cap vent clogged • overheated • Engine Too much idling or low speed • enough air flow) • Overloaded spark plug • Wrong Cooling fan screen clogged • Engine oil low • No Power overheated...
...; Engine flooded or intake blocked • Fuel tank vent clogged • Spark plug wire not on spark plug • Spark plug dirty • Engine Stops fuel in tank • No Water in fuel • Fuel filter • Choke leftclogged on too long • Air filter clogged or intake blocked • Fuel tank cap vent clogged • overheated • Engine Too much idling or low speed • enough air flow) • Overloaded spark plug • Wrong Cooling fan screen clogged • Engine oil low • No Power overheated...