Owners Manual
Page 5
... consumer.services@kawasaki-usa.com Have the carburetor adjusted by the Periodic Maintenance Chart are available. You should keep a maintenance record for inspection and diagnosis. As the owner of this vehicle above 500 m (1 600 feet). Kawasaki will work orders, bills, etc., as verification of this vehicle, you will continue to take it and any warranty issues. When the vehicle is a problem with your vehicle...
... consumer.services@kawasaki-usa.com Have the carburetor adjusted by the Periodic Maintenance Chart are available. You should keep a maintenance record for inspection and diagnosis. As the owner of this vehicle above 500 m (1 600 feet). Kawasaki will work orders, bills, etc., as verification of this vehicle, you will continue to take it and any warranty issues. When the vehicle is a problem with your vehicle...
Owners Manual
Page 7
... on their own work should remain with the proper operation of a new Kawasaki Mule. For those who plan to change without our prior written permission. This publication includes the latest information available at all times so that you need information. All products are subject to do their Mule, a Service Manual is available for your vehicle's controls, its features, capabilities, and limitations...
... on their own work should remain with the proper operation of a new Kawasaki Mule. For those who plan to change without our prior written permission. This publication includes the latest information available at all times so that you need information. All products are subject to do their Mule, a Service Manual is available for your vehicle's controls, its features, capabilities, and limitations...
Owners Manual
Page 8
... SAFE 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...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...
... SAFE 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...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...
Owners Manual
Page 9
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 ...STORAGE ...TROUBLESHOOTING GUIDE......
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 ...STORAGE ...TROUBLESHOOTING GUIDE......
Owners Manual
Page 12
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 (3.1 kgf·m, 22.1 ft·lb) @2 400 r/min (rpm) 3.6 m (11.8 ft) 2... lb) 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 × 76 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 (3.1 kgf·m, 22.1 ft·lb) @2 400 r/min (rpm) 3.6 m (11.8 ft) 2... lb) 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 × 76 mm (3.23 × 2.99 in...
Owners Manual
Page 19
Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Brake Light Switch 42. Light Switch Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40. Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. 18 LOCATION OF PARTS 28. 29. 30. 31. Brake Fluid Level 41.
Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Brake Light Switch 42. Light Switch Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40. Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. 18 LOCATION OF PARTS 28. 29. 30. 31. Brake Fluid Level 41.
Owners Manual
Page 30
... or use of accessories, or modification of your vehicle be genuine Kawasaki components. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of the ROPS. Braking • Reduce distance is not overloaded and that extends beyond the rear of gravity. Carrying cargo and pulling a trailer can make your determinations. Cargo weight should be...
... or use of accessories, or modification of your vehicle be genuine Kawasaki components. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of the ROPS. Braking • Reduce distance is not overloaded and that extends beyond the rear of gravity. Carrying cargo and pulling a trailer can make your determinations. Cargo weight should be...
Owners Manual
Page 35
... for cold starting. Follow guidelines provided in the cargo bed. Driving with the cargo bed tilted may result. Be careful not to catch any part of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering the bed. Always lower and latch the bed after the engine NOTE has warmed up using the choke and throttle until the idle speed...
... for cold starting. Follow guidelines provided in the cargo bed. Driving with the cargo bed tilted may result. Be careful not to catch any part of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering the bed. Always lower and latch the bed after the engine NOTE has warmed up using the choke and throttle until the idle speed...
Owners Manual
Page 43
... electrical circuits off . Hour meter works. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is used . Do not turn the ignition switch key to the "START" position with the engine running, or damage to the starter can be used for more than 5 seconds, or the starter will overheat and the battery power will return to recover power. Key B. Included with a starter lockout switch. Record the key...
... electrical circuits off . Hour meter works. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is used . Do not turn the ignition switch key to the "START" position with the engine running, or damage to the starter can be used for more than 5 seconds, or the starter will overheat and the battery power will return to recover power. Key B. Included with a starter lockout switch. Record the key...
Owners Manual
Page 55
... Gear Case ...No oil leaks Transmission Case Oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks will help ensure safe, reliable operation. j WARNING Failure to perform 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 a safe operating condition. DO NOT run the engine...
... Gear Case ...No oil leaks Transmission Case Oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks will help ensure safe, reliable operation. j WARNING Failure to perform 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 a safe operating condition. DO NOT run the engine...
Owners Manual
Page 77
...; 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 • 76 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service OPERATION Fuel hose-replace 5 years (D) Regular Service Every 500...
...; 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 • 76 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service OPERATION Fuel hose-replace 5 years (D) Regular Service Every 500...
Owners Manual
Page 82
... *Kawasaki Performance Oils and Lubricants have been specifically engineered for most conditions, the oil viscosity may need to be changed to extend the life of your vehicle. Start the engine and check for both the engine and the clutch. Consistent use of these products meets or exceeds warranty and service requirements and can help to accommodate atmospheric conditions in the table. Although 10W-40 engine oil is the recommended oil...
... *Kawasaki Performance Oils and Lubricants have been specifically engineered for most conditions, the oil viscosity may need to be changed to extend the life of your vehicle. Start the engine and check for both the engine and the clutch. Consistent use of these products meets or exceeds warranty and service requirements and can help to accommodate atmospheric conditions in the table. Although 10W-40 engine oil is the recommended oil...
Owners Manual
Page 85
... plug and gasket. Front Final Gear Case B. WARNING Gear case oil is damaged, replace it with a high quality oil as specified in the table. Drain Plug the vehicle level, place an oil pan beneath the • With gear case. • Remove the filler cap and drain plug. When draining or filling the gear case, be careful that no oil gets on the tires or rims. Clean off any oil...
... plug and gasket. Front Final Gear Case B. WARNING Gear case oil is damaged, replace it with a high quality oil as specified in the table. Drain Plug the vehicle level, place an oil pan beneath the • With gear case. • Remove the filler cap and drain plug. When draining or filling the gear case, be careful that no oil gets on the tires or rims. Clean off any oil...
Owners Manual
Page 88
... 80 Transmission Case Oil Capacity 2.4 L (2.5 US qt) • Install the filler plug and dipstick. the cargo bed and support it to the "H" (High) line on tires can get extremely hot during oil draining. the oil has completely drained out, install the • After drain plug with its gasket. MAINTENANCE AND ADJUSTMENT 87 WARNING The exhaust system can make them with soap and water. Tightening...
... 80 Transmission Case Oil Capacity 2.4 L (2.5 US qt) • Install the filler plug and dipstick. the cargo bed and support it to the "H" (High) line on tires can get extremely hot during oil draining. the oil has completely drained out, install the • After drain plug with its gasket. MAINTENANCE AND ADJUSTMENT 87 WARNING The exhaust system can make them with soap and water. Tightening...
Owners Manual
Page 94
... provide adequate fire protection. Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler. • Remove the drain plug from combustible materials, • start the engine with the gear shift lever in accordance with a spark arrester approved for off-highway use by the U.S. Forest Service. Drain Plugs B. MAINTENANCE AND ADJUSTMENT 93 Spark Arrester This vehicle is...
... provide adequate fire protection. Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler. • Remove the drain plug from combustible materials, • start the engine with the gear shift lever in accordance with a spark arrester approved for off-highway use by the U.S. Forest Service. Drain Plugs B. MAINTENANCE AND ADJUSTMENT 93 Spark Arrester This vehicle is...
Owners Manual
Page 99
... ∼ • 0.04 in.) at the choke knob. Guard Plate B. Clamps (6 p.c.s.) D. If there is too much or too little play is changed. A. Air Intake Ducts (2 p.c.s.) C. 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. Quick Rivets (6 p.c.s.) E. 98 MAINTENANCE AND ADJUSTMENT The proper amount of play. A.
... ∼ • 0.04 in.) at the choke knob. Guard Plate B. Clamps (6 p.c.s.) D. If there is too much or too little play is changed. A. Air Intake Ducts (2 p.c.s.) C. 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. Quick Rivets (6 p.c.s.) E. 98 MAINTENANCE AND ADJUSTMENT The proper amount of play. A.
Owners Manual
Page 109
... MAINTENANCE AND ADJUSTMENT WARNING Air in an accident. If brake lever travel . Inspection j Have the brake fluid changed by an authorized Kawasaki dealer. A. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. This may cause reduced braking performance or brake failure and result in brake line can make the brake feel mushy or soft. The brake light should be inspected in .) it immediately. Brake Light Switch When the brake...
... MAINTENANCE AND ADJUSTMENT WARNING Air in an accident. If brake lever travel . Inspection j Have the brake fluid changed by an authorized Kawasaki dealer. A. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. This may cause reduced braking performance or brake failure and result in brake line can make the brake feel mushy or soft. The brake light should be inspected in .) it immediately. Brake Light Switch When the brake...
Owners Manual
Page 110
Brake Light Switch B. D. Brake Light Switch Adjusting Nut Lights sooner. Lights later. C. B. adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. Throttle Pedal A. MAINTENANCE AND ADJUSTMENT 109 Adjustment light • Brake pedal. switch is located above the brake j 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 B. D. Brake Light Switch Adjusting Nut Lights sooner. Lights later. C. B. adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. Throttle Pedal A. MAINTENANCE AND ADJUSTMENT 109 Adjustment light • Brake pedal. switch is located above the brake j A. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.
Owners Manual
Page 124
... mechanical problems and increase the risk of the rear ROPS top) close opening - Do not park or store the vehicle in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. cover with tape. Air cleaner intake (middle of fire. When operating the vehicle in conditions that allow debris or flammable material to keep water off the following parts. j Preparation for this vehicle. MAINTENANCE...
... mechanical problems and increase the risk of the rear ROPS top) close opening - Do not park or store the vehicle in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. cover with tape. Air cleaner intake (middle of fire. When operating the vehicle in conditions that allow debris or flammable material to keep water off the following parts. j Preparation for this vehicle. MAINTENANCE...
Owners Manual
Page 129
...; 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...