Owners Manual
Page 4
... the bottom of the crankcase. 2. Exhaust Emission Control System The exhaust emission control system applied to this vehicle consists of low permeation fuel hoses and fuel tank. The blow-by fuel evaporation in the fuel system are not vented into the running engine to be burned, or stored in a canister when the engine is led to the intake manifold. Instead, fuel vapors are led to the breather...
... the bottom of the crankcase. 2. Exhaust Emission Control System The exhaust emission control system applied to this vehicle consists of low permeation fuel hoses and fuel tank. The blow-by fuel evaporation in the fuel system are not vented into the running engine to be burned, or stored in a canister when the engine is led to the intake manifold. Instead, fuel vapors are led to the breather...
Owners Manual
Page 7
... vehicle's controls, its features, capabilities, and limitations. This manual should remain with the proper operation of printing. No part of this Owner's Manual aboard your Mule at the time of your purchase of manufacturing high-quality consumer products. FOREWORD Congratulations on their own work should, of course, be competent mechanics and possess the special tools described in this manual. The Service Manual...
... vehicle's controls, its features, capabilities, and limitations. This manual should remain with the proper operation of printing. No part of this Owner's Manual aboard your Mule at the time of your purchase of manufacturing high-quality consumer products. FOREWORD Congratulations on their own work should, of course, be competent mechanics and possess the special tools described in this manual. The Service Manual...
Owners Manual
Page 8
... 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 Mode...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...
... 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 Mode...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
Page 9
...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
Page 12
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
Page 13
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
Page 14
SPECIFICATIONS 13 Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Steering Caster Trail 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...
SPECIFICATIONS 13 Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Steering Caster Trail 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...
Owners Manual
Page 19
Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Brake Fluid Reserve Tank 42. 43. 44. 45. 46. Right Glove Compartment 38. FI Warning Light 39. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. Power Steering Warning Light 40. Parking Brake Warning Light 37. Differential Shift Lever 41.
Left Glove Compartment Light Switch Horn Button Fuel Gauge/Hour Meter Ignition Switch Latch Release Knob Coolant Temperature Warning Light 36. Brake Fluid Reserve Tank 42. 43. 44. 45. 46. Right Glove Compartment 38. FI Warning Light 39. Brake Pedal Throttle Pedal Gear Shift Lever 2WD-4WD Shift Lever Oil Pressure Warning Light 18 LOCATION OF PARTS 29. 30. 31. 32. 33. 34. 35. Power Steering Warning Light 40. Parking Brake Warning Light 37. Differential Shift Lever 41.
Owners Manual
Page 21
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
Page 31
.... speed when carrying cargo. Braking • Reduce distance is stopped) and adjust as necessary. • • • • ○Kawasaki Parts and Accessories have been spe- All cargo should be carried as low as possible (while the vehicle is increased. This helps maintain stability by centralizing weight. Avoid carrying cargo that extends beyond the rear of accessories, or vehicle modifications...
.... speed when carrying cargo. Braking • Reduce distance is stopped) and adjust as necessary. • • • • ○Kawasaki Parts and Accessories have been spe- All cargo should be carried as low as possible (while the vehicle is increased. This helps maintain stability by centralizing weight. Avoid carrying cargo that extends beyond the rear of accessories, or vehicle modifications...
Owners Manual
Page 37
... electric power steering system. NOTE The steering wheel position can be adversely affected and will momentarily illuminate when the engine starts, then goes off in the "MAINTENANCE AND ADJUSTMENT" chapter. 36 GENERAL INFORMATION j Power Steering Warning Light The power steering warning light will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer to suit the operator (see "Steering Wheel" section). ○The power steering system functions only when engine is running...
... electric power steering system. NOTE The steering wheel position can be adversely affected and will momentarily illuminate when the engine starts, then goes off in the "MAINTENANCE AND ADJUSTMENT" chapter. 36 GENERAL INFORMATION j Power Steering Warning Light The power steering warning light will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer to suit the operator (see "Steering Wheel" section). ○The power steering system functions only when engine is running...
Owners Manual
Page 53
... the engine running, or damage to "ON" position. Upon release, key will drop temporarily. Wait 15 seconds between each operation of the starter to recover power. A. Ignition Switch B. "START" position E. All electrical circuits off . All electrical equipment can result. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is in "N" (neutral) position. The key can be used. Fuel gauge works. Hour meter works. OFF ON Engine off...
... the engine running, or damage to "ON" position. Upon release, key will drop temporarily. Wait 15 seconds between each operation of the starter to recover power. A. Ignition Switch B. "START" position E. All electrical circuits off . All electrical equipment can result. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is in "N" (neutral) position. The key can be used. Fuel gauge works. Hour meter works. OFF ON Engine off...
Owners Manual
Page 64
... to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for any irregularities are found during these checks will help ensure safe, reliable operation. j WARNING Failure to a safe operating condition. Check for the action required to return the vehicle to perform these checks before operation may result in tread. Fuel ...Enough fuel in the window. HOW...
... to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for any irregularities are found during these checks will help ensure safe, reliable operation. j WARNING Failure to a safe operating condition. Check for the action required to return the vehicle to perform these checks before operation may result in tread. Fuel ...Enough fuel in the window. HOW...
Owners Manual
Page 86
... (3,000 (6,000 miles) miles) of use of use 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 MAINTENANCE AND ADJUSTMENT...
... (3,000 (6,000 miles) miles) of use of use 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 MAINTENANCE AND ADJUSTMENT...
Owners Manual
Page 91
... Engine Oil Grade: Kawasaki Performance 4-Stroke ATV/UTV Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with new ones. Tightening Torque Drain Plug: 22 N·m (2.2 kgf·m, 16.0 ft·lb) ○Replace any chemical additive to • Install the specified torque. NOTE the engine up to extend the life of these products meets or exceeds warranty and service...
... Engine Oil Grade: Kawasaki Performance 4-Stroke ATV/UTV Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with new ones. Tightening Torque Drain Plug: 22 N·m (2.2 kgf·m, 16.0 ft·lb) ○Replace any chemical additive to • Install the specified torque. NOTE the engine up to extend the life of these products meets or exceeds warranty and service...
Owners Manual
Page 97
... touch a hot muffler or exhaust pipe during normal operation and cause serious burns. 96 MAINTENANCE AND ADJUSTMENT Oil Change WARNING NOTE The exhaust system can cause an accident and injury. j WARNING Oil on tires can make them with its gasket. Transmission Case B. the vehicle level, place an oil pan beneath the • With transmission case. • Remove the drain plug. Tighten it up to the spec- •...
... touch a hot muffler or exhaust pipe during normal operation and cause serious burns. 96 MAINTENANCE AND ADJUSTMENT Oil Change WARNING NOTE The exhaust system can cause an accident and injury. j WARNING Oil on tires can make them with its gasket. Transmission Case B. the vehicle level, place an oil pan beneath the • With transmission case. • Remove the drain plug. Tighten it up to the spec- •...
Owners Manual
Page 118
... ignition switch to adjust. j A. Depress the brake pedal. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is depressed, the brake light goes on after about 10 mm (0.4 in accordance with the Periodic Maintenance Chart. The brake light should be sure that the switch body does not turn during adjustment. Brake Pedal B. 10 mm (0.4 in.) it does not, check the bulb...
... ignition switch to adjust. j A. Depress the brake pedal. Adjustment is best performed by an authorized • Adjustment Kawasaki dealer since the brake light switch is depressed, the brake light goes on after about 10 mm (0.4 in accordance with the Periodic Maintenance Chart. The brake light should be sure that the switch body does not turn during adjustment. Brake Pedal B. 10 mm (0.4 in.) it does not, check the bulb...
Owners Manual
Page 136
... vehicle, inspect the engine, electrical component and exhaust areas frequently. Preparation for build-up of debris or flammable material 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 can ground out the spark. cover with tape. Front and rear brakes - Some soaps are not recommended. Do not park...
... vehicle, inspect the engine, electrical component and exhaust areas frequently. Preparation for build-up of debris or flammable material 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 can ground out the spark. cover with tape. Front and rear brakes - Some soaps are not recommended. Do not park...
Owners Manual
Page 138
... and rear wheels to keep • Put dampness away from any appliance with a pilot light. WARNING An air/oil mist may be used oil properly. boards under certain conditions. Install the spark plugs. Contact your local authorities for about five minutes to warm the oil, shut it off and drain the engine oil. • • ○As an alternative to coat the cylinder walls. Turn the ignition switch...
... and rear wheels to keep • Put dampness away from any appliance with a pilot light. WARNING An air/oil mist may be used oil properly. boards under certain conditions. Install the spark plugs. Contact your local authorities for about five minutes to warm the oil, shut it off and drain the engine oil. • • ○As an alternative to coat the cylinder walls. Turn the ignition switch...
Owners Manual
Page 140
...; 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...