Owners Manual
Page 5
... levels. As the owner of vehicles operated at the following address: Consumer Services Kawasaki Motors Corp., U.S.A. P.O. If there is used at your dealer to resolve any warranty issues. Those items identified by your vehicle will work orders, bills, etc., as verification of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. High Altitude Performance Adjustment Information The...
... levels. As the owner of vehicles operated at the following address: Consumer Services Kawasaki Motors Corp., U.S.A. P.O. If there is used at your dealer to resolve any warranty issues. Those items identified by your vehicle will work orders, bills, etc., as verification of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. High Altitude Performance Adjustment Information The...
Owners Manual
Page 7
... read this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. The Service Manual contains detailed disassembly and maintenance information. All products are subject to it the proper care and maintenance described in the Service Manual. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. This publication includes the latest information available at all times so...
... read this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. The Service Manual contains detailed disassembly and maintenance information. All products are subject to it the proper care and maintenance described in the Service Manual. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. This publication includes the latest information available at all times so...
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
Glove Compartment Brake Fluid Level Brake Light Switch Light Switch 18 LOCATION OF PARTS 28. 29. 30. 31. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Ignition Switch 38. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A) 37. Accessory Connector 39. 40. 41. 42. Parking Brake Warning Light 33. 34. 35. 36.
Glove Compartment Brake Fluid Level Brake Light Switch Light Switch 18 LOCATION OF PARTS 28. 29. 30. 31. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Ignition Switch 38. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A) 37. Accessory Connector 39. 40. 41. 42. Parking Brake Warning Light 33. 34. 35. 36.
Owners Manual
Page 30
.... Do not carry cargo on Kawasaki utility vehicles. We strongly recommend that extends beyond the rear of the vehicle. The following general guidelines have been prepared to reduce the effect on the vehicle's center of gravity. Braking • Reduce distance is sensitive to increases in weight and changes in the cargo bed. Do not operate this vehicle faster than 181 kg (400...
.... Do not carry cargo on Kawasaki utility vehicles. We strongly recommend that extends beyond the rear of the vehicle. The following general guidelines have been prepared to reduce the effect on the vehicle's center of gravity. Braking • Reduce distance is sensitive to increases in weight and changes in the cargo bed. Do not operate this vehicle faster than 181 kg (400...
Owners Manual
Page 35
... start the engine. Warm the engine up using the choke and throttle until the idle speed is stable, and then push the choke knob back. Follow guidelines provided in the cargo bed. Pull the choke knob all the way to catch any part of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering...
... start the engine. Warm the engine up using the choke and throttle until the idle speed is stable, and then push the choke knob back. Follow guidelines provided in the cargo bed. Pull the choke knob all the way to catch any part of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering...
Owners Manual
Page 38
...) 2 Minimum Rating 87 j NOTICE If engine "knocking" or "pinging" occurs, use in unsatisfactory performance. Operating problems that result from any appliance with a minimum Antiknock Index of a strategy to severe engine damage. this condition is well-ventilated and free from the use of a gasoline is spilled on service station pumps in the tank cap. The octane rating of poor quality or nonrecommended fuel may...
...) 2 Minimum Rating 87 j NOTICE If engine "knocking" or "pinging" occurs, use in unsatisfactory performance. Operating problems that result from any appliance with a minimum Antiknock Index of a strategy to severe engine damage. this condition is well-ventilated and free from the use of a gasoline is spilled on service station pumps in the tank cap. The octane rating of poor quality or nonrecommended fuel may...
Owners Manual
Page 55
j WARNING Failure to a safe operating condition. Always perform daily checks before operation. Check for any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for cuts, cracks, damage, or excessive wear. Operate only in enclosed areas. Fuel ...Enough fuel in tank, no leaks. DO NOT run the engine in a well...
j WARNING Failure to a safe operating condition. Always perform daily checks before operation. Check for any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for cuts, cracks, damage, or excessive wear. Operate only in enclosed areas. Fuel ...Enough fuel in tank, no leaks. DO NOT run the engine in a well...
Owners Manual
Page 56
... 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Brakes ...Check for mud and other debris. Electrical Equipment ...All lights and horn work. j Throttle ...Throttle pedal free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Parking brake lever travel: 8 ∼ 12 clicks. Throttle pedal operates smoothly and returns to lights. Check for dirt on or damage to rest position when released. Steering ...Steering wheel free play , rough spots, or strange noises. Brake fluid level between level lines...
... 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Brakes ...Check for mud and other debris. Electrical Equipment ...All lights and horn work. j Throttle ...Throttle pedal free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Parking brake lever travel: 8 ∼ 12 clicks. Throttle pedal operates smoothly and returns to lights. Check for dirt on or damage to rest position when released. Steering ...Steering wheel free play , rough spots, or strange noises. Brake fluid level between level lines...
Owners Manual
Page 77
... 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 1 000 km hrs. 76 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service OPERATION Fuel hose-replace...
... 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 1 000 km hrs. 76 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service OPERATION Fuel hose-replace...
Owners Manual
Page 85
Front Final Gear Case B. Filler Opening C. Drain Plug • Install the filler cap. Front Final Gear Case B. WARNING Gear case oil is already Oil Change NOTE NOTE the vehicle level, place an oil pan beneath the • With gear case. • Remove the filler cap and drain plug. Contact your local authorities for approved disposal methods or possible recycling. ○Before draining the oil, warm it...
Front Final Gear Case B. Filler Opening C. Drain Plug • Install the filler cap. Front Final Gear Case B. WARNING Gear case oil is already Oil Change NOTE NOTE the vehicle level, place an oil pan beneath the • With gear case. • Remove the filler cap and drain plug. Contact your local authorities for approved disposal methods or possible recycling. ○Before draining the oil, warm it...
Owners Manual
Page 86
... the vehicle on them slippery which can lock the rear wheels and skid the rear tires, with insufficient, deteriorated, or contaminated oil causes accelerated wear of control. Front Final Gear Case Oil about 0.35 L Oil Capacity (0.37 US qt) Oil Type API "GL-5" SAE140 or API "GL-6" SAE90 Hypoid gear oil for Limited Slip Differentials Transmission Case Oil In order for the transmission, differential, pinion, and ring gears to the periodic maintenance...
... the vehicle on them slippery which can lock the rear wheels and skid the rear tires, with insufficient, deteriorated, or contaminated oil causes accelerated wear of control. Front Final Gear Case Oil about 0.35 L Oil Capacity (0.37 US qt) Oil Type API "GL-5" SAE140 or API "GL-6" SAE90 Hypoid gear oil for Limited Slip Differentials Transmission Case Oil In order for the transmission, differential, pinion, and ring gears to the periodic maintenance...
Owners Manual
Page 88
... a hot muffler or exhaust pipe during normal operation and cause serious burns. Warm oil drains easily and picks up to the spec- • A. the oil has completely drained out, install the • After drain plug with a new one. If the gasket is damaged, replace it up by running the vehicle. Fill the transmission case up any oil that inadvertently gets on tires can...
... a hot muffler or exhaust pipe during normal operation and cause serious burns. Warm oil drains easily and picks up to the spec- • A. the oil has completely drained out, install the • After drain plug with a new one. If the gasket is damaged, replace it up by running the vehicle. Fill the transmission case up any oil that inadvertently gets on tires can...
Owners Manual
Page 100
... gear shift lever in the "N" (Neutral) position. • Put • Start the engine, and warm it with the Periodic Maintenance Chart or whenever the idle speed is changed. j A. The following procedure covers the idle speed adjustment. Operate only in enclosed areas. Clamps (6 p.c.s.) D. 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...
... gear shift lever in the "N" (Neutral) position. • Put • Start the engine, and warm it with the Periodic Maintenance Chart or whenever the idle speed is changed. j A. The following procedure covers the idle speed adjustment. Operate only in enclosed areas. Clamps (6 p.c.s.) D. 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...
Owners Manual
Page 110
... adjust the brake light switch. If brake lever travel . j A. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. Adjustment light • Brake pedal. The brake light switch should • go on . Inspection Have the brake fluid changed by an authorized Kawasaki dealer. Fluid Change the ignition switch to the "ON" position. • Turn Depress the brake pedal. MAINTENANCE AND ADJUSTMENT 109 WARNING Air in an accident. This may cause reduced braking performance or brake failure...
... adjust the brake light switch. If brake lever travel . j A. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. Adjustment light • Brake pedal. The brake light switch should • go on . Inspection Have the brake fluid changed by an authorized Kawasaki dealer. Fluid Change the ignition switch to the "ON" position. • Turn Depress the brake pedal. MAINTENANCE AND ADJUSTMENT 109 WARNING Air in an accident. This may cause reduced braking performance or brake failure...
Owners Manual
Page 111
NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. A. B. D. C. Brake Light Switch Adjusting Nut Lights sooner. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. Brake Light Switch B. Lights later. 110 MAINTENANCE AND ADJUSTMENT j A.
NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. A. B. D. C. Brake Light Switch Adjusting Nut Lights sooner. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. Brake Light Switch B. Lights later. 110 MAINTENANCE AND ADJUSTMENT j A.
Owners Manual
Page 125
... perform it has been splashed with sea water or exposed to keep water off the following parts. cover with tape. When operating the vehicle in conditions that allow debris or flammable material to cool, then remove any collected debris. 124 MAINTENANCE AND ADJUSTMENT General Lubrication In accordance with the Periodic Maintenance Chart, have collected, park the vehicle outside and stop the engine. Ignition switch...
... perform it has been splashed with sea water or exposed to keep water off the following parts. cover with tape. When operating the vehicle in conditions that allow debris or flammable material to cool, then remove any collected debris. 124 MAINTENANCE AND ADJUSTMENT General Lubrication In accordance with the Periodic Maintenance Chart, have collected, park the vehicle outside and stop the engine. Ignition switch...
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...