Owners Manual
Page 4
... air cleaner and exhaust system. Evaporative Emission Control System The evaporative emission control system for this engine family is stopped. 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 engine modifications that consist of a catalytic converter in the muffler, a modified carburetor and ignition system having optimum ignition timing characteristics. Exhaust...
... air cleaner and exhaust system. Evaporative Emission Control System The evaporative emission control system for this engine family is stopped. 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 engine modifications that consist of a catalytic converter in the muffler, a modified carburetor and ignition system having optimum ignition timing characteristics. Exhaust...
Owners Manual
Page 5
... the air/fuel mixture richer reducing performance and increasing fuel usage. If you have low emission levels. at the following address: Consumer Services Kawasaki Motors Corp., U.S.A. To assist you in this vehicle are unable to resolve any maintenance records to take it and any problem after consulting with the emission control system within the warranty period, you intend to resolve any warranty issues. Those...
... the air/fuel mixture richer reducing performance and increasing fuel usage. If you have low emission levels. at the following address: Consumer Services Kawasaki Motors Corp., U.S.A. To assist you in this vehicle are unable to resolve any maintenance records to take it and any problem after consulting with the emission control system within the warranty period, you intend to resolve any warranty issues. Those...
Owners Manual
Page 7
... change without our prior written permission. However, there may be minor differences between the actual product and illustrations and text in this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. KAWASAKI HEAVY INDUSTRIES, LTD. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. Keep this Owner's Manual aboard your purchase of a new Kawasaki Mule...
... change without our prior written permission. However, there may be minor differences between the actual product and illustrations and text in this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. KAWASAKI HEAVY INDUSTRIES, LTD. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. Keep this Owner's Manual aboard your purchase of a new Kawasaki Mule...
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 OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in.) 82 × 76 mm (3.23 × 2.99 in.) 8.6:1 1 085 mm (42.72 in.) 1 050 mm (41...
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 OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in.) 82 × 76 mm (3.23 × 2.99 in.) 8.6:1 1 085 mm (42.72 in.) 1 050 mm (41...
Owners Manual
Page 19
Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39. Light Switch Brake Light Switch 42. 18 LOCATION OF PARTS 28. 29. 30. 31. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Brake Fluid Level 41. 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. Light Switch Brake Light Switch 42. 18 LOCATION OF PARTS 28. 29. 30. 31. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Brake Fluid Level 41. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40.
Owners Manual
Page 22
LOCATION OF PARTS 21 28. 29. 30. 31. Brake Light Switch 42. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40. Brake Fluid Level 41. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Light Switch Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39.
LOCATION OF PARTS 21 28. 29. 30. 31. Brake Light Switch 42. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever Ignition Switch Accessory Connector Glove Compartment 40. Brake Fluid Level 41. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Light Switch Parking Brake Warning Light 33. 34. 35. 36. 37. 38. 39.
Owners Manual
Page 33
... INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your vehicle be genuine Kawasaki components. Do not carry cargo on the vehicle's center of gravity. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of the vehicle. This helps maintain stability by centralizing weight. Because any vehicle is sensitive to steer...
... INFORMATION WARNING Incorrect loading, improper installation or use of accessories, or modification of your vehicle be genuine Kawasaki components. Do not carry cargo on the vehicle's center of gravity. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of the vehicle. This helps maintain stability by centralizing weight. Because any vehicle is sensitive to steer...
Owners Manual
Page 38
... start the engine. Choke Knob Always lower and latch the bed after tilting. Warm the engine up using the choke and throttle until the idle speed is stable, and then push the choke knob back. Be careful not to the left of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering the bed. Driving with the cargo bed...
... start the engine. Choke Knob Always lower and latch the bed after tilting. Warm the engine up using the choke and throttle until the idle speed is stable, and then push the choke knob back. Be careful not to the left of your body, such as hands or arms, between the bed and ROPS or vehicle frame when lifting and lowering the bed. Driving with the cargo bed...
Owners Manual
Page 46
... starter will overheat and the battery power will return to the starter can be used for the ignition switch, and one spare key. Do not turn the ignition switch key to the "START" position with the engine running, or damage to "ON" position. j Keys This UV has a key, which is used . Upon release, key will drop temporarily. All electrical equipment can result. ○The vehicle is equipped with the key is a key...
... starter will overheat and the battery power will return to the starter can be used for the ignition switch, and one spare key. Do not turn the ignition switch key to the "START" position with the engine running, or damage to "ON" position. j Keys This UV has a key, which is used . Upon release, key will drop temporarily. All electrical equipment can result. ○The vehicle is equipped with the key is a key...
Owners Manual
Page 58
... refer to a safe operating condition. Front Final 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. Operate only in enclosed areas. DO NOT run the engine in a well-ventilated area. Fuel ...Enough fuel in tank, no leaks. The time required is cold), no leaks. DANGER Exhaust gas contains carbon monoxide, a colorless...
... refer to a safe operating condition. Front Final 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. Operate only in enclosed areas. DO NOT run the engine in a well-ventilated area. Fuel ...Enough fuel in tank, no leaks. The time required is cold), no leaks. DANGER Exhaust gas contains carbon monoxide, a colorless...
Owners Manual
Page 80
...; 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 j D D D D D D • MAINTENANCE AND ADJUSTMENT 79 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 j D D D D D D • MAINTENANCE AND ADJUSTMENT 79 FREQUENCY First Service OPERATION Fuel hose-replace 5 years (D) Regular Service Every 500...
Owners Manual
Page 88
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 up any sediment. Filler Opening C. Dispose of oil that is a toxic...
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 up any sediment. Filler Opening C. Dispose of oil that is a toxic...
Owners Manual
Page 91
... easily and picks up by running the vehicle. Fill the transmission case up to the spec- • A. 90 MAINTENANCE AND ADJUSTMENT Oil Change WARNING NOTE The exhaust system can cause an accident and injury. If the gasket is damaged, replace it with the hook. • Lift Remove the filler plug. • ○Before draining the oil, warm it up any oil that inadvertently gets on...
... easily and picks up by running the vehicle. Fill the transmission case up to the spec- • A. 90 MAINTENANCE AND ADJUSTMENT Oil Change WARNING NOTE The exhaust system can cause an accident and injury. If the gasket is damaged, replace it with the hook. • Lift Remove the filler plug. • ○Before draining the oil, warm it up any oil that inadvertently gets on...
Owners Manual
Page 103
... covers the idle speed adjustment. DO NOT run the engine in a well-ventilated area. Operate only in enclosed areas. 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. Clamps (6 p.c.s.) D. the gear shift lever in accordance with the hook. • Lift Remove • screw. Air Intake Ducts (2 p.c.s.) C. the cover plate on the idle...
... covers the idle speed adjustment. DO NOT run the engine in a well-ventilated area. Operate only in enclosed areas. 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. Clamps (6 p.c.s.) D. the gear shift lever in accordance with the hook. • Lift Remove • screw. Air Intake Ducts (2 p.c.s.) C. the cover plate on the idle...
Owners Manual
Page 112
.... • Turn Depress the brake pedal. The brake light should be inspected in an accident. j A. Brake Light Switch When the brake pedal 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 Pedal B. 10 mm (0.4 in.) it immediately. If brake lever travel . MAINTENANCE AND ADJUSTMENT 111 WARNING Air in...
.... • Turn Depress the brake pedal. The brake light should be inspected in an accident. j A. Brake Light Switch When the brake pedal 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 Pedal B. 10 mm (0.4 in.) it immediately. If brake lever travel . MAINTENANCE AND ADJUSTMENT 111 WARNING Air in...
Owners Manual
Page 113
Throttle Pedal A. Brake Light Switch B. C. Lights later. adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. D. B. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. 112 MAINTENANCE AND ADJUSTMENT Adjustment light • Brake pedal. switch is located above the brake j A. Brake Light Switch Adjusting Nut Lights sooner.
Throttle Pedal A. Brake Light Switch B. C. Lights later. adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. D. B. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. 112 MAINTENANCE AND ADJUSTMENT Adjustment light • Brake pedal. switch is located above the brake j A. Brake Light Switch Adjusting Nut Lights sooner.
Owners Manual
Page 127
... referring to the Service Manual for Washing • • • Before washing, precautions must be taken to inspecting for build-up of debris or flammable material in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Muffler rear opening with sea water or exposed to cool, then remove any collected debris. cover with tape. Air cleaner intake (middle of fire.
... referring to the Service Manual for Washing • • • Before washing, precautions must be taken to inspecting for build-up of debris or flammable material in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Muffler rear opening with sea water or exposed to cool, then remove any collected debris. cover with tape. Air cleaner intake (middle of fire.
Owners Manual
Page 132
... cold • Air filterisclogged • 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...
... cold • Air filterisclogged • 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...