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Mule 600 - Arizona Kawasaki

1. 56 GENERAL 31 Throttle linked choke system 56 Lighting Electrical Accessory Connector 31 Jump Starting 57 31 Moving Off tede ete bebes 59 Cargo Bed itt e ERE RR 32 Biakingz siano uec 59 Tailgate 2c luii ire 32 Stopping the Engine 60 Cargo Bed eee eerte 32 Parking the Mule 60 Choke a 34 Hi Lo Shifting KAF4004A 62 Engine Oil Temperature Warning Light Reversing Gears 63 35 2WD 4WD Shifting KAF400A 63 Fuel Tank iini Rides 36 Shifting the 64 Fuel Gauge 38 Catalytic 65 Glove 39 SAFE OPERATION 67 Front Cargo Compartment 39 Unfamiliar Terrain 67 Ignition Switch eeeenee 41 Driving in Reverse 68 KOyS cc enira ras de plur
2. A WARNING Oil on tires can make them slippery which can cause an accident and injury When draining or filling the gear case be careful that no oil gets on the tires or rims Clean off any oil that inadvertently gets on them with soap and water e After the oil has completely drained out install the drain plug and gasket If the gasket is damaged replace it with a new one Tightening Torque Drain Plug 20 N m 2 0 kgf m 15 0 16 e Fill the gear case up to the bottom thread of the filler opening with a high quality oil as specified in the table Front Final Gear Case Oil about 0 35 L 0 37 US qt Oil Capacity API GL 5 SAE140 or API GL 6 SAE90 Hypoid gear oil for Limited Slip Differentials Oil Type e Install the filler cap Transmission Case Oil In order for the transmission differential pinion and ring gears to function properly check the oil level and change the oil in accordance with the Periodic Maintenance Chart A WARNING Vehicle operation with insufficient deterio rated or contaminated oil causes acceler ated wear of the transmission differential pinion and ring gears and may result in seizure Seizure can lock the rear wheels and skid the rear tires with consequent loss of control Check the differential oil accord MAINTENANCE AND ADJUSTMENT 85 ing to the periodic maintenance chart Oil Level Inspection e Park
3. CORP U S A LINCOLN NE This structure meets ROPS requirements for wheeled tractors peer wel jn uu i This also meels P PULL OFF oof Crush resistance requiremen GAUGE TS CHAWFER 2 V 2 56030 0096 CF03403BM2 C 0 039598 5 14 16 CONTROL INFORMATION THIS EQUIPMENT MEETS U S EPA EVP STANDARDS PROPOSITION AND EZA CALIFORNIA EVP EWISSION REGULATIONS ee ies FOR SHALL OFF ROAD ENGINES FLUSH EYES ACID ACCESSORIES EPA EQUIPMENT FAMILY 66666554 Bases rcu ise is CAN CAUSE CARB EVP FAMILY 1 55555559 BLINDNESS OR FLAMES BLINDNESS OR INJURY SMOKING SEVERE BURNS HELP FAST DATE OF HFG KEEP QUT OF REACH OF CHILDREN n EE Kawasa THE STATE OF CALIFORNIA TO CAUSE MR CANCER WASH HANDS AFTER HANDLING 5PSYMBWPD MOTORS WANUFACTURING __ 28 LOCATION OF LABELS 7 CF03962B 5 LOADING INFORMATION 29 LOADING INFORMATION A WARNING Incorrect loading improper installation or use of accessories or modification of your vehicle may result in an unsafe operating condition Before you operate it make sure that the vehicle is not overloaded and that you have followed these instructions With the exception of genuine Kawasaki Parts and Accessories Kawasaki has no control over the de sign or application of accessories In some cases improper installation or u
4. Remember e Some hills are too steep Use common sense e Never drive past your limit of visibility If you can t see what is on the other side of the crest of a hill slow down until you can get a clear view e Don t turn sideways to the hill e If you get stuck on a hill roll slowly straight back down using the brake with the gear shift lever left in the High and L Low position for KAFA00A or Forward position for KAF400B NOTE O When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking This is caused by the ve hicle s automatic transmission which releases the engine at very low speed to prevent it from stalling Use the brakes to control the vehicle s speed Descending Hills Slow down or stop at the top of a hill so you can pick a straight safe path for descent to avoid any ob stacles Normally you should descend straight down a hill since driving at an angle could cause the vehi cle to lean to one side and possibly tip over Proceed slowly and cautiously Apply the brake as necessary Be careful if the surface is loose because the tires are more likely to skid and braking effectiveness will be reduced Turning while descending a slope must be done very carefully and gradually to avoid tipping the ve hicle over A WARNING Riding sideways across a hill may cause the vehicle to overturn causing severe injury or
5. Service more frequently when operated in mud dust or other harsh riding conditions Emission Related MAINTENANCE AND ADJUSTMENT 75 FREQUENCY Whichever First Service Regular Service comes first After 50 hrs Every 250 Every 500 OPERATION or 1 000 km hrs or 5 000 f 000 km of of use km of use Every use Converter belt inspect o Converter driven pulley shoe inspect Converter air cleaner element clean e Converter dust or water drain e O Fuel filter change e Fuel hoses and connections inspect D O Fuel system cleanliness inspect e o Spark plug clean and gap e O Valve clearance inspect D Engine oil change 1 year Oil filter replace e O Throttle pedal play inspect LE e O Idle speed adjust e Spark arrester clean e 76 MAINTENANCE AND ADJUSTMENT FREQUENCY Whichever First Service Regular Service comes first After 50 hrs Every 250 Every 900 OPERATION or 1 000 km jhrs or 5 000 000 km of CNET S of use km of use ise Fuel hose replace 5 years D O Evaporative emission control system function CHASSIS Steering inspect e Steering and axle shaft joint dust boots inspect D Brake pedal play inspect e e Parking brake lever inspect Brake hose pipe inspect D Brake fluid level inspect e e Brake wear inspect D Tire wear inspect e e Brake light sw
6. 4 Kawasaki Includes Important Safety Information Operating Instructions Maintenance and Storage MULE 610 4x4 600 Utility Vehicle Read this manual carefully It contains safety information OWNER MANUAL Quick Reference Guide This Quick Reference Guide will assist you in finding the information you re looking for A Table of Contents is included after the Foreword GENERAL INFORMATION HOW TO OPERATE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE Whenever you see the symbols shown below heed their instructions Always follow safe operat ing and maintenance practices A DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE NOTICE is used to address practices not re lated to personal injury NOTE O NOTE indicates information that may help or guide you in the operation or service of the vehicle A WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of Cali fornia to cause cancer and birth defects or other reproductive harm EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and ex haust emission
7. 90 Engine Air 90 Spark Arrester oed 93 Throttle 94 Choke 96 Carb retor 98 Fuel System 101 ein ett oe 102 Evaporative Emission Control System 102 Belt Drive Torque Converter 103 Belt Drive Torque Converter Air Cleaner 104 Brak6S iae ende mu 107 Brake 107 Brake Light 109 Parking Brake 111 Steering 112 Wheels eee ee teet ent 112 ic t 112 Wheel Nuts sssseeeeenn 112 T te 112 Joint Boots oti eee aede 114 S spehSiOM 115 Belts agone tg eds 116 Headlight 117 Battery sone etie itle iib 117 actos 123 General Lubrication 124 Cleaning iere eerie 124 Bolt and Nut Tightening 126 STORAQGE ub eoi e en tede 127 BASIC SAFE DRIVING 9 BASIC SAFE DRIVING Knowing and following these rules for safe oper
8. A Gear Shift Lever R Reverse Position Neutral Position H High Position L Low Position NOTE O Before shifting make certain that the vehicle is completely stopped The gear shift lever cannot be shifted when the vehicle is in motion When shifting the lever from L to N if it is hard to move the shift lever passing H position and does not move to N position return the shift lever to L once and repeat to move the lever to N position slowly Reversing Gears HOW TO OPERATE 63 2WD 4WD Shifting KAF400A e Release the throttle pedal and stop the vehicle e When you want to operate the vehicle in reverse stop the vehicle completely allowing the engine to slow to idling speed and move the gear shift lever to the R Reverse position NOTICE Do not shift from High or L Low to Reverse and vice versa for KAF400A or F Forward to Reverse and vice versa for KAF400B when the vehicle is mov ing or with the engine running above idling speed or the transmission could be dam aged e Pull the stopper under the 2WD 4WD shift lever knob and while holding it against the knob move the shift lever to the all way down AWD e To shift back into 2WD position pull and hold the stopper then move the shift lever all the way up 2WD NOTE OWhen the shift lever is moved from 2WD to
9. death Do not turn sideways to the hill Remember e Stop and look for obstacles before descending a hill e Go straight downhill e Go slowly e If you must turn do so carefully and gradually SAFE OPERATION 71 NOTE OWhen the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking This is caused by the ve hicle s automatic transmission which releases the engine at very low speed to prevent it from stalling Use the brakes to control the vehicle s speed 72 SAFE OPERATION Traversing Hillsides Sliding and Skidding When driving across the side of a hill reduce vehi cle speed and exercise extreme caution to prevent tipping or loss of control Avoid hills with slippery sides that will cause you to lose traction Also avoid traversing hillsides covered with rocks or other ob stacles which may cause you to lose your balance or tip over When driving on soft terrain steer slightly uphill to keep the vehicle on a straight line across the hillside Ifthe vehicle begins to tip steer downhill if possible to regain control Obviously on slippery or loose surfaces special care is required Sliding any vehicle may be haz ardous because the wheels may suddenly regain traction and cause the vehicle to tip or overturn Therefore never drive over your head or when you are unsure or unprepared for the surface Often you can correct a skid by turni
10. OThe vehicle is equipped with a starter lockout switch This switch prevents the electric starter from operating when the gear shift lever is in the High and L Low for KAF400A or Forward for KAF400B or Reverse position Keys This UV has a key which is used for the ignition Switch and one spare key Included with the key is a key number which is stamped on the key itself Record the key number in the space provided and store the number in a safe place 96 REESE o CH16007BM2 B Key Number Write your key number here In the event you lose your keys you will need the key number to have a duplicate made If you cannot locate your key number contact the dealer where you purchased your Kawasaki UV It s possible the dealer may have the number in its records If the key number is lost completely you will need to replace the ignition switch Contact your Kawasaki dealer to purchase addi tional spare keys either using your original key as a master or using the key code on the tag or your key Store one key at home and keep another spare in your wallet or riding gear in case the original is lost GENERAL INFORMATION 43 Hour Meter The hour meter shows the total hours that the vehi cle has been operated This meter cannot be reset NOTE The data
11. Wash the vehicle in fresh water if it has been ex posed to salt water or operated in muddy conditions A WARNING Wet brakes provide greatly reduced effi ciency and could lead to an accident and injury After operation in water always apply the brakes long enough for friction to dry the linings Also the brake that gets wet may wear out faster Check for brake wear more frequently if the vehicle is used in water Remember e Avoid driving through water whenever possible e Don t drive in deep and fast moving water e Dry out the brakes 74 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor dance with the Periodic Maintenance Chart to keep the Mule in good running condition The initial mainte nance is vitally important and must not be neglected If you are in doubt as to any adjustment or vehicle operation please ask your authorized Kawasaki dealer to check the Mule Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect mainte nance or improper adjustment done by the owner Periodic Maintenance Chart In addition to the following items always perform the Daily Checks listed in the HOW TO OPERATE chapter e Clean adjust lubricate replace parts as necessary D Service to be performed by an authorized Kawasaki Dealer or someone equally competent
12. 2 and evaporative emission 3 control systems in compliance with applicable regulations of the United States Environmental Protections Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the intake manifold Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of the crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a catalytic converter in the muffler a modified carburetor and ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thor ough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere 3 Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and fuel tank Also vapors caused by fuel evaporation in the fuel system are not vented into the atmos
13. 4WD the transmission shifts immediately When the shift lever is moved from 4WD to 2WD the transmission may not shift all the way into 2WD until the vehicle has rolled a short distance 64 HOW TO OPERATE Shifting the Differential NOTE O Do not operate the differential shift lever if the ve hicle is moving faster than 8 km h 5 mph Shifting to Locked Axle Mode e Pull the stopper under the differential shift lever knob and while holding it against the knob move the shift lever all the way down LOCK 2WD 4WD Shift Lever Stopper 2WD position AWD position com A Differential Shift Lever B Stopper C Differential Unlocked Axle Mode Position UN LOCK D Locked Axle Mode Position LOCK Shifting to Differential Unlocked Axle Model e Pull and hold the stopper then move the shift lever all the way up UN LOCK NOTE O When the shift lever is moved the differential may not immediately lock or unlock until the vehicle has rolled a short distance HOW TO OPERATE 65 Catalytic Converter This vehicle is equipped with a catalytic converter in the exhaust system The converter react with car bon monoxide hydrocarbons and nitrogen oxides to convert them into carbon dioxide water nitrogen and oxygen resulting in much cleaner exhaust gases to be discharged into the atmosphere For proper operation of the catalytic converter the fol
14. GENERAL INFORMATION 47 A WARNING If the vehicle should move after it is parked it might be damaged or cause injury Be sure to apply the parking brake before leaving the vehicle 48 GENERAL INFORMATION Parking Brake Warning Light Seat The parking brake warning light goes on when the The seat can be raised for vehicle maintenance parking brake is applied with the ignition switch in and adjustment the position e Pull up on the rear edge of the seat NOTE O This light shows only that the parking brake is on A It does not show the degree of parking brake ap plication A Seat Raised Position A Parking Brake Warning Light Seat Belts The vehicle is equipped with lap style seat belts for operator and passenger Always wear the seat belts when operating and riding in the vehicle A Seat Belt B Latch Plate C Buckle GENERAL INFORMATION 49 A WARNING Not wearing a seat belt or wearing one im properly can result in serious injury or death in the event of an accident Make certain the driver and passenger always wear their seat belts properly WARNING Operator and passenger must be able to place both feet flat on the floorboards while seated upright with their backs against the seatbacks To wear the seat belt properly follow this proce dure 1 Place the belt across your lap as low on your hips as possible taking
15. Make sure the cargo will not move around while the vehicle is moving Recheck cargo security as often as possible while the vehicle is stopped and adjust as necessary NOTICE The front body work and fenders are not designed to carry cargo or to support your weight They may break 30 LOADING INFORMATION e Always subtract trailer tongue weight from the Maximum Load capacity Refer to the Trailer Hitch Bracket section in the General Informa tion chapter Maximum Vehicle Load Weight of operator passenger and cargo must not exceed 420 kg 924 Ib e This vehicle is not designed to carry passengers in the cargo bed Installing additional passenger seating or carrying passengers in the cargo bed can cause changes in vehicle handling A WARNING Passengers riding in the cargo bed can be tossed about or even thrown out causing se rious injury or death Do not install seating or carry passengers in the cargo bed GENERAL INFORMATION 31 GENERAL INFORMATION M Lighting Electrical Accessory Brake Pedal Connector The brake pedal is the left pedal on the foot board The lighting electrical accessory 12 volt connector Depress the pedal to slow or stop the vehicle is located on the dashboard An auxiliary light or an accessory may be con nected to this connector A Brake Pedal B Throttle Pedal A Accessory Connector B Ignition Switch NOTICE Do not connect a ligh
16. high spots indicate internal damage requiring tire replacement e Remove any imbedded stones or other foreign particles from the tread Joint Boots In accordance with the Periodic Maintenance Chart inspect the joint boots on the front axles tie rod ends and steering knuckles for cracks holes damage or deterioration If there is any one of them have the joint boot replaced by an authorized Kawasaki dealer 2 200008 6 A Steering Knuckle B Tie Rod C Front Axle KAF400A D Joint Boots Suspension Rear Shock Absorber Spring Force Adjustment The spring adjusting sleeves on the rear shock ab Sorbers have 5 positions so that the springs can be adjusted for different riding and loading conditions p i CL230048 6 A Shock Absorber B Adjusting Sleeve MAINTENANCE AND ADJUSTMENT 115 A Adjusting Sleeve If the spring action feels too soft or too stiff have the sleeves adjusted by an authorized Kawasaki dealer in accordance with the following table e Turn the adjusting sleeves on the shock absorbers to the desired position with the hook wrench 116 MAINTENANCE AND ADJUSTMENT Spring Action A WARNING Uneven shock absorber adjustment can cause poor handling and loss of stability which could lead to an accident Always adjust the shock absorbers on the left and right side to the same setting Seat Belts In acco
17. Latch 17 Tail Gate 18 Handgrip LOCATION OF PARTS 17 18 Handgrip 21 Latch 25 Fuel Tank 19 Air Cleaner Belt Drive 22 Dashboard 26 Fuel Tank Cap Torque Converter 23 Tail Brake Light 27 Fuel Gauge 20 Belt Drive Torque Converter 24 Muffler 18 LOCATION OF PARTS Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light Parking Brake Warning Light Hour Meter Gear Shift Lever Front Cargo Latch 2WD 4WD Shift Lever KAF400A Ignition Switch Accessory Connector 39 Glove Compartment 40 Brake Fluid Level 41 Brake Light Switch 42 Light Switch 010028 LOCATION OF LABELS 19 LOCATION OF LABELS All warning labels which are on your vehicle are repeated here Read labels on your vehicle and un derstand them thoroughly They contain information which is important for your safety and the safety of anyone else who may operate your vehicle There fore it is very important that all warning labels be on your vehicle in the locations shown If any label is missing damaged or worn get a replacement from your Kawasaki dealer and install it in the correct po sition NOTE The sample warning labels in this section have part numbers to help you and your dealer obtain the correct replacement O Refer to the actual vehicle label for model specific data grayed out in the illustration 1 Warning Off Highwa
18. OPERATION Driving in Reverse Driving in 4WD KAF400A Start the engine following the procedure in the Starting the Engine section Before shifting into re verse stop the vehicle completely Refer to the Gear Shift Lever in the Shift Levers section and Revers ing Gears section Turn around and look behind you before backing up to be sure there are no obstacles or people in your way Gradually open the throttle and begin backing up cautiously To stop while driving in reverse close the throttle and gradually apply the brake Avoid sudden appli cation of the brake NOTICE Do not operate the gear shift lever to change gears while driving the vehicle in reverse or the transmission may be damaged Remember e Look behind you before backing up e Open the throttle gradually e To stop gradually apply the brake AWD gives greater traction when you are climb ing steep inclines or driving on bumpy sandy or snowy surfaces It also helps break loose with the differential locked under certain circumstances for example when the vehicle is stuck in the mud If maximum torque is needed in these situations shift into the low position with the shift lever Refer to the Shift Levers section and 2WD 4WD Shifting KAF400A Shifting the Differential and Hi Lo Shifting KAF400A sections NOTE O Do not drive 4WD on paved surfaces because itincreases tire and driv
19. a fire and can result in property damage or severe personal injury Do not idle or park your vehicle in an area where tall or dry vegetation or other flammable materials could come into con tact with the muffler or exhaust pipe A WARNING The engine and exhaust system get ex tremely hot during normal operation and can cause serious burns Never touch a hot engine exhaust pipe or muffler during operation or after stopping the engine e Stop the vehicle on a level surface NOTICE Avoid parking on steeply inclined surfaces e When the engine has stopped apply the parking brake to help prevent the vehicle from rolling HOW TO OPERATE 61 WARNING Gasoline is extremely flammable and can be explosive under certain conditions A Parking Brake Lever A WARNING If the vehicle should move after it is parked it might be damaged or cause injury Be sure to apply the parking brake before leaving the vehicle e Remove the ignition switch key to prevent unau thorized use e When parking inside a garage or other structure be sure the structure is well ventilated and the ve hicle is not close to any source of flame or sparks This includes any appliance with a pilot light 62 HOW TO OPERATE Hi Lo Shifting KAF400A Shifting to High or Low Range e Stop the vehicle completely e Move the shift lever to the L Low or H High positions
20. assist us in resolving your inquiry please include copies of related receipts and any other pertinent informa tion including the name of the dealership personnel with whom you have been working Upon receipt of your correspondence Kawasaki Motors Corp U S A will contact the dealership and work with it in resolving your problem YOUR WARRANTY OWNER SATISFACTION 133 Want to Contact Kawasaki This owner s manual should answer most of your questions about your Kawasaki Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you Please send your correspondence to Consumer Services Kawasaki Motors Corp U S A P O Box 25252 Santa Ana CA 92799 5252 949 460 5688 134 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly a program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands When using your Kawasaki Utility Ve hicle UV please follow these Tread Lightly guidelines Tread Lightly T se responsibly on designated roads and trails or in permitted areas Respect the rights of others including private property owners and all recreational trail users campers and others to allow them to enjoy their recreational activities undisturbed Ese yourself by obtaining travel maps and regulations from public agencies planning for your tr
21. bed to support it with the hook e Remove the cover plate on the idle adjusting screw e Loosen the axel lever stopper screw on the base plate above the transmission case and the idle ad justing screw on the engine MAINTENANCE AND ADJUSTMENT 99 Axel Lever Stopper Screw Base Plate Axel Lever Idle adjusting Screw Cover Plate Link Lever mmoou e Adjust the idle speed to the lowest stable speed by turning the idle adjusting screw located on the carburetor Idle Speed 1 175 75 r min rpm 100 MAINTENANCE AND ADJUSTMENT e Depress and release the throttle pedal a few times to make sure that the idle speed does not change Readjust if necessary 6 A Idle Adjusting Screw B Throttle Link C Choke Cable D Carburetor e After adjustment screw in the idle adjusting screw on the base plate until it lightly touches the link lever e Finally screw in the axel lever stopper screw until it keeps clearance by 1 mm to the axel lever NOTE O The idling speed could become unstable with the throttle valve stuck closed if the adjustment screw is turned excessively MAINTENANCE AND ADJUSTMENT 101 Fuel System Accumulation of moisture or sediment in the fuel system can restrict the flow of fuel and cause carbu retor malfunction The system should be checked in accordance with the Periodic Maintenance Chart A WARNING Gasoline is extremely flammable a
22. care that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Adjust the seat belt for a SNUG FIT A Buckle B Latch Plate 50 GENERAL INFORMATION EI To tighten the belt pull on the end of the belt com To unfasten the belt press the red button in the ing from the latch plate To loosen the belt pull the buckle latch plate at a right angle to the belt A Red Button A WARNING Too much belt slack could reduce its protec tion effectiveness in an accident Always ad just the belt to a SNUG FIT Throttle Pedal GENERAL INFORMATION 51 Trailer Hitch Bracket Accessory The throttle pedal is the right pedal on the floor board Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throt tle pedal returns normally before starting the engine In addition there must be adequate throttle pedal play and correct throttle stop position adjustment Refer to the Maintenance and Adjustment chapter for the throttle pedal adjustment procedure A Throttle Pedal This vehicle can be equipped with an optional bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage observe the following precautions A WARNING Improper towing of a loaded trailer could cause an accident resulting in serious
23. common sense and good judgement are your best defenses against accident and injury in everything you do Your safety and the safety of others depends on you and your common sense Use good judgement in the operation of this or any other motor vehicle This vehicle is designed for an operator and one passenger only Never carry persons in the cargo bed Refer to the Loading Information chapter be fore operating this vehicle Novice operators should practice braking and turn ing in an open off highway area away from other vehicles and persons The terrain should be flat and free of obstacles with either a loose or hard dirt sur face but not a mixture of both A WARNING Incorrect loading improper installation or use of accessories or modification of your vehicle may result in an unsafe operating condition Before operation make sure that the vehicle is not overloaded and that you have followed the instructions in the Load ing Information chapter Unfamiliar Terrain Before driving in a new area be sure to check for hidden obstacles or hazards Keep your speed down until you know the area well You must know the terrain you intend to drive on and be familiar with your machine and its handling characteristics Use existing trails and stay away from hazardous areas Such as steep rocky slopes or swamps Be cautious when visibility is limited as you may not be able to see obstacles in your path 68 SAFE
24. ensure safe reliable operation If any irregularities are found during 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 A WARNING Failure to perform these checks before operation may result in serious damage or an accident Al ways perform daily checks before operation A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area tute teet Thats Enough fuel in tank no leaks Engine oil ees Oil level between H and L lines when engine is cold no leaks TIEGS dnb sene M Air pressure when cold KAF400A KAF400B Front 47 kPa 0 47 kgf cm 7 psi 47 kPa 0 47 kgf cm 7 psi Rear 97 kPa 0 97 kgf cm 14 psi 110 kPa 1 1 kgf cm 16 psi Check for cuts cracks damage or excessive wear Check for any imbedded stones or other foreign particles in tread Front Final Gear Case No oil leaks KAF400A HOW TO OPERATE 55 Transmission Case Oil Oil level between H and L lines no leaks Thitottle Throttle pedal free play 2 5 mm 0 1 0 2 in Throttle pedal oper
25. first Moving Off HOW TO OPERATE 59 Braking e Depress the brake pedal e Put the gear shift lever into the High and L Low position for KAF400A or F Forward posi tion for KAF400B e Release the parking brake e Gradually increase engine speed by pressing on the throttle pedal NOTE O Practice starting and stopping using the brakes until you are familiar with the controls NOTE OWhen the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking This is caused by the ve hicle s automatic transmission which releases the engine at very low speed to prevent it from stalling Employ the brakes to control the vehicle s speed e Release the throttle pedal completely e Press on the brake pedal evenly and firmly A WARNING Carrying cargo or towing a trailer will in crease braking distances Failure to allow for increased braking distance may result in accident and injury Always allow more dis tance to stop when carrying cargo or towing a trailer 60 HOW TO OPERATE Stopping the Engine Parking the Mule e Release the throttle pedal completely e Put the gear shift lever into the N Neutral posi tion e Apply the parking brake to help prevent the vehicle from rolling e Turn the ignition switch key to the OFF position A WARNING Operating or parking the vehicle near flammable materials can cause
26. in jury or death Never carry a passenger in a trailer Never load more than 40 kg 88 Ibs tongue weight on the towing bracket Do not operate the vehicle faster than 16 km h 10 mph when towing Remember that tow ing a trailer increases braking distance Do not tow more than 500 kg 1 100 Ibs trailer weight trailer plus cargo weight Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the vehicle and have an accident 52 GENERAL INFORMATION CN290008 6 A Trailer Hitch Bracket Installation Position Winch Installation There is a location on the frame of this vehicle be hind the front bumper designed for winch installa tion Kawasaki offers winches and installation brack ets as optional equipment Contact an authorized Kawasaki dealer for more information To avoid injury and property damage observe the following precautions A WARNING Improper installation or operation of a winch could cause an accident resulting in serious injury or death Do not operate or install winch without reading and understanding the operators manual supplied with the winch GENERAL INFORMATION 53 CN300008 A Winch installing position 54 HOW TO OPERATE HOW TO OPERATE Daily Checks Check the following items each day before operation The time required is minimal and habitual performance of these checks will help
27. is maintained even if the battery is dis connected The hour meter shows the operating hours to a maximum of 5 digits The value is shown to the nearest 0 1 hr until the total reaches 10 000 hrs after which the meter counts in complete hours only O When the figures come to 99999 they turn back to 0 0 and start counting upward again when the vehicle is operated A Hour Meter 44 GENERAL INFORMATION Light Switch Shift Levers Turn on the headlights and taillights by pushing the light switch in with the ignition switch key in the position The lights go off when the switch is pushed again A Light Switch This vehicle is equipped with three different shift levers the gear shift lever the 2WD 4WD shift lever KAF400A only and the differential shift lever Gear Shift Lever The gear shift lever is located on the dashboard to the right of the steering shaft The gear shift lever has four KAF400A or three KAF400B po sitions High and L Low for KAF400A or F Forward for KAF400B Neutral and Re verse Model Gear Position KAFA400A High L Low N Neutral Reverse Forward N Neutral Reverse KAF400B Make certain that the vehicle is completely stopped and the engine is idling before shifting from H High or L Low for KAF400A or
28. of gravity and that the higher the center of gravity the more likely the vehicle is to tip on uneven surfaces Slippery loose or bumpy surfaces on hills are es pecially hazardous Some hills are just too steep to climb Always use common sense and practice good judgement 70 SAFE OPERATION Climbing Hills Do not attempt to climb hills or steep inclines until you have mastered the controls and basic operating maneuvers of this vehicle Always go straight uphill and if the incline is steep and or the surface is loose use AWD with the differential locked for greater traction and in low range for maximum torque Avoid hills with slippery sides that will cause you to lose traction Do not climb hills where you cannot see far enough ahead If you cannot see what is on the other side of the crest of a hill slow down until you can get a clear view Don t apply power suddenly while climbing or the front wheels might rise off the ground If the vehicle does not have enough power to reach the top of the hill and stalls allow the vehicle to roll slowly straight back down the hill controlling its descent with the brakes Leave the gear shift lever in the High and L Low position for KAF400A or F Forward position for KAF400B until you stop at the bottom of the hill A WARNING Riding sideways across a hill may cause the vehicle to overturn causing severe injury or death Do not turn sideways to the hill
29. record we have pro vided space at the end of this manual where an authorized Kawasaki dealer or someone equally competent can record the maintenance You should also retain copies of maintenance work orders bills etc as verifica tion of this maintenance If there is a problem with the emission control system within the warranty period you will need to take it and any maintenance records to an authorized Kawasaki dealer for inspection and diagnosis Kawasaki will work closely with your dealer to resolve any warranty issues If you are unable to resolve any problem after consulting with the dealership management and need further assistance contact Kawasaki Motors Corp U S A at the following address Consumer Services Kawasaki Motors Corp U S A P O Box 25252 Santa Ana CA 92799 5252 866 802 9381 consumer services kawasaki usa com Tampering with Emission Control System Prohibited Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the act
30. tank cap is closed securely If gaso line is spilled on the fuel tank wipe it off im mediately Fuel Requirements Fuel Type This vehicle is certified to operate on unleaded regular grade gasoline only Use clean fresh unleaded gasoline with a mini mum Antiknock Index of 87 The Antiknock Index is posted on service station pumps in the U S A The octane rating of a gasoline is a measure of its re sistance to detonation or knocking The Antiknock Index is an average of the Research Octane Num ber RON and the Motor Octane Number MON as shown in the table below Minimum Octane Rating Method Rating RON MON Antiknock Index 2 87 NOTICE If engine knocking or pinging occurs use a different brand of gasoline of a higher octane rating If this condition is allowed to continue it can lead to severe engine dam age Gasoline quality is important Fuels of low quality or not meeting standard industry specifications may result in unsatisfac tory performance Operating problems that result from the use of poor quality or nonrec ommended fuel may not be covered under warranty Fuels Containing Oxygenates Gasoline frequently contains oxygenates alco hols and ethers especially in areas of the U S and Canada which are required to sell such reformu lated fuels as part of a strategy to reduce exhaust emissions GENERAL INFORMATION 37 The types and volume of fuel oxygenates ap prove
31. the ignition switch and be sure the fan has stopped turning 2 000006 6 A Cooling Fan B Screen The standard spark plug is shown in the table The spark plug should be taken out periodically in ac cordance with the Periodic Maintenance Chart for cleaning inspection and resetting of the plug gap Maintenance If the plug is oily or has carbon built up on it have it cleaned preferably in a sand blasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a brush Measure the gap with a wire type thickness gauge and adjust the gap if incorrect by bending the outer electrode If the insulator is cracked replace the plug Use the standard plug MAINTENANCE AND ADJUSTMENT 89 0 7 0 8 mm 0 028 0 032 in Spark Plug Standard Plug NGK BPR5ES 0 7 0 8 mm 0 028 0 032 in Tightening Torque 22 N m 2 2 kgf m 16 ft lb Spark Plug Removal e Raise the seat e Carefully pull the spark plug cap from the spark plug A Spark Plug Cap B Engine Oil Dipstick Cap e Unscrew the spark plug NOTE When installing the spark plug fit the plug cap se curely onto the spark plug and pull the cap lightly to make sure that it is properly installed 90 MAINTENANCE AND ADJUSTMENT Valve Clearance Engine Air Cleaner Valve and valve seat wear decrease valve clear ance upsetting valve ti
32. the vehicle on level ground e Lift the cargo bed and support it with the hook e Unscrew the oil filler plug and dipstick wipe its dipstick dry and insert it into the filler hole but DO NOT SCREW IT IN A Transmission Case B Dipstick C Oil Filler Plug NOTICE Be careful not to allow any dirt or foreign ma terials to enter the transmission case e Pull out the dipstick and check the oil level The oil level should be between the H High and L Low lines on the dipstick 86 MAINTENANCE AND ADJUSTMENT Oil Filler Plug and Dipstick Insert the dipstick into the filler hole but do not screw it in H High Line L Low Line Up e If the oil level is too high remove the excess oil using a syringe or other suitable device through the oil filler opening e If the oil level is too low add the correct amount of oil e Install the filler plug and dipstick NOTE Use the same type and brand of oil that is already in the transmission case Oil Change NOTE O Before draining the oil warm it up by running the vehicle Warm oil drains easily and picks up any sediment e With the vehicle level apply the parking brake se curely e Place an oil pan beneath the transmission case e Remove the drain plug A Transmission Case B Drain Plug C Guard Plate A WARNING The exhaust system can get extremely hot during norma
33. using a solution of baking soda and water Be sure that the lead connections are clean e Perform a visual inspection Inspect for defective or cracked case and cover and loose or damaged terminal posts or cables Replace battery and or cables immediately if any damage is found Battery Installation e Check that the rubber dampers on the battery holder and the battery case are properly in place e Putthe battery in place and route the battery vent hose through the hole in the floor board e Connect the capped lead to the terminal and then connect the black lead to the terminal e Put a light coat of grease on the terminals to pre vent corrosion e Cover the terminal with its protective cap e Reinstall the battery holder and rubber mud cover A DANGER Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive Use caution when handling batteries and do not expose them to spark or flame Read and understand the battery safety label NOTICE Do not reverse the battery connections or damage to the regulator rectifier unit will re sult Battery Characteristics The battery installed in this Mule is a conventional type and requires regular inspection to maintain the proper electrolyte level and a full charge In order to maximize battery life and ensure that it will provide the power needed to start your Mule you must properly maintain the batt
34. BIL with the gasoline in the fuel tank Fuel stabilizer additives inhibit oxidation of the fuel which minimizes gummy deposits Never store this product with gasohol in the fuel system Before storage it is recom mended that you drain all fuel from the fuel tank and carburetors See the STORAGE A Filling Cap chapter in this manual B Fuel Gauge Fuel Gauge The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank When the red indicator needle comes near the E Empty mark refuel at the earliest opportunity Glove Compartment GENERAL INFORMATION 39 Front Cargo Compartment A glove compartment is provided at the right end of the dashboard Store only light items to avoid damage to the inside of the compartment Release the plug in the bottom of the glove compartment to remove any water that may have entered Do not put items which must not get wet or dirty in it A Glove Compartment The front cargo compartment is located under the front cargo hood Store only light weight items in it to avoid damage to the inside of the compartment Do not put items which must not get wet or dirty in it A A Front Cargo Compartment B Hood Hood Opening Pull the hood latch release button and raise the hood until it locks 40 GENERAL INFORMATION A Latch Release Button A Latch Lever B Hood B Hood e After the hood is closed push
35. F Forward for KAF400B to R Reverse or vice versa Move the gear shift lever up or down as indicated on the label next to the shift lever Refer to the Reversing Gears section in the How to Operate chapter Gear Shift Lever Reverse Position Neutral Position High Position KAF400A only L Low Position KAF400A only or F Forward Position KAF400B only moou NOTICE Do not shift from High or L Low to Reverse and vice versa for KAF400A or F Forward to Reverse and vice versa for KAF400B when the vehicle is mov ing or with the engine running above idling speed or the transmission could be dam aged GENERAL INFORMATION 45 The KAF400A is equipped with a sub transmission to allow maximum transmission efficiency Use the low gearing for maximum torque at low speeds for climbing hills pulling a trailer or keeping constant low speeds The high gearing raises the speed range for ordinary off highway use Stop the vehicle before moving the Hi Lo shift lever NOTICE Use of the high range for heavy loads climb ing hills pulling a trailer and sustained low speed riding can lead to premature wear of the torque converter belt and pulleys Use low range for these conditions Refer to the Hi Lo Shifting section in the How to Operate chapter 2WD 4WD Shift Leve
36. Have the brake fluid changed by an authorized Kawasaki dealer MAINTENANCE AND ADJUSTMENT 109 Brake Light Switch When the brake pedal is depressed the brake light goes on The brake light switch should be inspected in accordance with the Periodic Maintenance Chart Inspection e Turn the ignition switch to the position e Depress the brake pedal The brake light should go on after about 10 mm 0 4 in of pedal travel A Brake Pedal B 10 mm 0 4 in e If it does not check the bulb and if necessary adjust the brake light switch Adjustment e Brake light switch is located above the brake pedal 110 MAINTENANCE AND ADJUSTMENT iam c B gt BL22005BM2 C A Brake Light Switch B Throttle Pedal e To adjust the brake light switch move the switch forward or rearward by turning the adjusting nut NOTICE To avoid damaging the electrical connec tions inside the switch be sure that the switch body does not turn during adjust ment A Brake Light Switch B Adjusting Nut C Lights sooner D Lights later Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked In accordance with the Periodic Maintenance Chart check that the parking brake lever functions properly Inspection A Parking Brake Lever e Pull the parking brake lever up and to the rear e After 8 to 12
37. Ib in the cargo bed A Latch B Handgrip C Fuel Tank Cap Maximum Cargo Bed Load 181 kg 400 Ib 34 GENERAL INFORMATION A WARNING e Overloading or improper use of the cargo bed can cause changes in handling which can lead to an accident Follow guidelines provided in the LOADING INFORMATION chapter e Passengers riding in the cargo bed can be tossed about or even thrown out causing serious injury or death Do not install seat ing or carry passengers in the cargo bed e Driving with the cargo bed tilted may be hazardous Failure to lower and lock the bed into place may cause serious injury or death Always lower and latch the bed after tilting e Lifting and lowering the bed could be dan gerous Be careful not to catch any part of your body such as hands or arms be tween the bed and ROPS or vehicle frame when lifting and lowering the bed Choke Knob The choke knob located on the dashboard to the left of the steering wheel provides a rich mixture for cold starting Pull the choke knob all the way to start the engine Warm the engine up using the choke and throttle un til the idle speed is stable and then push the choke knob back Refer to the Starting the Engine section in the How to Operate chapter for detailed information A Choke Knob NOTE Olf the choke is left on pulled out after the engine has warmed up spark plug fouling and poor fuel economy ma
38. OWNER SATISFACTION How Do I Get Warranty Service If there is a problem with your vehicle within the limited warranty period you will need to schedule a service appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and diag nosis You can go to any Kawasaki dealer for warranty repairs Your Kawasaki dealer will inspect your vehicle and give you the results of the inspection The dealer will perform the repairs at no cost to you if it is determined that the problem is covered by the warranty Kawasaki will work with your dealer to resolve any warranty issues No authorization for warranty work can be given until your vehicle has been inspected by a Kawasaki dealer What if am not Satisfied With My Warranty Service If you aren t satisfied with your dealership s repair work or operations it is best to discuss the situation with the appropriate dealership manager If you have already done this then contact the dealership s owner or general manager to request a review of the issue If you are unable to resolve a problem after consulting with the dealership management and need further as sistance contact Kawasaki Motors Corp U S A at the address below Please be certain to provide the model vehicle identification number VIN mileage or hours of use accessories dates that events occurred and what action has been taken by both you and your dealer Include the name and address of the dealership To
39. There should be 2 5 mm 0 1 0 2 in of free play A Brake Pedal B 2 5 mm 0 1 0 2 in e f the brake pedal has more or less free play than specified or the pedal action feels rough or MAINTENANCE AND ADJUSTMENT 107 catchy have the brake system inspected imme diately by an authorized Kawasaki dealer Brake Shoe Linings Brake Shoe Lining Wear Inspection In accordance with the Periodic Maintenance Chart have the brake shoe linings checked for wear by an authorized Kawasaki dealer Brake Fluid In accordance with the Periodic Maintenance Chart inspect the brake fluid level in the reservoir and change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Fluid Requirement Use heavy duty brake fluid only from a fresh un opened container marked DOT3 A WARNING Over time brake fluid can absorb moisture lowering its boiling point and reducing brake effectiveness Do not use fluid from a con tainer that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brakes Don t leave the reservoir cap off for any length of time to avoid moisture con tamination of the fluid Don t add or change brake fluid in the rain or during conditions of blowing dust or debris 108 MAINTENANCE AND ADJUSTMENT NOTICE Brake fluid quickly ruins painted surfaces Wipe up any spilled f
40. Tubeless 14 SPECIFICATIONS Rim Size Front Rear Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail Brake Light LOAD CAPACITY Maximum Vehicle Load Including occupants and cargo Maximum Cargo Bed Load A KAFA00A B KAFA00B MODEL INFORMATION MULE610 4 x 4 KAF400A MULE600 KAF400B 10 x 7 0 AT 10 x 8 5 AT 15 5 L 4 1 US gal 12 V 14 Ah 12 35 2 12V 5 21 W x2 420 kg 924 Ib 181 kg 400 Ib Specifications are subject to change without notice SERIAL NUMBER LOCATIONS 15 SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the vehicle They are the only means of identifying your particular machine from others of the same model type These serial numbers may be needed by your dealer when ordering parts In the event of theft the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it Frame No Engine No 0010158 Frame Number A Engine Number B Seat Raised Position 16 LOCATION OF PARTS LOCATION OF PARTS 1 Headlights 2 ROPS 3 Front Cargo Hood 4 Front Cargo Compartment 5 Steering Wheel 6 Seat 7 Seat Belts 8 Cargo Bed 9 Grille Front Bumper 10 Air Cleaner Intake 11 Parking Brake 12 Air Cleaner Carburetor 13 Battery 14 Suspensions 15 Carburetor 16
41. Weight 300kg I100lbs Trailer Plus Cargo Weight Do Hot Garry Passengers On Trailer eMODEL KAF4004 iw 56053 0503 CF03586BM2 C LOCATION OF LABELS 25 8 HOOK OPERATION Open the seat and operate the carrier s hook 56030 0081 CF03060BM2 C 7 KAF400B IMPORTANT INFORMATION eTires Front 22X 9 00 10 Rear 22X11 00 10 e6old Tire Pressure Front 47kPa 0 47kgf cm 7 1 Rear 110 1 lkef om 16psi Max Vehicle Load 420kg 924lbs Including occupants and cargo e Trailer Wax Trailer Tongue Weight d0kg 88168 Wax Trailer Weight 500kg 1100lbs Trailer Plus Cargo Weight Do Hot Garry Passengers On Trailer eMODEL KAFA00B 56053 0505 CF03588BM2 C 26 LOCATION OF LABELS 9 11 AWARNING CF03823BN8 C pif i n accessi KISS WARNING Gasoline is flammable Eng Ex pipe Dil filter Fire can cause severe injury or death 56070 1125 CF03082BM2 C Refuel in well ventilated area Shut engine off Keep away from flame or sparks PORTANT EMISSION CONTROL INFORMATION 56071 1501 U S EPA ARD CALIFORNIA EXH REGULATIONS FOR KXXA FF ROAD ENG KS DISPLACEMENT BOS DATE OF MANUFACTURE BOQ CF03150BM2 ENGINE FAMILY CF03857BM2 LOCATION OF LABELS 27 13 15 fT 1 MED BY KAWASAKI MOTORS
42. air cleaner intake rear ROPS top to prevent mois ture or small animals from entering e Put a cover over the vehicle to keep dust and dirt from collecting on it Removal from Storage A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area e Remove the plastic bags from the exhaust pipe and air cleaner intake e Clean the terminals of the battery charge the bat tery if necessary and install it in the vehicle e Make sure the spark plug is tight e Fill the fuel tank with fuel e Check all the points listed in the Daily Checks section e Lubricate as indicated in the General Lubrication section TROUBLESHOOTING GUIDE 129 TROUBLESHOOTING GUIDE Starter Motor Won t Turn e Engine overheated e Fuse failed be sure to check for cause of failure e much idling or low speed running not e Battery leads do not make good electrical contact enough air flow with battery terminals e Overloaded e Battery discharged e Wrong spark plug e Cooling fan screen clogged Engine Cranks But Won t Start e Engine oil low e No fuel in tank e Fuel filter clogged No Power e Water in fuel e Engine overheated e Choke is not used when engine is cold e Too much idling or low speed running not e Air filter clogged or intake blocked enough ai
43. at the rims like automotive rims are not symmetrical All wheels must be installed so that the valve stems are on the outside of the vehicle Wheel Nuts Check for wheel nut tightness in accordance with the Periodic Maintenance Chart Tightening Torque 29 39 3 0 4 0 kgf m 21 29 ft lb The front and rear tires are knobby tubeless tires When replacing tires check the valve stems and cores for damage Take care not to damage the tire sealing surfaces of the rims Standard Tires KAF400A Front 24 x 9 00 10 DUNLOP KT869M 24 x 9 00 10 DURO DI K968M Rear 24 x 11 00 10 DUNLOP KT869 24 x 11 00 10 DURO DI K968 KAF400B Front 22 x 9 00 10 DUNLOP KT901 22 x 9 00 10 DURO DI K109 22 x 11 00 10 DUNLOP 869 22 x 11 00 10 DURO DI K968 Tire Air Pressure when cold KAF400A KAF400B Front 47 kPa 0 47 47 kPa 0 47 kgficm 7 psi kgficm 7 psi Rear 97 kPa 0 97 110 kPa 1 1 kgf cm 14 psi kgf cm 16 psi NOTE Tires are an important part of the suspension of the vehicle Tire construction characteristics and tire inflation pressure can greatly influence vehicle handling Kawasaki recommends that you always replace tires with standard replacement tires as shown above It is also very important to have MAINTENANCE AND ADJUSTMENT 113 tires of the same type and size on all axles and at the same inflation pressure on each axle O Installation
44. at the proper level and change the oil and oil filter in accordance with the Periodic Main tenance Chart Not only do dirt and metal particles collect in the oil but the oil itself loses its lubricative quality if used too long A WARNING Vehicle operation with insufficient deterio rated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart in the owner s manual Oil Level Inspection e If the oil has just been changed start the engine and run it for several minutes at idle speed This A Dipstick amp Oil Filler Hole B Seatback e Pull up the dipstick wipe it dry and insert the dip stick till it bottoms NOTE Olt is important to insert the dipstick with its cham fered cap edge facing rearwards A Dipstick B Oil Filler Hole e Pull out the dipstick and check the oil level The oil level should be between the Full and L Low lines on the dipstick MAINTENANCE AND ADJUSTMENT 79 CLOMOOR A Dipstick B H High Line C L Low Line e f the oil level is too high remove the excess oil using a syringe or other suitable device e f the oil level is too low add the correct amount of oil through the oil filler hole Use the same type and brand of oil that is already in the e
45. ates smoothly and returns to rest position when released Steering uc eese Steering wheel free play 0 20 mm 0 0 8 in Action smooth without excessive play rough spots or strange noises Brakes 1 2 eei Check for braking effectiveness while test running Brake pedal free play 2 5 mm 0 1 0 2 in Brake fluid level between level lines no leaks Parking brake lever travel 8 12 clicks Electrical Equipment All lights and horn work Check for dirt on or damage to lights Battery eerie Electrolyte level between level lines in each cell Engine Cooling Fan Screen Check for mud and other debris 56 HOW TO OPERATE Starting the Engine Throttle linked choke system This vehicle is equipped with the choke that con trols the throttle operation without pressing the throt tle pedal when starting the engine Mechanism of the System e By pulling the choke knob out the choke valve in the carburetor starts to close e By further pulling the knob over the stepping re sponse throttle valve linked to the choke starts to open slightly You can feel this move by in creased resistance of the choke knob A Full Choke Stroke B Ordinary Choke Stroke C Throttle linked Choke Stroke Using this choke system start the engine with the following procedure A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon mono
46. ation will increase your satisfaction with your new Kawasaki vehicle Perform the Daily Checks Refer to the Daily Checks section for a list of items to check each day before use Habitual performance of these checks will help to insure safer more re liable usage Be sure that any irregularities found during these checks are corrected before operating the vehicle Drive Carefully and with Good Judgement We want you to be satisfied with your new Kawasaki vehicle so drive carefully safely and ex ercise good judgement Practice basic maneuvers so you can drive confidently and safely Read the Owner s Manual Read and understand this Owner s Manual This is especially important for inexperienced drivers Refer to this Owner s Manual if you have any ques tions Off Highway Use Only This vehicle is not an all terrain vehicle it is de signed and equipped to be a multiuse utility vehicle for off highway use only Operation on public roads is not recommended Occupant Capacity Make sure operators are 16 years or older with a valid driver s license Each occupant must be able to sit with back against seat feet flat on floor and hands on steer ing wheel handgrip or handhold The operator should be tall enough to wear the seat belt properly and reach all controls Passenger s should also be tall enough for the seat belt to fit properly and to be able to brace them selves as necessary by placing both feet firmly on the fl
47. clicks of lever travel the vehicle should not roll while parked e If it does adjust the parking brake lever Adjustment e Raise the seat MAINTENANCE AND ADJUSTMENT 111 e Loosen the locknut upper nut on the middle of the parking brake lever and turn the nut next to the locknut until the brake lever will only move 8 12 clicks upward A Locknut B Nut C Brake Lever e Tighten the locknut securely NOTE OBe sure to hold the cable end with a wrench to prevent the cable from twisting Olf the brake lever can not be adjusted with the nuts shown here or if there is any doubt as to the condition or braking effectiveness have the parking brake system inspected by an authorized Kawasaki dealer 112 MAINTENANCE AND ADJUSTMENT Steering Wheel Wheels In accordance with the Periodic Maintenance Chart check the steering wheel for the specified free play and smooth operation Free Play Inspection e Park the vehicle on level ground e Lightly turn the steering wheel left and right e There should be 0 20 mm 0 0 8 in of free play e there is excessive free play or strange noises or the steering feels rough or catchy have the steering system checked by an authorized Kawasaki dealer A 0 20 mm 0 0 8 in Rims The rims are a drop center tubeless tire design Take care not to damage the sealing surfaces of the tire or rim when removing or installing tires Note th
48. d a spare key in a secure location Traveled Distance Maintenance Performed Dealer Name Dealer Address 136 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 137 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address 138 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 139 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address 140 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address KAF400AE KAF400BE MNADA COV NAA AM 99 987 1765 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Printed in Japan Part No 99987 1765
49. d for use in unleaded gasoline by the U S Environmental Protection Agency include a broad range of alcohols and ethers but only two compo nents have seen any significant level of commercial use Gasoline Alcohol Blends Gasoline containing up to 10 ethanol alcohol produced from agricultural products such as corn also known as gasohol is approved for use NOTICE Avoid using blends of unleaded gasoline and methanol wood alcohol whenever possible and never use gasohol containing more than 5 methanol Fuel system damage and performance problems may result Gasoline Ether Blends The most common ether is methyl tertiary butyl ether MTBE You may use gasoline containing up to 15 MTBE NOTE O Other oxygenates approved for use in unleaded gasoline include TAME up to 16 7 and ETBE up to 17 296 Fuel containing these oxygenates can also be used in your Kawasaki 38 GENERAL INFORMATION NOTICE Never use gasoline with an octane rat ing lower than the minimum specified by Kawasaki Never use gasohol with more than 10 ethanol or more than 5 methanol Gaso line containing methanol must also be blended with cosolvents and corrosion inhibitors Certain ingredients of gasoline may cause paint fading or damage Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling When not operating your Kawasaki for 30 to 60 days mix a fuel stabilizer such as STA
50. d pull the air cleaner element out of the housing e Push a clean lint free towel into the air cleaner housing to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the carburetor the throttle may stick or be come inoperable resulting in a hazardous op erating condition MAINTENANCE AND ADJUSTMENT 91 NOTICE If dirt gets into the engine excessive engine wear and possible engine damage may oc cur A Element B Screw NOTE O Element installation is performed in the reverse order of removal O Install the housing cover with its snaps Element Cleaning e Remove the element see Element Removal e Remove the urethane foam element from the pa per element 92 MAINTENANCE AND ADJUSTMENT e Clean the foam element in a bath of high flash point solvent using a soft bristle brush e Squeeze it dry in a clean towel Do not wring the element or blow it dry the element can be dam aged e Inspect the foam element for damage If it is torn punctured or hardened replace it NOTE Replace the foam element after cleaning it five times or if it is damaged e Clean the paper element by tapping it lightly to loosen dust e Blow away the remaining dust by applying com pressed air from the inside to the outside from the clean side to the dirty side e Inspect the element material for damage If any part of the element is damaged
51. d the SAE 10W 30 SA front and rear tires with consequent loss of 20 10 0 10 20 30 40 control Check the differential oil according A 0A a2 50 104 to the periodic maintenance chart BLO3006BM2 C Oil Level Inspection e With the vehicle level front to rear and side to side remove the filler cap from the front final gear case MAINTENANCE AND ADJUSTMENT 83 A Front Final Gear Case B Filler Cap on the left side C Front Axle NOTICE Be careful not to allow any dirt or foreign ma terials to enter the gear case e Check the oil level The oil level should come to the bottom thread of the filler opening If it is low add oil through the oil filler opening as necessary A Front Final Gear Case B Filler Opening C Bottom Thread e Install the filler cap NOTE the same type and brand of oil that is already in the gear case Oil Change NOTE O Before draining the oil warm it up by running the vehicle Warm oil drains easily and picks up any sediment 84 MAINTENANCE AND ADJUSTMENT A Front Final Gear Case B Drain Plug e With the vehicle level place an oil pan beneath the gear case e Remove the filler cap and drain plug A WARNING Gear case oil is a toxic substance Dispose of used oil properly Contact your local au thorities for approved disposal methods or possible recycling
52. damage to the electrical system could result Refer to the Fuse Location label on the other side fuse case lid MAINTENANCE AND ADJUSTMENT 123 A Fuse Cases 30 A B Fuse Cases 10 A 124 MAINTENANCE AND ADJUSTMENT General Lubrication Cleaning In accordance with the Periodic Maintenance To prolong the life of your vehicle wash it down Chart have the general lubrication performed by an immediately after it has been splashed with sea wa authorized Kawasaki dealer or perform it referring ter or exposed to salt air or operated on rainy days to the Service Manual for this vehicle rough terrain or in dusty areas A WARNING 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 fire When operating the vehicle in conditions that allow debris or flammable material to collect in and around the vehicle inspect the engine electrical component and exhaust areas frequently If debris or flammable materials have collected park the vehicle outside and stop the engine Allow the engine to cool then remove any collected debris Do not park or store the vehicle in an enclosed space prior to inspecting for build up of debris or flammable materials Preparation for Washing Before washing precautions must be taken to keep water off the following parts e Muffler rear opening cover with a plastic bag
53. e Ignition switch cover the keyhole with tape e Air cleaner intake middle of the rear ROPS top close opening with tape or stuff in rags Where to be Careful Avoid spraying water with any great force near the following places e Front and rear brakes if water gets into the brake drums they will not work effectively until they have dried out e Under the seat if water gets into the ignition coils or into the spark plug cap it can ground out the spark When this happens the vehicle will not operate properly and the affected parts must be wiped dry NOTICE Coin operated high pressure spray wash ers are not recommended Water may be forced into bearings and other components causing eventual failure from rust and cor rosion Some soaps are highly alkaline and may leave a residue or cause spotting Semi gloss Finish To clean the semi gloss finish e When washing the vehicle always use a mild neu tral detergent and water e The semi gloss finish effect may be lost when the finish is excessively rubbed e f any doubt consult an authorized Kawasaki dealer MAINTENANCE AND ADJUSTMENT 125 After Washing e Remove the plastic bag and tape and open the air cleaner intake e Lubricate as indicated in the General Lubrication section e Test the brakes before operation e Start the engine and run it for 5 minutes to dry it thoroughly 126 MAINTENANCE AND ADJUSTMENT Bolt and Nut Tightening I
54. e charging rate can be reduced to the level required for this vehi cle s battery Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause inter nal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 113 F during charging reduce the charging rate to lower the temperature and increase charg ing time proportionately Battery posts terminals and related acces sories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling e After charging check the electrolyte level in each cell If the level has fallen add distilled water to bring it back up to the upper level line e Install the caps on the cells e Install the battery See Battery Installation Fuse There are two plastic fuse cases next to the park ing brake under the left end of the seat one for the main 30 A and the other for the accessory con nector 10 A If the electrical systems do not func tion inspect the fuse Before replacing a fuse check the wiring harness and electrical equipment for bare wires or other possible damage NOTICE Do not use a fuse of a higher capacity than the specified fuse rating or
55. e train wear and makes the steering feel tight Remember e Use 4WD on steep inclines or loose surfaces or when stuck in the mud with the differential locked if necessary e For maximum torque shift into low range e Do not drive 1WD on paved surfaces Turning the Vehicle SAFE OPERATION 69 Hills The vehicle will turn in a smaller radius with the differential unlocked in differential mode In this mode the rear wheels can turn at different speeds allowing the vehicle to turn tighter and more smoothly Even in this mode however avoid sharp turns to keep the vehicle from tipping Reduce vehicle speed before entering the turn and use the throttle to maintain an even speed through the turn AWARNING In the differential mode if either rear wheel leaves the ground it will spin freely and the wheel on the ground will transmit very little power When a spinning wheel touches the ground it may grab abruptly causing the op erator to lose control Do not make sharp turns even in the differential mode in order to avoid loss of control or tipping Remember e Slow down before entering the turn e Maintain an even speed through the turn As with any motor vehicle loading of the vehicle and the surface and steepness of the hill are among the critical considerations in climbing descending or traversing hills Use extreme caution on hills Keep in mind that loading changes a vehicle s center
56. er caps and fill with distilled water until the electrolyte level in each cell reaches the upper level line DO NOT OVERFILL Overfilling can cause the electrolyte to leak out of the battery vent tube Battery electrolyte contains sulfuric acid that will corrode vehicle components and parking sur faces plus cause burns to exposed skin BL28003BM2 C A Filler Caps B Upper Level Line C Lower Level Line NOTICE Add only distilled water to the battery Ordi nary tap water is not a substitute for distilled water and will shorten the life of the battery If you are riding your Mule infrequently inspect the battery voltage weekly using a voltmeter If it drops below 12 5 volts the battery should be charged using an appropriate charger check with your Kawasaki dealer or visit buy kawasaki com at a rate of 1 10th of the battery capacity If you will not be using your vehicle for longer than two weeks the battery should be charged using an appropriate charger Do not use an automotive type quick charger that may overcharge the battery and damage it NOTE OLeaving the battery connected causes the electri cal components to make the battery discharged resulting the over discharge of the battery In this case the repair or replacement of the battery is not included in the warranty If you do not drive for four weeks or more disconnect the battery from the vehicle Battery Charging e Rem
57. ery s electrolyte level and charge When used regularly the charg ing system in your Mule helps keep the battery fully charged If your Mule is only used occasionally or for short periods of time the battery is more likely to discharge Due to their internal composition batteries contin ually self discharge The discharge rate depends on the type of battery and ambient temperature As temperatures rise so does the rate Every 15 59 F doubles the rate Electrical accessories also draw current from the battery even when the key is switched off Combine such key off draws with hot temperatures and a battery can go from fully charged to completely dis charged in a matter of days Self discharge Approx Number of Days From 10096 Charged to 100 Temperature discharged Lead Antimony Lead Calcium Battery Battery 40 104 F 100 Days 300 Days 25 C 77 F 200 Days 600 Days 0 C 32 F 550 Days 950 Days MAINTENANCE AND ADJUSTMENT 119 Current Drain Y50 N18L A Days from Discharging eR Mo P 100 Charged Ampere ed to 10096 9 discharged 7 mA 60 Days 119 Days 10 mA 42 Days 83 Days 15 mA 28 Days 56 Days 20 mA 21 Days 42 Days 30 mA 14 Days 28 Days In extremely cold weather the fluid in an inade quately charged battery can easily freeze which can crack the case and buckle the plates A fully charged properly maintained battery can withstand sub freezing
58. es 42 Driving 4WD 400 68 Hour Metom iie et ipee 43 Turning the 69 Eiaht SWItCI ac d e eite led 44 Hills cote atten 69 Shift Levers 44 Climbing amp ner rettet 70 Gear Shift 44 Descending 5 71 2WD 4WD Shift Lever KAF4004A 45 Traversing Hillsides 72 Differential Shift 46 Sliding and 72 Parking Brake 47 Driving through 73 Parking Brake Warning Light 48 MAINTENANCE AND ADJUSTMENT 74 SIL AS 48 Periodic Maintenance Chart 74 Seat Belts dee 49 Engine 78 Front Final Gear Case Oil KAF4004A 82 TROUBLESHOOTING GUIDE 129 Transmission Case 85 YOUR WARRANTY OWNER SATISFACTION 130 Cooling Rees 88 ENVIRONMENTAL PROTECTION 134 Spark PUO etre ec rere tn 88 MAINTENANCE RECORD 135 Valve Clearance
59. formance 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 API SG SH SJ SL SM and JASO MA MA1 MA2 rating Viscosity SAE 10W 40 Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle Con sistent use of these products meets or exceeds war ranty and service requirements and can help to ex tend the life of your Kawasaki Although 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric condi tions in your riding area NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formu lated and provide adequate lubrication for both the engine 82 MAINTENANCE AND ADJUSTMENT Engine Oil Capacity when filter is not removed 1 11 1 16 US qt Front Final Gear Case Oil KAF400A when filter is removed 1 3 L 1 37 US qt In order for the differential pinion and ring gears to function properly check the oil level and change the oil in accordance with the Periodic Maintenance SAE 20W 50 Chart SAE 20W 40 A WARNING SAE 10W 50 Vehicle operation with insufficient deterio Rae TONG rated or contaminated oil causes acceler ated wear of the differential pinion and ring gears and may result in seizure Seizure can lock the front and rear wheels and ski
60. free towel into the air cleaner housing to keep dirt or other foreign material from entering A Urethane Foam Element 106 MAINTENANCE AND ADJUSTMENT NOTICE If dirt gets into the belt drive torque con verter excessive wear and loss of driving power may result NOTE O Element installation is performed in the reverse order of removal Element Cleaning e Remove the element see Element Removal e Remove the urethane foam element from the holder e Clean the foam element in a bath of high flash point solvent using a soft bristle brush e Squeeze it dry in a clean towel Do not wring the element or blow it dry the element can be dam aged e Inspect the foam element for damage If it is torn punctured or hardened replace it NOTE OReplace the foam element after cleaning it five times or if it is damaged e Clean the holder by tapping it lightly to loosen dust e Blow away the remaining dust by applying com pressed air from the inside to the outside from the clean side to the dirty side e Inspect the element material for damage If any part of the element is damaged the element must be replaced Brakes The vehicle is equipped with hydraulically acti vated drum brakes on all four wheels Brake Pedal Brake Pedal Free Play Inspection In accordance with the Periodic Maintenance Chart check the brake pedal free play e Depress the brake pedal lightly by hand e
61. gn material or water can be seen trapped in the fuel filter A Fuel Filter B Fuel Tank Evaporative Emission Control System This system routes fuel vapors from the fuel sys tem into the running engine or stores the vapors in a canister when the engine is stopped Although no adjustments are requited a thorough visual inspec tion must be made at the intervals specified by the Periodic Maintenance Chart Inspection e Check that the hoses are securely connected e Replace any kinked deteriorated or damaged hoses MAINTENANCE AND ADJUSTMENT 103 ELE Belt Drive Torque Converter CANISTER The vehicle is equipped with a belt drive torque converter type automatic transmission The belt driven pulley shoes and drain hose should be checked in accordance with the Periodic Mainte nance Chart The belt and driven pulley shoes inspection should be done by an authorized Kawasaki dealer AIR CLEANER FILTER INTAKE DUCT CARBURETOR FUEL VAPOR HOSES ROUTING DIAGRAM CL14016BM2 A Belt Drive Torque Converter inside B Drain Boot C Clamp Dust and or Water Inspection e Remove the clamp to take off the drain boot on the bottom of the converter housing to expel dust and or water accumulated inside 104 MAINTENANCE AND ADJUSTMENT High Altitude Use The original belt drive torque converter settings of this vehicle are best for seal level use when the
62. hains brakes and for repairs needed because of a lack of maintenance misuse or racing Whether you do it yourself or take your vehicle to a Kawasaki dealer be sure to record your service in the Maintenance Record section of this Owner s Manual Keep all receipts for the service and or items necessary to perform the maintenance so that in the event of a failure you can document the service history What Are The Dealership s Responsibilities Your Kawasaki dealer offers a wide range of services parts accessories and information on your product and on Kawasaki Each dealer is independently owned and operated and is responsible for the dealership s operations its repair warranty and service work and its personnel Your dealer is responsible for completing the set up and pre delivery service of your new Kawasaki vehicle The dealership should also explain its operation maintenance and warranty provisions so you understand them at the time of purchase or at any other time you have questions The dealership is responsible for inspecting your Kawasaki vehicle if there is a failure investigating the cause of the problem and getting any needed authorization from Kawasaki if the repair is one that will be covered by the limited warranty The dealership will also file all necessary paperwork The dealership is responsible for correctly completing any necessary repairs whether they are covered by the limited warranty or not 132 YOUR WARRANTY
63. he positive ter minal of the booster battery to the positive ter minal of the vehicle battery 58 HOW TO OPERATE A DANGER Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive Do not make this last con nection at the carburetor or battery Take care not to touch the positive and negative cables together and do not lean over the bat tery when making this last connection Do not connect to a frozen battery It could ex plode Do not reverse polarity by connecting positive to negative a battery ex plosion and serious damage to the electrical system may occur A Battery B Vehicle Battery Positive Terminal e Follow the standard engine starting procedure C From Booster Battery Positive Terminal D Unpainted Metal Surface NOTICE E From Booster Battery Negative Terminal Do not operate the starter continuously for e Connect another jumper cable from the negative more than 5 seconds or the starter overheat terminal of the booster battery to an unpainted and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power metal surface on your vehicle Do not use the negative terminal of the battery After the engine starts disconnect the jumper ca bles Disconnect the negative cable from the vehicle
64. ip taking recreation skills classes and knowing how to use and operate your equipment safely Avoic sensitive areas such as meadows lakeshores wetlands and streams unless on designated routes This protects wildlife habitat and sensitive soils from damage D your part by leaving the area better than you found it properly disposing of waste minimizing the use of fire avoiding the spread of invasive species restoring degraded areas and joining a local enthusiast organi zation Properly discard used batteries tires engine oil other vehicle components or the entire vehicle that you might dispose of in the future Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure MAINTENANCE RECORD 135 MAINTENANCE RECORD Owner ORDRE dcm IRE Phone Number e eec E eee deos ae eee a ee Vehicle Number esses nennen mu nnnnnu anh RR RAN RR ERAN RR RR RR RR ARR GENER R4 SR RR RR GS R44 RR RR ga 4 nanana Selling Dealer Ren E ER dvuscededdewesaaetvecdeee AddE6ss 2 et eiie iig iiia iiic es iron upllge c H Warranty Start Date iiie iio tid itae re ad iaa irae duda e Le da Pr uada RR Rig Note Keep this information an
65. is vehicle All operators of this vehicle should possess a valid driver s license Protective head gear reduces the risk of head injuries A helmet is recommended when this vehicle is being used for recreational purposes or any aggressive driving Please refer to the Owner s Manual for information on proper riding gear Seat belts reduce injuries Operator and passenger must always fasten seat belts during vehicle operation Carrying passengers outside the passenger compartment can be hazardous This vehicle is designed to carry the operator and only one passenger in the seat provided Never carry a passenger in the cargo bed Failure to apply parking brake may result in vehicle moving inadvertently with the potential for causing damage and injury Always apply parking brake before exiting vehicle Alcohol and drugs impair reaction time and judgment Never operate this vehicle under influence of alcohol or drugs 56071 0101 CFO3336BN4 6 WARNING Driving with the bed raised is hazardous Always lower and latch bed before driving 56070 7515 CF03124BM2 7 KAF400A C IMPORTANT INFORMATION eTires Front 24X 9 00 10 Rear 24X11 00 10 e6old Tire Pressure Front 47kPa 0 4Tkgf cm 7 1 Rear 7 0 97kgf cm 14psi Max Vehicle Load 420kg 924165 Including occupants and cargo e Trailer Wax Trailer Tongue Weight d0kg 88168 Max Trailer
66. isonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area 94 MAINTENANCE AND ADJUSTMENT e Stop the engine e Install the drain plug Throttle Pedal If the throttle pedal has excessive play due to ei ther cable stretch or misadjustment it will cause a delay in throttle response especially at low engine speed Also the throttle may not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary Throttle Pedal Play Inspection e Apply the parking brake e Putthe gear shift lever in the N Neutral position e Start the engine and warm it up thoroughly e Measure the distance the throttle pedal moves be fore the engine begins to pick up speed Free play should be 2 5 mm 0 1 0 2 in MAINTENANCE AND ADJUSTMENT 95 2 110018 6 A Throttle Pedal A Throttle Cable B 2 5 mm 0 1 0 2 in B Mounting Nuts Throttle Pedal Play Adjustment e Tighten the mounting nuts securely e Lift the cargo bed and support it with the hook Throttle Pedal Stop Position Adjustment e Loosen and turn the throttle cable mounting nuts The full throttle pedal stop position can be adjusted located above the transmission case until
67. itch inspect Seat belt inspect e General lubrication perform D Bolts nuts and fasteners tightness inspect D D Wheel nuts tightness inspect MAINTENANCE AND ADJUSTMENT 77 FREQUENCY Whichever First Service Regular Service comes first After 50 hrs Every 250 Every 500 OPERATION or 1 000 km hrs or 5 000 f 000 km of of use km of use Every use Battery inspect e Front final gear case oil 400 1 year transmission case oil change Brake fluid change 2 years D Brake master cylinder cup and dust seal replace 2 years D Brake wheel cylinder assembly replace 2 years D 2 Jom Brake hose replace 4 years D 78 MAINTENANCE AND ADJUSTMENT Engine Oil A WARNING The cargo bed requires a supporting hook to remain in the raised position and will fall down if not supported creating the potential for injury Always latch the supporting hook when lifting the bed for engine or other main tenance below the bed fills the oil filter with oil Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil reaches ev ery part can cause engine damage e If the vehicle has just been used wait several min utes for all the oil to drain down e Park the vehicle on level ground e Raise the seat In order for the engine to function properly main tain the engine oil
68. kout switch This switch prevents the electric starter from operating when the gear shift lever is in the High and L Low for KAF400A or F Forward for KAF400B or Reverse position Olf the brake pedal is depressed it is possible to start in any position e Gradually return the choke knob to the OFF po sition a little at a time as necessary to keep the engine running properly during warm up NOTE Olf you drive the vehicle before the engine is warmed up return the choke to the OFF position as soon as you start moving HOW TO OPERATE 57 Jump Starting If your vehicle s battery is run down it should be removed and charged If this is not practical a 12 volt booster battery and jumper cables may be used to start the engine A DANGER Battery acid generates hydrogen gas which is flammable and explosive under certain conditions It is present within a battery at all times even in a discharged condition Keep all flames and sparks cigarettes away from the battery Wear eye protection when working with a battery In the event of bat tery acid contact with skin eyes or clothing wash the affected areas immediately with water for at least 5 minutes Seek medical attention Connecting Jumper Cables e Make sure the ignition switch is turned to OFF e Raise the seat the battery is located under the left end of the seat e Connect a jumper cable from t
69. l operation and cause serious burns To avoid a serious burn never touch a hot muffler or exhaust pipe during oil drain ing e Lift the cargo bed and support it with the hook e Remove the filler plug A WARNING Oil on tires can make them slippery which can cause an accident and injury When draining or filling the transmission case be careful that no oil gets on the tires or rims Clean off any oil that inadvertently gets on them with soap and water e After the oil has completely drained out install the drain plug with its gasket Tighten it to the spec ified torque If the gasket is damaged replace it with a new one e Fill the transmission case up to the H High line on the dipstick with a good quality oil as specified in the table Tightening Torque Drain Plug 15 N m 1 5 kgf m 11 16 MAINTENANCE AND ADJUSTMENT 87 Transmission Case Oil Type API GL 5 Hypoid gear oil above 5 C 41 F SAE 90 below 5 C 41 F SAE 80 Transmission Case Oil Capacity KAF400A 2 4 L 2 5 US qt KAF400B 2 2 L 2 3 US qt e Install the filler plug and dipstick 88 MAINTENANCE AND ADJUSTMENT Cooling Fan Spark Plug The engine is cooled by the cooling fan attached to the left side of the engine Check and clean the screen for mud and other debris A WARNING A spinning fan can cause serious injury To avoid injury when checking and cleaning the screen turn off
70. lowing cautions must be observed A WARNING Operating or parking the vehicle near flammable materials can cause a fire and can result in property damage or severe personal injury Do not idle or park your vehicle in an area where tall or dry vegetation or other flammable materials could come into con tact with the muffler or exhaust pipe A WARNING The engine and exhaust system get ex tremely hot during normal operation and can cause serious burns Never touch a hot engine exhaust pipe or muffler during operation or after stopping the engine 66 HOW TO OPERATE e Use only unleaded gasoline Never use leaded NOTICE gasoline Leaded gasoline significantly reduces EN the capability of the catalytic converter e Do not coast the vehicle with the ignition switch and or engine stop switch off Do not attempt to In order to protect the emission control parts do not turn off the ignition switch when the motorcycle is in motion start the engine by rolling the vehicle if the battery is discharged Do not operate the vehicle with the engine of the cylinder misfiring Under this condi tions unburned air fuel mixture flowing out of en gine excessively accelerates reaction in the con verter allowing the converter to overheat and be come damaged when the engine is hot or reduces converter performance when the engine is cold SAFE OPERATION 67 SAFE OPERATION Safety is an attitude Your
71. luid immediately Fluid Level Inspection e With the vehicle on level ground check through the inspection hole in the dashboard that the fluid level in the reservoir is between the upper marked MAX and lower marked MIN level lines A Inspection Hole e f the fluid level is lower than the lower level line check for fluid leaks in the brake lines and open the front cargo hood see Front Cargo Compart ment section in the General Information chap ter and remove a round cap on the cargo com partment rear wall e The brake fluid reservoir is inside the access hole and using a funnel fill the reservoir to the upper level line 2190108 A Brake Fluid Reservoir B Cargo Compartment Wall A WARNING Mixing two types and brands of fluid for use in the brake lowers the brake fluid boiling point and could reduce brake effectiveness Change the fluid in the brake system com pletely if the fluid level is low but the type and brand of the fluid already in the reservoir are unknown e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings WARNING Air in brake line can make the brake feel mushy or soft This may cause reduced braking performance or brake failure and result in an accident If brake lever travel is excessive or the brake feels mushy have an authorized Kawasaki dealer inspect it immediately Fluid Change
72. ming NOTICE If valve clearance is left unadjusted wear will eventually cause the valves to remain partly open which lowers performance burns the valves and valve seats and may cause seri ous engine damage Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Main tenance Chart Inspection and adjustment should be done by an authorized Kawasaki dealer Valve Clearance EX amp IN 0 10 0 15 mm 0 0039 0 0059 in A clogged engine air cleaner restricts the engine s air intake increasing fuel consumption reducing en gine power and causing spark plug fouling A WARNING A clogged air cleaner may allow dirt and dust to enter the carburetor and the throttle may stick resulting in a hazardous operating condition Clean the air filter according to the periodic maintenance chart more often if the vehicle is used in extremely dusty conditions NOTICE A clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and possible engine damage The air filter element should be cleaned in accor dance with the Periodic Maintenance Chart In dusty areas the elements should be cleaned more fre quently than the recommended interval Element Removal e Raise the seat e Release the snaps and remove the air cleaner housing cover from the housing A Air Cleaner Housing Cover B Snaps e Remove the screw an
73. n accordance with the Periodic Maintenance Chart have the tightness of the bolts nuts and fas teners checked by an authorized Kawasaki dealer STORAGE 127 STORAGE Gasoline is a toxic substance Dispose of Preparation for Storage e Clean the entire vehicle thoroughly e Run the engine for about five minutes to warm the oil shut it off and drain the engine oil A WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local author ities for approved disposal methods or pos sible recycling e Put in fresh engine oil e Empty the fuel from the fuel tank and empty the carburetor by loosening the drain screw atthe float bowl Catch the fuel in a suitable container After a period of time fuel will break down and could clog the fuel system Close the drain screw when finished A WARNING Gasoline is extremely flammable and can be explosive under certain conditions and cause severe burns Do not smoke Turn the ignition switch OFF Make sure the area is well ventilated and free from any source of flame or sparks including any appliance with a pilot light fuel properly Contact your local authorities for approved disposal methods NOTE OAsan alternative to draining the fuel system a fuel stabilizer such as STA BIL may be used Follow the manufacturer s instructions for use A WARNING Fuel stabilizers may contain poisonous sub stances Heed
74. n distract or inpair visibility of the operator causing loss of vehicle control and potential serious injury or death Latch the hood securely before operating the vehicle 5 56070 0053 CF03051BM2 C WARNING Overloading or improper use of the cargo bed can cause changes in handling which can lead to an accident Do not install passenger seats in the cargo bed e argo Only no passengers e Don t overload cargo bed capacity l81kg 400165 Read your Owner s Manual for additional loading information 56071 0134 CF03370BM2 C 24 3 LOCATION OF LABELS 4 WARNING The Owner s Manual and warning labels contain important information on safe operation of this vehicle You must read and fully understand instructions in Owner s Hanual and warning labels before operating this vehicle Keep Owner s Manual with this vehicle at all time Improper use of this vehicle can be hazardous Never operate at speeds too fast for your skills or conditions Handling characteristics of this vehicle change depending upon cargo load and driving modes Use proper driving techniques on hills in rough terrain and in water Use of this vehicle on public roads and paved surfaces is hazardous This vehicle is designed and equipped for off highway use only Do not operate this vehicle on public roads or paved surfaces Children may not have skills and judgment to safely operate th
75. nd can be explosive under certain conditions and cause severe burns Before performing any service turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source A Guard Plate of flame or sparks including any appliance B Air Intake Ducts 2 p c s with a pilot light Make sure the engine is C Clamps 2 p c s D Quick Rivets 6 p c s E Cap e Place a suitable container under the carburetor e Turn out the drain screw a few turns to drain the carburetor and check to see if water or dirt has accumulated in the carburetor cold before servicing Wipe any fuel off the engine before starting it Dust and or Water Inspection e Lift the cargo bed to support it with the hook e Raise the seat e Remove the guard plate by releasing the two air intake ducts and the 6 quick rivets 102 MAINTENANCE AND ADJUSTMENT CL140008 6 A Drain Screw B Carburetor e Tighten the drain screw NOTE Olf any water or dirt appears during the above oper ation have the fuel system checked by an autho rized Kawasaki dealer Fuel Filter The vehicle is equipped the fuel filter at the middle ofthe fuel line to prevent dirt or other foreign material from entering the carburetor and fuel pump Have your authorized Kawasaki dealer inspect and clean or replace the fuel filter in accordance with the Periodic Maintenance Chart or whenever any forei
76. ng the wheels in the direction of the skid Do not apply heavy brak ing force or accelerate when skidding since this may cause further loss of control Use caution and maintain low speeds to avoid uncontrolled skidding on areas covered with clay mud ice or snow Use 4WD KAF400A and low KAF400A range gearing efficiently These condi tions are particularly hazardous when descending a hill or making a turn Remember that this vehicle is not for use on public streets roads or highways Remember e Be especially careful on very slippery surfaces e Don t drive on public streets roads or highways Driving through Water Avoid driving through water whenever it is possi ble When driving across shallow water choose a location to enter and exit the water where the banks are not too steep or slippery Check before entering for rocks holes or other obstacles which may cause you to overturn or become stuck or submerged Observe the following rules for operating the vehi cle in water 10008 6 A Axle Cap SAFE OPERATION 73 A WARNING Operating the vehicle in rivers or streams where water is flowing quickly can cause the tires to lose traction and allow the vehicle to be swept into the current Never operate the vehicle in fast flowing water or in water deeper than the bottom edge of the axle caps After prolonged exposure to water the wheel bear ings may require lubrication or replacement
77. ngine e Install the dipstick Oil and or Oil Filter Change e Warm up the engine thoroughly and then stop the engine e Place an oil pan beneath the engine e Remove the drain plug on the right side at the bot tom of the engine e Remove the dipstick 80 MAINTENANCE AND ADJUSTMENT A Drain Plug B Torque Converter Case e With the vehicle held level let the oil drain com pletely A WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local author ities for approved disposal methods or pos sible recycling e f the oil filter is to be changed first lift the cargo bed to support it with the hook and then remove the oil filter cartridge and replace it with a new one COMO 6 A Cartridge e Apply a thin film of oil to the gasket and screw the cartridge in until the gasket touches the engine then turn it 3 4 turn BL03004BM2 C A Gasket e Install the drain plug with its gasket Tighten it to the specified torque NOTE Replace any damaged gaskets with new ones e Fill the engine up to the F Full line on the dip Stick with high quality engine oil as specified in the table e Start the engine and check for oil leakage Tightening Torque Drain Plug 6 9 N m 0 7 kgf m 61 in Ib Filter Cartridge 9 8 N m 1 kgf m 87 in Ib MAINTENANCE AND ADJUSTMENT 81 Recommended Engine Oil Type Kawasaki Per
78. of non standard tires or use of differ ent tires on one axle can change or impair the handling of the vehicle O Installation of tubeless tires on rims requires com pressed air and is normally recommended as a dealer service operation Nevertheless a tube can be inserted into the tire by the operator as an emergency repair Maximum Tire Air Pressure for Seating Beads Front and Rear 250 kPa 2 5 kgf cm 36 psi Payload and Tire Pressure Failure to maintain proper inflation pressures or observe payload limits for your tires can change or impair handling and performance of the vehicle The maximum recommended load carrying capacity is 420 kg 924 Ib Use a tire pressure gauge to accurately set tire pressure A WARNING Operating with unequally or improperly pres surized tires can adversely affect steering or handling Inflate both front tires to the same pressure and both rear tires to the same pressure 114 MAINTENANCE AND ADJUSTMENT Tire Wear Damage As tire tread wears down tires become more sus ceptible to puncture and failure e n accordance with the Periodic Maintenance Chart measure the depth of the tread with a depth gauge and replace any tire that has worn down to the minimum allowable tread depth A Tire Depth Gauge Minimum Tread Depth 3 mm 0 12 in e Visually inspect the tire for cracks and cuts replac ing the tire in case of bad damage Swelling or
79. oor while gripping the handhold Stay com pletely inside the vehicle Never Drink and Drive Alcohol and drugs impair your judgement and slow your reactions Even drugs prescribed by a physi cian can be dangerous Check with your doctor 10 BASIC SAFE DRIVING Protect Yourself Use Proper Riding Gear As appropriate to your operating conditions wear approved helmet eye protection and protective clothing Operating in a recreational setting like trail driving or any aggressive riding could increase the risk of head injury and thus require head protection In these conditions Kawasaki recommends that operators and passengers wear a properly fitting D O T approved helmet Wearing proper protective gear can make driving more comfortable and could reduce the severity of injury in the event of an acci dent Wearing Seat Belt Both the operator and passenger s should al ways wear their seat belts properly Seat belts cannot completely protect you in every accident but in many cases a seat belt can reduce the risk of serious injury Also to avoid injury do not put any part of your body outside of the vehicle for any reason Before Starting the Engine Three musts before starting the engine are 1 Apply the parking brake 2 Putthe gear shift lever in the N neutral posi tion 3 Check the throttle pedal for proper operation It should return to its rest position when released Use the Parking Brake Always ap
80. ove the battery from the vehicle See Battery Removal NOTICE Always remove the battery from the vehicle for charging If the battery is charged while still installed battery electrolyte may spill and corrode the frame or other parts of the vehicle e Before charging check the electrolyte level in each cell If the electrolyte level is low in any cell fill to above the lower level line but not up to the upper level line since the level rises during charging e Remove the caps from all the cells and connect the battery charger leads to the battery terminals red to black to MAINTENANCE AND ADJUSTMENT 121 BL28004BM2 C A Battery Charger B Filler Caps removed C Terminal D Terminal A DANGER Batteries produce hydrogen gas which can cause an explosion Charge the battery in well ventilated area Keep sparks flame and cigarettes away from the battery during charging When using a battery charger connect the battery to the charger before turning on the charger This procedure pre vents sparks at the battery terminals which could ignite any battery gasses 122 MAINTENANCE AND ADJUSTMENT e Charge the battery at a rate that is 1 10th of the A WARNING battery capacity For example the charging rate for a 10 Ah battery would be 1 0 ampere NOTICE Do not use a high rate battery charger as is typically employed at automotive service stations unless th
81. pecial tools described in the Service Manual Keep this Owner s Manual aboard your Mule at all times so that you can refer to it whenever you need infor mation This manual should be considered a permanent part of the Mule and should remain with the Mule when it is sold All rights reserved No part of this publication may be reproduced without our prior written permission This publication includes the latest information available at the time of printing However there may be minor differences between the actual product and illustrations and text in this manual All products are subject to change without prior notice or obligation KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company 2012 Kawasaki Heavy Industries Ltd Dec 3 2012 1 TABLE OF CONTENTS BASIC SAFE 9 Throttle Pedal eee 51 11 Trailer Hitch Bracket 51 SERIAL NUMBER LOCATIONS 15 Winch Installation 52 LOCATION OF PARTS 16 HOW TO 54 LOCATION OF LABELS 19 Daily Checks sse 54 LOADING 29 Starting the
82. phere Instead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped High Altitude Performance Adjustment Information The original carburetor settings for this vehicle are best for sea level use When the vehicle is used at high altitude the thinner atmosphere makes the air fuel mixture richer reducing performance and increasing fuel usage To improve the performance of vehicles operated at high altitude optional replacement of certain car buretor components are available Have the carburetor adjusted by your authorized Kawasaki dealer if you intend to use this vehicle above 500 m 1 600 feet However the carburetor must be returned to original settings before using at lower altitudes Otherwise lean high altitude carburetor setting may cause rough engine idling stalling or engine damage Maintenance and Warranty Proper maintenance is necessary to ensure that your vehicle will continue to have low emission levels This Owner s Manual contains those maintenance recommendations for your vehicle Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards As the owner of this vehicle you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner s Manual at your own expense You should keep a maintenance record for your vehicle To assist you in keeping this
83. ply the parking brake before getting out of your vehicle Obey Local Laws Know and obey all laws and regulations govern ing the use of off highway vehicles in your area Re spect private property Always try to preserve nature and the environment Refueling Before refueling the vehicle shut the engine off and make sure the area is well ventilated and free of any source of flame or sparks Gasoline is very flammable Tire Air Pressure Tire inflation and type can affect the vehicle s han dling characteristics Check the tire pressure fre quently Use only the recommended tires for re placement 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 x W x H SPECIFICATIONS 11 SPECIFICATIONS A 29 7 N m 3 0 22 0 ft lb 92 400 r min rpm 27 9 N m 2 8 21 0 ft lb 92 200 r min rpm 3 3 m 10 8 ft 2 764 mm 108 82 in 1 335 mm 52 56 in A 1 802 mm 70 94 in B 1 781 mm 70 12 in 1 779 mm 70 04 in 1 051 mm 41 38 in 999 mm 39 33 in A 170 mm 6 69 in B 155 mm 6 10 in A 463 kg 1 021 Ib B 434 kg 957 Ib 1 044 x 900 x 245 mm 41 10 x 35 43 x 9 65 in 12 SPECIFICATIONS ENGINE Type Displacement Bore x Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spa
84. r KAF400A This vehicle can be operated either in 2WD or AWD The 2WD 4WD shift lever is located on the dash board to the right of the steering shaft Move the 2WD 4WD shift lever up or down as necessary Refer to the 2WD 4WD Shifting section in the How to Operate chapter 46 GENERAL INFORMATION 2WD 4WD Shift Lever Stopper 2WD Position AWD Position com Differential Shift Lever This vehicle is equipped with a dual mode rear dif ferential The differential shift lever is located on the dashboard to the left of the steering shaft Move the shift lever up or down as indicated on the label next to the shift lever Refer to the Shifting the Differential section in the How to Operate chapter A Differential Shift Lever B Stopper C Differential Unlocked Axle Mode Position UN LOCK D Locked Axle Mode Position LOCK Parking Brake Lever The parking brake lever is located at the left side of the seat Pull the lever up and to the rear to apply the parking brake To release push in and hold the knob on the end of the lever and push the lever all the way down Spring pressure helps return the lever to the released posi tion Be sure to release the parking brake before driving off Failure to do so may result in poor performance and premature wearing of the rear brakes and belt converter system A Parking Brake Lever
85. r flow e Engine flooded e Overloaded e Fuel tank vent clogged e Wrong spark plug e Spark plug wire not on spark plug e Cooling fan screen clogged e Spark plug dirty e Engine oil low e Compression leakage e Valve clearance insufficient e Fuel filter clogged e Air filter clogged or intake blocked e Spark plug dirty or worn e Choke left on e Engine oil incorrect e Water in fuel Engine Stops e No fuel in tank e Water in fuel e Fuel filter clogged e Choke left on too long e Air filter clogged or intake blocked e Fuel tank cap vent clogged Gear Shift lever won t move e Idling too high 130 YOUR WARRANTY OWNER SATISFACTION YOUR WARRANTY OWNER SATISFACTION Welcome to the Kawasaki family Congratulations on buying your Kawasaki vehicle You ve chosen a great high quality product with state of the art features and built to Kawasaki s high standards Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki Motors Corp U S A Here is some important information regarding your vehicle s lim ited warranty Frequently Asked Questions What is a Limited Warranty The most important thing to know about your warranty is that it protects you from manufacturing defects in material or workmanship during the warranty period You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale The warranty does not cover the cost of regularl
86. rdance with the Periodic Maintenance Chart check that each seat belt functions properly Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle The click sound indicates it is securely latched Push the red button in the buckle to make sure it releases freely Also check the belt webbing for wear cuts or damage If any irregularities are found have the seat belt system checked or replaced by an authorized Kawasaki dealer A Latch Plate B Buckle C Red Button Headlight Beam MAINTENANCE AND ADJUSTMENT 117 Battery The headlight beams can be adjusted vertically e Turn the adjusting screw on each headlight rim to adjust the headlight vertically A Lamp Body backside B Adjusting Screws The battery is located under the left end of the seat A DANGER Battery contains sulfuric acid and produce hydrogen gas Sulfuric acid can cause burns and hydrogen gas can cause an explosion Read and heed the battery safety label Battery Removal e Raise the seat The battery is located under the left end of the seat e Remove the rubber mud cover on the battery e Unscrew the battery holder 118 MAINTENANCE AND ADJUSTMENT A Bolt B Holder C Terminal D Terminal e Disconnect the leads from the battery first from the terminal and then the terminal e Lift the battery out of the case e Clean the battery
87. rk Plug Lubrication System Engine Oil Type Viscosity Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear OHV 1 cylinder 4 stroke positive air cooled 401 cm 24 47 cu in 82 x 76 mm 3 23 x 2 99 in A 8 6 1 8 3 1 Electric starter NIKKI 6C1026 Magneto and transistor 20 constant NGK BPR5ES Forced lubrication wet sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 14 L 1 5 US qt A Gear 2WD 4WD B Gear 2WD A 2 speed amp reverse automatic B 1 speed amp reverse automatic 3 653 0 794 Belt drive torque converter A 3 852 4 000 Overall Drive Ratio Forward Reverse 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 Castor Trail Tire Size Front Rear SPECIFICATIONS 13 9 263 High A 13 706 Low 11 910 2 916 High A 4 315 Low 3 750 A API GL 5 SAE 140 or API GL 6 SAE 90 Hypoid gear oil for Limited Slip Differentials A 0 35 L 0 37 US qt API GL 5 Hypoid gear oil SAE 90 above 5 C 41 SAE 80 below 5 C 41 F A 2 4 L 2 5 US qt B 2 2 L 2 3 US qt Steel tube ladder type 8 0 A 40 mm 1 6 in B 33 mm 1 3 in A 24 x 9 00 10 Tubeless B 22 x 9 00 10 Tubeless A 24 x 11 00 10 Tubeless B 22 x 11 00 10
88. s listed below Do not tamper with the original emission related parts e Carburetor and internal parts e Air cleaner element e Spark plug e Fuel hoses e Magneto or electronic battery ignition system e Fuel tank e Fuel filter e Muffler and carbon canister PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product Kawasaki has equipped it with effective intake and exhaust silencing systems They are designed to give optimum performance while maintaining a low noise level Please do not remove these systems or alter them in any way which results in an increase in noise level FOREWORD Congratulations on your purchase of a new Kawasaki Mule It is the result of Kawasaki s engineering exper tise and a tradition of manufacturing high quality consumer products Please read this Owner s Manual carefully before starting your new Mule so that you will be thoroughly familiar with the proper operation of your vehicle s controls its features capabilities and limitations To ensure a long trouble free life for your Mule give it the proper care and maintenance described in this manual For those who would like more detailed information on their Mule a Service Manual is available for purchase from any authorized Kawasaki Mule dealer The Service Manual contains detailed disassembly and mainte nance information Those who plan to do their own work should of course be competent mechanics and possess the s
89. se of accessories or vehi cle modifications will void the utility vehicle warranty In selecting and using accessories and in loading the vehicle you are personally responsible for your own safety and the safety of others NOTE OKawasaki Parts and Accessories have been spe cially designed for use on Kawasaki utility vehi cles We strongly recommend that all parts and accessories you add to your vehicle be genuine Kawasaki components Because any vehicle is sensitive to increases in weight and changes in weight distribution you must take care in carrying cargo The following general guidelines have been prepared to help you make your determinations e Reduce speed when carrying cargo Braking distance is increased Use extreme caution when climbing and descending hills and traversing slopes Carrying cargo and pulling a trailer can make the vehicle difficult to steer and may affect vehicle handling in an unpredictable manner e Do not operate this vehicle faster than 16 km h 10 mph when pulling a trailer e All cargo should be carried as low as possible to reduce the effect on the vehicle s center of gravity Cargo weight should be equally distributed from side to side This helps maintain stability by cen tralizing weight Avoid carrying cargo that extends beyond the rear of the vehicle Do not carry cargo on top of the ROPS Do not carry more than 181 kg 400 Ib in the cargo bed Cargo should be securely anchored
90. t or load of more than 120 watts to these connectors or the battery may become discharged very rapidly 32 GENERAL INFORMATION Cargo Bed Tailgate Before lowering the tailgate select a firm level sur face and set the parking brake Replace the latches at each end of the tailgate The tailgate can now be lowered The gate is held level to the cargo bed floor with wire loops To close the tailgate lift into upright position and secure firmly with the latches Do not drive the vehi cle with the tailgate lowered CH05029BM2 A Tailgate B Latch CH05EO B8 P A Wire Loop Cargo Bed The cargo bed can be tilted by releasing the latches on each side and then lifting the bed with the handgrips Before tilting the cargo bed select a firm level surface and set the parking brake NOTE O Raise the seat first before releasing the latch Support the bed in the tilted position with the sup porting rod provided on the bottom of the cargo bed Do not drive the vehicle with the front end of the cargo bed raised or unlatched To lower the bed check to be sure the area un der the front of the cargo bed is clear then carefully lower the bed into position GENERAL INFORMATION 33 Check that the both latches have locked the bed into place Do not leave the cargo bed unlatched A Supporting Rod B Cargo Bed Bottom Tilted Condition NOTICE Do not carry more than 181 kg 400
91. temperatures with no damage Battery Sulfation A common cause of battery failure is sulfation Sulfate is a normal byproduct of the chemical re actions within a battery Sulfation occurs when the electrolyte level is low and exposes the plates within the battery to air The active lead on the plates ox idizes and sulfates causing permanent damage so that the battery will not hold a charge Low elec trolyte levels also concentrates the acid in the elec trolyte causing further corrosion to the plates that often falls off and settles at the bottom of the battery The accumulated corrosion can eventually bridge the plates and cause the battery to short 120 MAINTENANCE AND ADJUSTMENT Sulfation also occurs when the battery is left in a discharged condition for an extended time Sulfate is a normal byproduct of the chemical reactions within a battery But when continuous discharge allows the sulfate to crystallize in the cells the battery plates become permanently damaged and will not hold a charge Battery failure due to sulfation is not war rantable Battery Maintenance It is the owner s responsibility to maintain the bat tery electrolyte level and a full charge Failure to do socan lead to battery failure and leave you stranded Inspect the battery fluid level monthly e The electrolyte level in each cell should be be tween the upper and lower level lines e If the fluid level is low in any cell remove the bat tery fill
92. the element must be replaced 6 A Urethane Foam Element B Paper Element Dust and or Water Inspection e There is a plastic drain cap at the bottom of the air cleaner housing If you see any dust and or water accumulated in the housing remove the drain cap and expel it Spark Arrester This vehicle is equipped with a spark arrester ap proved for off highway use by the U S Forest Ser vice It must be properly maintained to ensure its efficiency Clean the spark arrester in accordance with the Periodic Maintenance Chart NOTICE The spark arrester must be functioning prop erly to provide adequate fire protection Spark Arrester Cleaning MAINTENANCE AND ADJUSTMENT 93 CL10008BM2 A WARNING The muffler can become extremely hot dur ing normal operation and cause severe burns Since the engine must be running during this procedure wear heat resistant gloves while cleaning the spark arrester e Remove the drain plug from the muffler A Drain Plug B Spark Arrester inside the muffler e Apply the parking brake e In an open area away from combustible materials start the engine with the gear shift lever in the Neutral position e Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon parti cles are purged from the muffler A DANGER Exhaust gas contains carbon monoxide a colorless odorless po
93. the manufacturer s warnings for use e Remove the spark plug and spray fogging oil such as Kawasaki K Kare Fogging Oil part number K61030 002 directly into each cylinder Turn the engine over several times with the ignition switch key to coat the cylinder walls Install the spark plugs 128 STORAGE A WARNING An air oil mist may be forcibly ejected from the spark plug hole and could get into your eyes Do not lean over the engine when per forming this procedure If you do get oil in your eyes wash them immediately with lib eral amounts of clean fresh water and con sult a physician as soon as possible e Put boards under the front and rear wheels to keep dampness away from the tire rubber e Spray oil on all unpainted metal surfaces to pre vent rusting Avoid getting oil on rubber parts or in the brakes e Lubricate all the cables as indicated in the General Lubrication section e Remove the battery and store it where it will not be exposed to direct sunlight moisture or freezing temperatures During storage it should be given a slow charge one ampere or less about once a month NOTICE Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery The more discharged a battery becomes the more easily it freezes Never remove the sealing strip or the battery can be damaged e Tie a plastic bag over the exhaust pipe and
94. the to prevent pulling the throttle cable more than re proper amount of throttle pedal play is obtained quired e Loosen the locknut e Screw in the throttle pedal stop bolt e Depress the throttle pedal until the speed control lever above the transmission case is in the fully opened position and hold it there e Turn the throttle pedal stop bolt until the bolt head lightly touches the bottom of the throttle pedal e Tighten the locknut securely 96 MAINTENANCE AND ADJUSTMENT A Throttle Pedal B Locknut C Throttle Pedal Stop Bolt Choke Knob Pulling the choke knob makes the carburetor pro vide a rich mixture for easy starting when the engine is cold If starting is difficult or rich fuel mixture trouble oc curs inspect the choke knob and adjust it if neces sary Inspection e Check that the choke knob returns properly and that the inner cable slides smoothly If there is any irregularity have the choke cable checked by an authorized Kawasaki dealer e Lift the cargo bed and support it with the hook e Raise the seat e Remove the guard plate by releasing the two air intake ducts and the 6 quick rivets MAINTENANCE AND ADJUSTMENT 97 A Guard Plate A Starter Lever B Air Intake Ducts 2 p c s B Mounting Nuts C Clamps C Choke Cable D Quick Rivets 6 p c s D Throttle Link Er Cap e The proper amount of play is 0 1 mm 0 00 e Make sure the choke knob is all the wa
95. the two parts of the Hood Closing hood to ensure the hood is latched While lifting the latch lever at the front of the cargo hood push and close the cargo hood A Push here WARNING An open front cargo hood can distract or im pair visibility of the operator causing loss of vehicle control and potential serious injury or death Latch the hood securely before operating the vehicle GENERAL INFORMATION 41 Ignition Switch This is a three position key operated switch The key can be removed from the switch only when it is in the OFF position A Ignition Switch B OFF position C ON position D START position E Accessory Connector 42 GENERAL INFORMATION OFF Engine off All electrical circuits off All electrical equipment can be used on Hour meter works Electric starter is engaged by holding ignition switch key in this position START only when gear shift lever is in N neutral position Upon release key will return to ON position NOTICE Do not operate the starter continuously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power Do not turn the ignition switch key to the START position with the engine running or damage to the starter can result NOTE
96. vehicle is used at high altitude the engine perfor mance will decrease This is why readjustment of the weights of the torque converter are required Have the torque converter adjusted by your autho rized Kawasaki dealer if you intend to use tis vehicle above 1 500 m 4 900 feet However the belt drive transmission must be re turned to original settings before using at lower alti tudes for best sea level use Belt Drive Torque Converter Air Cleaner A clogged belt drive torque converter air cleaner may cause the torque converter to malfunction NOTICE A clogged air cleaner may allow dirt and dust to enter the belt drive torque converter caus ing excessive wear of the inner parts and loss of driving power The air cleaner elements must be cleaned in ac cordance with the Periodic Maintenance Chart In dusty areas the elements should be cleaned more frequently than the recommended interval The ele ments should be replaced if they are damaged Element Removal e Lift the cargo bed and support it with the hook e Raise the seat e Remove the guard plate by releasing the two air intake ducts and the 6 quick rivets MAINTENANCE AND ADJUSTMENT 105 A Guard Plate B Air Intake Ducts 2 p c s B Snaps C Clamps D Quick Rivets 6 p c s E Cap e Release the snaps and remove the air cleaner housing cover from the housing e Pull the air cleaner element out of the housing e Push a clean lint
97. xide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area e Wear the seat belts both operator and passen ger e Apply the parking brake e Putthe gear shift lever in the N Neutral position e Put the ignition key in the switch NOTE O When engine is cold and air temperature is be low 20 C 68 F pull the choke knob all the way out and keep holding the knob so that the throt tle linked choke system functions Release the choke knob when the engine has started and push in the choke knob after the engine starts to warm up When engine is warm or air temperature is 20 68 or higher do not use the choke Push down the throttle pedal slightly If the engine is hard to start use the choke for a short time only e Turn the key in the ignition switch to the start po sition to activate the electric starter Repeat until engine starts NOTICE Do not operate the electric starter continu ously for more than 5 seconds or the starter may overheat and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and for battery power to recover NOTE Olf the engine is flooded make sure the choke knob is all the way in Then crank the engine over with the throttle fully open throttle pedal fully de pressed until the engine starts OThe vehicle is equipped with a starter loc
98. y Utility Vehicle 2 Notice Shifting 3 Warning General 4 Warning Front Cargo Hood 20 LOCATION OF LABELS 6 5 Warning Passengers in Cargo Bed 6 Warning Cargo Bed 7 Important Information Tires Max Load 8 Carrier Hook Operation 9 Specification 15 Specification T LN LOCATION OF LABELS 21 C0200708 6 10 Warning Refueling 11 Warning Hot Surface 12 Important Emission Control Information 13 Engine Oil Information cro20t08 6 22 LOCATION OF LABELS CF02126BM2 CF02175BM2 21898 G 14 Important Emission Information 16 Battery Danger Poison On the backside 17 Brake Fluid WARNING This is an off highway utility vehicle which will handle and maneuver differently from an ordinary passenger car Sharp high speed turns or abrupt maneuvers can cause this vehicle to roll over or go out of control Read and understand operating instructions in the Owner s Manual and follow all warning instructions The handling characteristics of this vehicle change depending upon cargo load and driving modes 56070 0050 CFO3052BM2 2 NOTICE ifting incorrectly can damage transmission t only when Coco 77 56071 0132 CF03963B 5 4 LOCATION OF LABELS 23 A WARNING An open front cargo hood ca
99. y into its 0 04 in at the choke knob If there is too much or released position too little play adjust the choke cable e To determine the amount of choke cable play at the knob pull the choke knob out until the starter lever at the carburetor starts to move the amount of choke knob travel is the amount of cable play 98 MAINTENANCE AND ADJUSTMENT A Choke Knob B 0 1 mm 0 00 0 04 in Adjustment e Loosen and turn the choke cable mounting nuts next to the starter lever until the cable has the proper amount of play e Tighten the nuts after adjustment Carburetor The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed The following procedure covers the idle speed ad justment Idle Speed Adjustment e Apply the parking brake e Raise the seat e Remove the guard plate by releasing the two air intake ducts and the 6 quick rivets A Guard Plate B Air Intake Ducts 2 p c s C Clamps 6 p c s D Quick Rivets 6 p c s E Cap e Putthe gear shift lever in the Neutral position e Start the engine and warm it up thoroughly A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area e Lift the cargo
100. y result Engine Oil Temperature Warning Light KAF400A The oil temperature warning light comes on when ever the engine oil temperature rises too high while the vehicle is in operation If it stays on stop the en gine and check the engine oil level after the engine cools down Refer to the Engine Oil section in the Mainte nance and Adjustment chapter A Engine Oil Temperature Warning Light GENERAL INFORMATION 35 NOTICE Do not let the engine continue running with a warning light on Prolonged engine opera tion can result in engine damage from over heating 36 GENERAL INFORMATION Fuel Tank The fuel tank is mounted under the right end of the seat The gasoline octane rating listed is recom mended Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated 100008 6 A Fuel Tank B Filling Cap A WARNING Gasoline is extremely flammable and can be explosive under certain conditions creating the potential for serious burns Turn the ig nition switch to OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Never fill the tank completely to the top If the tank is filled completely to the top heat may cause the fuel to expand and overflow through the vents in the tank cap After refueling make sure the
101. y scheduled maintenance The warranty also does not apply to the normal wear of items such as tires brake pads transmission drive belts chains sprockets etc What is the Good Times Protection Plan Much of the warranty coverage offered by the limited warranty can be extended by purchasing Kawasaki s Good Time Protection Plan GTPP See your Kawasaki dealer or go to Kawasaki com for more information if you don t already have the GTPP What Am I Responsible For You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner s manual You are responsible for notifying your dealer immediately if there is a problem and you as the owner will need to authorize the dealer to inspect the unit YOUR WARRANTY OWNER SATISFACTION 131 You will be responsible for paying for routine maintenance including the first scheduled service You can have the required servicing done by your Kawasaki dealer recommended or an equally qualified service facility You can also do your own maintenance work if you have the proper tools service references and mechanical skills However if a failure is found to be caused by improper servicing it would not be covered by the limited warranty You may purchase a Kawasaki Service Manual and any necessary special tools directly from your Kawasaki dealer You will be responsible for paying for repairs needed because of an accident to replace worn parts such as tires c

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