Owners Manual
Page 5
... intake manifold. Instead, fuel vapors are led to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of the crankcase. 2. Evaporative Emission Control System (Other than California model) The evaporative emission control system for this engine family is stopped. The blow-by gases. High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of exhaust pollutants entering the atmosphere. 3-1. A maintenance free ignition...
... intake manifold. Instead, fuel vapors are led to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of the crankcase. 2. Evaporative Emission Control System (Other than California model) The evaporative emission control system for this engine family is stopped. The blow-by gases. High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of exhaust pollutants entering the atmosphere. 3-1. A maintenance free ignition...
Owners Manual
Page 6
... parts Spark plug Magneto or electronic battery ignition system Fuel filter Air cleaner element the acts listed below: NOTE hoses • Fuel Fuel tank • Muffler and carbon canister (California model only) • Installation Instructions: High altitude adjustment requires replacement of design incorporated into any person. Among those maintenance recommendations for purposes of maintenance, repair, or replacement, of any device or element of certain carburetor components and belt drive torque converter...
... parts Spark plug Magneto or electronic battery ignition system Fuel filter Air cleaner element the acts listed below: NOTE hoses • Fuel Fuel tank • Muffler and carbon canister (California model only) • Installation Instructions: High altitude adjustment requires replacement of design incorporated into any person. Among those maintenance recommendations for purposes of maintenance, repair, or replacement, of any device or element of certain carburetor components and belt drive torque converter...
Owners Manual
Page 8
... their Mule, a Service Manual is available for your Mule, give it is the result of Kawasaki's engineering expertise and a tradition of manufacturing high-quality consumer products. The Service Manual contains detailed disassembly and maintenance information. Keep this Owner's Manual aboard your Mule at the time of printing. No part of this manual. Those who would like more detailed information on your purchase of a new Kawasaki Mule...
... their Mule, a Service Manual is available for your Mule, give it is the result of Kawasaki's engineering expertise and a tradition of manufacturing high-quality consumer products. The Service Manual contains detailed disassembly and maintenance information. Keep this Owner's Manual aboard your Mule at the time of printing. No part of this manual. Those who would like more detailed information on your purchase of a new Kawasaki Mule...
Owners Manual
Page 9
... ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Choke Knob...Engine Oil Temperature Warning Light (KAF400 A/C) ...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF400A/C)...Differential Shift Lever ...Parking Brake Lever...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch...
... ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Choke Knob...Engine Oil Temperature Warning Light (KAF400 A/C) ...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF400A/C)...Differential Shift Lever ...Parking Brake Lever...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch...
Owners Manual
Page 10
Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System (California model only) ...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ...Battery ...Fuse ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ......
Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System (California model only) ...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ...Battery ...Fuse ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ......
Owners Manual
Page 13
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Track: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) ENGINE Type Displacement (A/C) 29.7 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) (B) 27.9 N·m (2.8 kgf·m, 21.0 ft·lb) @2 ...lb) (C) 469 kg (1 034 lb) 1 044 × 900 × 245 mm (41.10 × 35.43 × 9.65 in.) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in)
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Track: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) ENGINE Type Displacement (A/C) 29.7 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) (B) 27.9 N·m (2.8 kgf·m, 21.0 ft·lb) @2 ...lb) (C) 469 kg (1 034 lb) 1 044 × 900 × 245 mm (41.10 × 35.43 × 9.65 in.) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in)
Owners Manual
Page 14
...; Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio: Forward Reverse 9.263 (High) (A/C) 13.706 (Low) 11.910 (A/C) 3.851 4.000 (A/C) Gear (2WD/4WD) (B) Gear (2WD) (A/C) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic 3.653 ∼ 0.794 (Belt drive torque converter) 82 × 76 mm (3,23 × 2.99 in.) (A/C) 8.6 : 1 (B) 8.3 : 1 Electric starter NIKKI 6C1026 Magneto...
...; Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio: Forward Reverse 9.263 (High) (A/C) 13.706 (Low) 11.910 (A/C) 3.851 4.000 (A/C) Gear (2WD/4WD) (B) Gear (2WD) (A/C) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic 3.653 ∼ 0.794 (Belt drive torque converter) 82 × 76 mm (3,23 × 2.99 in.) (A/C) 8.6 : 1 (B) 8.3 : 1 Electric starter NIKKI 6C1026 Magneto...
Owners Manual
Page 20
18 LOCATION OF PARTS 28. 29. 30. 31. Parking Brake Warning Light 33. 34. 35. 36. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A/C) 37. Accessory Connector 39. 40. 41. 42. Ignition Switch 38. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32.
18 LOCATION OF PARTS 28. 29. 30. 31. Parking Brake Warning Light 33. 34. 35. 36. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A/C) 37. Accessory Connector 39. 40. 41. 42. Ignition Switch 38. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32.
Owners Manual
Page 29
... an unsafe operating condition. They may affect vehicle handling in loading the vehicle, you make your own safety and the safety of others. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories, or vehicle modifications, will not move around while the vehicle is increased. Braking • Reduce distance is moving. Cargo weight should be...
... an unsafe operating condition. They may affect vehicle handling in loading the vehicle, you make your own safety and the safety of others. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories, or vehicle modifications, will not move around while the vehicle is increased. Braking • Reduce distance is moving. Cargo weight should be...
Owners Manual
Page 42
... gear shift lever is equipped with your Kawasaki dealer. Hour meter works. Ask your dealer to make any additional spare keys you need, using the key code on the tag with a starter lockout switch. This switch prevents the electric starter from the tag with the engine running, or damage to recover power. NOTICE Do not operate the starter continuously for the battery to the starter can result. START Blank keys...
... gear shift lever is equipped with your Kawasaki dealer. Hour meter works. Ask your dealer to make any additional spare keys you need, using the key code on the tag with a starter lockout switch. This switch prevents the electric starter from the tag with the engine running, or damage to recover power. NOTICE Do not operate the starter continuously for the battery to the starter can result. START Blank keys...
Owners Manual
Page 53
..., or refer to the Service Manual for the action required to return the vehicle to perform these checks will help ensure safe, reliable operation. HOW TO OPERATE 51 HOW TO OPERATE Daily Safety Checks Check the following items each day before operation. j WARNING Failure to a safe operating condition. Fuel ...Enough fuel in tread. The time required is cold), no leaks. Check for cuts...
..., or refer to the Service Manual for the action required to return the vehicle to perform these checks will help ensure safe, reliable operation. HOW TO OPERATE 51 HOW TO OPERATE Daily Safety Checks Check the following items each day before operation. j WARNING Failure to a safe operating condition. Fuel ...Enough fuel in tread. The time required is cold), no leaks. Check for cuts...
Owners Manual
Page 54
... TO OPERATE Transmission Case Oil ...Oil level between level lines, no leaks. Steering ...Steering wheel free play , rough spots, or strange noises. Brake fluid level between H and L lines, no leaks. Battery ...Electrolyte level between level lines in .). Engine Cooling Fan Screen ...Check for braking effectiveness (while test running). Action smooth without excessive play 0 ∼ 20 mm (0 ∼ 0.8 in .). Brake pedal free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Throttle ...Throttle pedal free...
... TO OPERATE Transmission Case Oil ...Oil level between level lines, no leaks. Steering ...Steering wheel free play , rough spots, or strange noises. Brake fluid level between H and L lines, no leaks. Battery ...Electrolyte level between level lines in .). Engine Cooling Fan Screen ...Check for braking effectiveness (while test running). Action smooth without excessive play 0 ∼ 20 mm (0 ∼ 0.8 in .). Brake pedal free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Throttle ...Throttle pedal free...
Owners Manual
Page 55
... stepping re- the seat belts (both operator and passen• Wear ger). Push down the throttle pedal slightly. If the engine is equipped with the following procedure. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the switch. • j Mechanism of the choke knob.) żWhen engine is cold and air temperature is 20...
... stepping re- the seat belts (both operator and passen• Wear ger). Push down the throttle pedal slightly. If the engine is equipped with the following procedure. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the switch. • j Mechanism of the choke knob.) żWhen engine is cold and air temperature is 20...
Owners Manual
Page 73
... use of use 4 years (D) ż Fuel hose-replace Evaporative emission control system-function (California model only)* j • • D • • D CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect D • •...
... use of use 4 years (D) ż Fuel hose-replace Evaporative emission control system-function (California model only)* j • • D • • D CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect D • •...
Owners Manual
Page 84
... gasket is a toxic substance. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) 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/C: 2.4 L (2.5 US qt) KAF400B: 2.2 L (2.3 US qt) j the cargo bed and support it with soap and water. 82 MAINTENANCE AND ADJUSTMENT WARNING The exhaust...
... gasket is a toxic substance. Tightening Torque Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) 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/C: 2.4 L (2.5 US qt) KAF400B: 2.2 L (2.3 US qt) j the cargo bed and support it with soap and water. 82 MAINTENANCE AND ADJUSTMENT WARNING The exhaust...
Owners Manual
Page 90
... the spark arrester in the "N" and lower engine speed while tapping on • Raise the muffler with the Periodic Maintenance Chart. Since the engine must be properly maintained to provide adequate fire protection. A. Do not run the engine in a well-ventilated area. Drain Plug the parking brake. • Apply In an open area away from combustible materials, • start the engine with the gear shift lever in...
... the spark arrester in the "N" and lower engine speed while tapping on • Raise the muffler with the Periodic Maintenance Chart. Since the engine must be properly maintained to provide adequate fire protection. A. Do not run the engine in a well-ventilated area. Drain Plug the parking brake. • Apply In an open area away from combustible materials, • start the engine with the gear shift lever in...
Owners Manual
Page 95
... 93 Carburetor The idle speed adjustment should be performed in .) j Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • proper amount of play. The following procedure covers the idle speed adjustment. Idle Speed Adjustment the parking brake. • Apply Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and...
... 93 Carburetor The idle speed adjustment should be performed in .) j Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • proper amount of play. The following procedure covers the idle speed adjustment. Idle Speed Adjustment the parking brake. • Apply Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and...
Owners Manual
Page 107
... A. The brake light switch should • go on . j A. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. MAINTENANCE AND ADJUSTMENT 105 Brake Light Switch When the brake pedal is located above the brake Inspection the ignition switch to the "ON" position. • Turn Depress the brake pedal. To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and...
... A. The brake light switch should • go on . j A. Brake Pedal B. 10 mm (0.4 in accordance with the Periodic Maintenance Chart. MAINTENANCE AND ADJUSTMENT 105 Brake Light Switch When the brake pedal is located above the brake Inspection the ignition switch to the "ON" position. • Turn Depress the brake pedal. To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and...
Owners Manual
Page 108
In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. j Inspection A. Brake Light Switch Adjusting Nut Lights sooner. Parking Brake Lever the parking brake lever up and to the rear. • Pull After to 12 clicks of lever travel, the vehicle • should8 not roll while parked. B. Lights later. If it does, adjust the parking brake lever. • Adjustment • Raise the seat. D. A. C. 106 MAINTENANCE AND ADJUSTMENT 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. j Inspection A. Brake Light Switch Adjusting Nut Lights sooner. Parking Brake Lever the parking brake lever up and to the rear. • Pull After to 12 clicks of lever travel, the vehicle • should8 not roll while parked. B. Lights later. If it does, adjust the parking brake lever. • Adjustment • Raise the seat. D. A. C. 106 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked.
Owners Manual
Page 124
... ignition switch "OFF". Install the spark plugs. Contact your local authorities for use . 122 STORAGE STORAGE Preparation for about five minutes to draining the fuel system, a fuel stabilizer, such as Kawasaki K-Kare Fogging Oil (part number K61030-002), directly into each cylinder. the spark plug and spray fogging oil, such • Remove as STA-BIL, may contain poisonous substances. Turn the engine over several times with a pilot light. WARNING...
... ignition switch "OFF". Install the spark plugs. Contact your local authorities for use . 122 STORAGE STORAGE Preparation for about five minutes to draining the fuel system, a fuel stabilizer, such as Kawasaki K-Kare Fogging Oil (part number K61030-002), directly into each cylinder. the spark plug and spray fogging oil, such • Remove as STA-BIL, may contain poisonous substances. Turn the engine over several times with a pilot light. WARNING...