Owners Manual
Page 5
.... Exhaust Emission Control System The exhaust emission control system applied to this vehicle consists of the United States Environmental Protections Agency and California Air Resources Board. 1. Oil is led to the intake manifold. The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of low permeation fuel hoses and fuel tank. Instead, fuel vapors are not vented into the running engine...
.... Exhaust Emission Control System The exhaust emission control system applied to this vehicle consists of the United States Environmental Protections Agency and California Air Resources Board. 1. Oil is led to the intake manifold. The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of low permeation fuel hoses and fuel tank. Instead, fuel vapors are not vented into the running engine...
Owners Manual
Page 6
... purposes of maintenance, repair, or replacement, of any device or element of emission control prior to its sale or delivery to be emissions system "tampering" and vehicle performance is generally unchanged as verification of certain carburetor components and belt drive torque converter components. Installation Instructions: High altitude adjustment requires replacement of this record, we have low emission levels. This Owner's Manual contains those...
... purposes of maintenance, repair, or replacement, of any device or element of emission control prior to its sale or delivery to be emissions system "tampering" and vehicle performance is generally unchanged as verification of certain carburetor components and belt drive torque converter components. Installation Instructions: High altitude adjustment requires replacement of this record, we have low emission levels. This Owner's Manual contains those...
Owners Manual
Page 8
... plan to do their Mule, a Service Manual is sold. This publication includes the latest information available at all times so that you need information. Please read this Owner's Manual aboard your Mule at the time of your new Mule so that you can refer to change without our prior written permission. Keep this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations...
... plan to do their Mule, a Service Manual is sold. This publication includes the latest information available at all times so that you need information. Please read this Owner's Manual aboard your Mule at the time of your new Mule so that you can refer to change without our prior written permission. Keep this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations...
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
Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Ignition Switch 38. 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. Parking Brake Warning Light 33. 34. 35. 36. Accessory Connector 39. 40. 41. 42. 18 LOCATION OF PARTS 28. 29. 30. 31.
Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Ignition Switch 38. 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. Parking Brake Warning Light 33. 34. 35. 36. Accessory Connector 39. 40. 41. 42. 18 LOCATION OF PARTS 28. 29. 30. 31.
Owners Manual
Page 29
... hills, and traversing slopes. Cargo weight should be equally distributed from side to steer and may break. They may affect vehicle handling in an unsafe operating condition. Before you make sure that extends beyond the rear of the cab frame. This helps maintain stability by centralizing weight. In some cases, improper installation or use of accessories. Braking • Reduce distance is...
... hills, and traversing slopes. Cargo weight should be equally distributed from side to steer and may break. They may affect vehicle handling in an unsafe operating condition. Before you make sure that extends beyond the rear of the cab frame. This helps maintain stability by centralizing weight. In some cases, improper installation or use of accessories. Braking • Reduce distance is...
Owners Manual
Page 42
... and the battery power will return to recover power. Upon release, key will drop temporarily. NOTICE Do not operate the starter continuously for the battery to "ON" position. START Blank keys are lost. Hour meter works. Record the code from operating when the gear shift lever is equipped with your original keys are available at your key number here. żThe NOTE vehicle is in "N" (neutral) position.
... and the battery power will return to recover power. Upon release, key will drop temporarily. NOTICE Do not operate the starter continuously for the battery to "ON" position. START Blank keys are lost. Hour meter works. Record the code from operating when the gear shift lever is equipped with your original keys are available at your key number here. żThe NOTE vehicle is in "N" (neutral) position.
Owners Manual
Page 53
... refer to the Service Manual for cuts, cracks, damage, or excessive wear. j WARNING Failure to a safe operating condition. Engine oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks before operation may result in serious damage or an accident. Fuel ...Enough fuel in a well-ventilated area. Do not run the engine in tread. DANGER Exhaust gas contains carbon monoxide...
... refer to the Service Manual for cuts, cracks, damage, or excessive wear. j WARNING Failure to a safe operating condition. Engine oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks before operation may result in serious damage or an accident. Fuel ...Enough fuel in a well-ventilated area. Do not run the engine in tread. DANGER Exhaust gas contains carbon monoxide...
Owners Manual
Page 54
... .). Throttle pedal operates smoothly and returns to lights. Engine Cooling Fan Screen ...Check for braking effectiveness (while test running). Electrical Equipment ...All lights and horn work. j Steering ...Steering wheel free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Brakes ...Check for mud and other debris. 52 HOW TO OPERATE Transmission Case Oil ...Oil level between level lines, no leaks. Battery ...Electrolyte level between level lines in .). Brake pedal free play , rough spots, or strange noises. Brake fluid level...
... .). Throttle pedal operates smoothly and returns to lights. Engine Cooling Fan Screen ...Check for braking effectiveness (while test running). Electrical Equipment ...All lights and horn work. j Steering ...Steering wheel free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Brakes ...Check for mud and other debris. 52 HOW TO OPERATE Transmission Case Oil ...Oil level between level lines, no leaks. Battery ...Electrolyte level between level lines in .). Brake pedal free play , rough spots, or strange noises. Brake fluid level...
Owners Manual
Page 55
... only in the ignition switch to the start po• Turn sition to close. żBy further pulling the knob over the stepping re- the seat belts (both operator and passen• Wear ger). the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the carburetor starts to activate the electric starter. If the engine is hard...
... only in the ignition switch to the start po• Turn sition to close. żBy further pulling the knob over the stepping re- the seat belts (both operator and passen• Wear ger). the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the carburetor starts to activate the electric starter. If the engine is hard...
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
... up to the spec- • Install the filler plug and dipstick. • ified torque. 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 tires can get extremely hot during oil draining. If the gasket is a toxic substance. 82 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can...
... up to the spec- • Install the filler plug and dipstick. • ified torque. 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 tires can get extremely hot during oil draining. If the gasket is a toxic substance. 82 MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can...
Owners Manual
Page 90
... gear shift lever in accordance with a rubber mallet until carbon particles are purged from the muffler. (Neutral) position. • Remove the drain plug from the muffler. Do not run the engine in a well-ventilated area. Operate only in enclosed areas. Clean the spark arrester in the "N" and lower engine speed while tapping on • Raise the muffler with the Periodic Maintenance Chart. Spark Arrester Cleaning WARNING...
... gear shift lever in accordance with a rubber mallet until carbon particles are purged from the muffler. (Neutral) position. • Remove the drain plug from the muffler. Do not run the engine in a well-ventilated area. Operate only in enclosed areas. Clean the spark arrester in the "N" and lower engine speed while tapping on • Raise the muffler with the Periodic Maintenance Chart. Spark Arrester Cleaning WARNING...
Owners Manual
Page 95
...; 0.04 in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. Air Intake Ducts (2 p.c.s.) C. The following procedure covers the idle speed adjustment. Clamps (6 p.c.s.) D. A. Guard Plate B. Tighten the nuts after adjustment. Cap A. MAINTENANCE AND ADJUSTMENT 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...
...; 0.04 in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. Air Intake Ducts (2 p.c.s.) C. The following procedure covers the idle speed adjustment. Clamps (6 p.c.s.) D. A. Guard Plate B. Tighten the nuts after adjustment. Cap A. MAINTENANCE AND ADJUSTMENT 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...
Owners Manual
Page 107
... Maintenance Chart. To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. NOTICE A. j A. Brake Light Switch B. MAINTENANCE AND ADJUSTMENT 105 Brake Light Switch When the brake pedal is located above the brake Inspection the ignition switch...
... Maintenance Chart. To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. NOTICE A. j A. Brake Light Switch B. MAINTENANCE AND ADJUSTMENT 105 Brake Light Switch When the brake pedal is located above the brake Inspection the ignition switch...
Owners Manual
Page 108
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. D. C. A. If it does, adjust the parking brake lever. • Adjustment • Raise the seat. Lights later. 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. D. C. A. If it does, adjust the parking brake lever. • Adjustment • Raise the seat. Lights later. 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.
Owners Manual
Page 124
... an alternative to warm the oil, shut it off and drain the engine oil. • • WARNING Gasoline is a toxic substance. Follow the manufacturer's instructions for use . Run the engine for Storage: Clean the entire vehicle thoroughly. Dispose of fuel properly. 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...
... an alternative to warm the oil, shut it off and drain the engine oil. • • WARNING Gasoline is a toxic substance. Follow the manufacturer's instructions for use . Run the engine for Storage: Clean the entire vehicle thoroughly. Dispose of fuel properly. 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...