Owners Manual
Page 6
... injection timing characteristics. Maintenance and Warranty Proper maintenance is separated from the gases while passing through the crankcase to ensure that consist of this maintenance. The blow-by gases. Oil is necessary to the intake manifold. Exhaust Emission Control System The exhaust emission control system applied to provide lean air/fuel mixture characteristics, with a suitable air cleaner and exhaust system. This Owner's Manual contains those maintenance recommendations for your engine.
... injection timing characteristics. Maintenance and Warranty Proper maintenance is separated from the gases while passing through the crankcase to ensure that consist of this maintenance. The blow-by gases. Oil is necessary to the intake manifold. Exhaust Emission Control System The exhaust emission control system applied to provide lean air/fuel mixture characteristics, with a suitable air cleaner and exhaust system. This Owner's Manual contains those maintenance recommendations for your engine.
Owners Manual
Page 8
... this Owner's Manual aboard your Mule, give it whenever you can refer to do their Mule, a Service Manual is sold. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. It is the result of Kawasaki's engineering expertise and a tradition of printing. All rights reserved. Those who would like more detailed information on your vehicle's controls, its features, capabilities...
... this Owner's Manual aboard your Mule, give it whenever you can refer to do their Mule, a Service Manual is sold. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. It is the result of Kawasaki's engineering expertise and a tradition of printing. All rights reserved. Those who would like more detailed information on your vehicle's controls, its features, capabilities...
Owners Manual
Page 9
... 49 49 Parking Brake Warning Light...Seats ...Seat Belts ...Steering Wheel...Power Steering Warning Light...Throttle Pedal ...Trailer Hitch Bracket ...Winch Installation ...HOW TO OPERATE ...Daily Safety Checks ...Starting the Engine ...Cold Weather Starting ...Starting After Fuel System Service ...Jump Starting ...Moving Off ...Braking ...Stopping the Engine ...Parking the Mule ...Hi-Lo Shifting ...Reversing Gears ...2WD-4WD Shifting ...Shifting the Differential ...Converting Rear Seat and Cargo Bed...Raising & Lowering the Cargo Bed ...Raising the cargo bed (Shortened Condition) : ...Raising...
... 49 49 Parking Brake Warning Light...Seats ...Seat Belts ...Steering Wheel...Power Steering Warning Light...Throttle Pedal ...Trailer Hitch Bracket ...Winch Installation ...HOW TO OPERATE ...Daily Safety Checks ...Starting the Engine ...Cold Weather Starting ...Starting After Fuel System Service ...Jump Starting ...Moving Off ...Braking ...Stopping the Engine ...Parking the Mule ...Hi-Lo Shifting ...Reversing Gears ...2WD-4WD Shifting ...Shifting the Differential ...Converting Rear Seat and Cargo Bed...Raising & Lowering the Cargo Bed ...Raising the cargo bed (Shortened Condition) : ...Raising...
Owners Manual
Page 10
... ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Injection Pump...Fuel Filter ...Fuel Tank Vent...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Shoe Linings ...Brake Fluid ...Brake Light Switch...Parking Brake Lever...Steering Wheel...Power Steering System...Cargo Bed Latches...Wheels ...Rims ... 78 79 79 80 81 82 82 83 84 85 89 94 97 100 103 104 107 108 110 112 114 114 115 117 117 117 117 119 120 122 122 123 124 124 Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight...
... ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Injection Pump...Fuel Filter ...Fuel Tank Vent...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Shoe Linings ...Brake Fluid ...Brake Light Switch...Parking Brake Lever...Steering Wheel...Power Steering System...Cargo Bed Latches...Wheels ...Rims ... 78 79 79 80 81 82 82 83 84 85 89 94 97 100 103 104 107 108 110 112 114 114 115 117 117 117 117 119 120 122 122 123 124 124 Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight...
Owners Manual
Page 12
... the cab frame while the vehicle is operated. Apply the parking brake, Put the gear shift lever in a recreational setting, like trail driving or any source of a sudden stop or collision. Use only the recommended tires for proper operation. Before Starting the Engine Three "musts" before getting out of an accident. Use the Parking Brake Always apply the parking brake before starting the engine are: 1. 2. Diesel fuel is...
... the cab frame while the vehicle is operated. Apply the parking brake, Put the gear shift lever in a recreational setting, like trail driving or any source of a sudden stop or collision. Use only the recommended tires for proper operation. Before Starting the Engine Three "musts" before getting out of an accident. Use the Parking Brake Always apply the parking brake before starting the engine are: 1. 2. Diesel fuel is...
Owners Manual
Page 13
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Diesel, 3 cylinder, 4-stroke, liquid-cooled 953 cm3 (58.2 cu in.) 72.0 × 78.0 mm (2.83 × 3.07 in.) Long bed mode Short bed mode Front Rear... 287 mm (30.31 × 47.72 × 11.30 in.) Front Rear 3.9 m (12.8 ft) 2 persons 2 persons 52 N·m (5.3 kgf·m, 38.3 ft·lb) @2 800 r/min (rpm)
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Ground Clearance Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Diesel, 3 cylinder, 4-stroke, liquid-cooled 953 cm3 (58.2 cu in.) 72.0 × 78.0 mm (2.83 × 3.07 in.) Long bed mode Short bed mode Front Rear... 287 mm (30.31 × 47.72 × 11.30 in.) Front Rear 3.9 m (12.8 ft) 2 persons 2 persons 52 N·m (5.3 kgf·m, 38.3 ft·lb) @2 800 r/min (rpm)
Owners Manual
Page 18
16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. Belt Drive Torque Converter 17. Battery 14. Handgrip Air Cleaner (Belt Drive Torque Converter) 16. Latch 15. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13.
16 LOCATION OF PARTS LOCATION OF PARTS (Four-person mode) 1. 2. 3. 4. 5. 6. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Front Seat 7. 8. 9. 10. 11. 12. Belt Drive Torque Converter 17. Battery 14. Handgrip Air Cleaner (Belt Drive Torque Converter) 16. Latch 15. Rear Seat Seat Belts Cargo Bed Front Bumper Radiator Parking Brake 13.
Owners Manual
Page 31
... vehicle is sensitive to increases in weight and changes in carrying cargo. The following general guidelines have followed these instructions. Carrying cargo and pulling a trailer can make your own safety and the safety of accessories, or vehicle modifications, will not move around while the vehicle is increased. Make sure the cargo will void the utility vehicle warranty. NOTICE The front body work and fenders...
... vehicle is sensitive to increases in weight and changes in carrying cargo. The following general guidelines have followed these instructions. Carrying cargo and pulling a trailer can make your own safety and the safety of accessories, or vehicle modifications, will not move around while the vehicle is increased. Make sure the cargo will void the utility vehicle warranty. NOTICE The front body work and fenders...
Owners Manual
Page 37
... fully heated. Do not install seating or carry passengers in the "LOADING INFORMATION" chapter. GENERAL INFORMATION 35 WARNING Overloading or improper use of your body, such as hands or arms, between the bed and cab frame or vehicle frame when lifting and lowering the bed. Be careful not to Operate" chapter for 5 seconds when the main key is turned to an accident. Glow Plug Light The light...
... fully heated. Do not install seating or carry passengers in the "LOADING INFORMATION" chapter. GENERAL INFORMATION 35 WARNING Overloading or improper use of your body, such as hands or arms, between the bed and cab frame or vehicle frame when lifting and lowering the bed. Be careful not to Operate" chapter for 5 seconds when the main key is turned to an accident. Glow Plug Light The light...
Owners Manual
Page 45
... main switch key in this position, only START when gear shift lever is equipped with a starter lockout switch. Key B. GENERAL INFORMATION 43 OFF ON Engine off . All electrical circuits off . All electrical equipment can result. Included with the engine running, or damage to the "START" position with the key is a key number, which is stamped on the key itself. NOTICE Do not operate the starter continuously for the ignition switch...
... main switch key in this position, only START when gear shift lever is equipped with a starter lockout switch. Key B. GENERAL INFORMATION 43 OFF ON Engine off . All electrical circuits off . All electrical equipment can result. Included with the engine running, or damage to the "START" position with the key is a key number, which is stamped on the key itself. NOTICE Do not operate the starter continuously for the ignition switch...
Owners Manual
Page 55
... the main switch is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected. Installing such equipment improperly may be adversely affected and will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer. NOTE żThe power steering system functions only when engine is "ON...
... the main switch is running. żIf you experience other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected. Installing such equipment improperly may be adversely affected and will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer. NOTE żThe power steering system functions only when engine is "ON...
Owners Manual
Page 60
... cause serious brain injury or death. Check the restriction gauge for cuts, cracks, damage, or excessive wear. Always perform daily safety checks before operation. Fuel ...Engine oil ...Air Cleaner ...Tires ...Enough fuel in tread. Oil level between level holes (when engine is minimal, and habitual performance of these checks before operation may result in the window. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous...
... cause serious brain injury or death. Check the restriction gauge for cuts, cracks, damage, or excessive wear. Always perform daily safety checks before operation. Fuel ...Engine oil ...Air Cleaner ...Tires ...Enough fuel in tread. Oil level between level holes (when engine is minimal, and habitual performance of these checks before operation may result in the window. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous...
Owners Manual
Page 62
... parking brake. • Apply Shift the gear shift lever in enclosed areas. the engine at that the glow plug NOTE żThe vehicle is turned to the START position, the glow plug light goes on at slow idle until the engine starts. Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power. This switch prevents the electric starter from operating when the gear shift...
... parking brake. • Apply Shift the gear shift lever in enclosed areas. the engine at that the glow plug NOTE żThe vehicle is turned to the START position, the glow plug light goes on at slow idle until the engine starts. Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power. This switch prevents the electric starter from operating when the gear shift...
Owners Manual
Page 63
... required before engine starting if air was introduced into the fuel system during maintenance. (Fuel filter draining/replacement, repairs, etc.) j To bleed out the air: Loosen the air vent plug on top of the fuel filter (It has a 10 mm wrench head. HOW TO OPERATE 61 Cold Weather Starting When parking your vehicle overnight, leaving it back ON again. Wipe up any spilled diesel fuel. Tighten the air vent plug bolt using a 10...
... required before engine starting if air was introduced into the fuel system during maintenance. (Fuel filter draining/replacement, repairs, etc.) j To bleed out the air: Loosen the air vent plug on top of the fuel filter (It has a 10 mm wrench head. HOW TO OPERATE 61 Cold Weather Starting When parking your vehicle overnight, leaving it back ON again. Wipe up any spilled diesel fuel. Tighten the air vent plug bolt using a 10...
Owners Manual
Page 88
.... or or 6,000 10,000 miles of miles of use OPERATION j Engine oil-change* Oil filter-replace ż Throttle pedal play-inspect Idle speed-adjust Fuel hose-replace • • • • • 4 years (D) ż Fuel filter element-change* ż Fuel filter water-drain* Fuel hoses and connections -inspect * Spark arrester-clean Radiator-clean* Radiator hoses and connections-inspect* Coolant-change Cooling fan belt-inspect 1 year D • D • D 2 year (D) D • • D 86 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service After 50 hrs. or 3,000...
.... or or 6,000 10,000 miles of miles of use OPERATION j Engine oil-change* Oil filter-replace ż Throttle pedal play-inspect Idle speed-adjust Fuel hose-replace • • • • • 4 years (D) ż Fuel filter element-change* ż Fuel filter water-drain* Fuel hoses and connections -inspect * Spark arrester-clean Radiator-clean* Radiator hoses and connections-inspect* Coolant-change Cooling fan belt-inspect 1 year D • D • D 2 year (D) D • • D 86 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service After 50 hrs. or 3,000...
Owners Manual
Page 89
...,000 miles of miles of use OPERATION CHASSIS Steering-inspect Steering joint dust boots-inspect Brake pedal play-inspect* Brake fluid level-inspect Parking brake lever-inspect Brake hose and pipe-inspect Brake wear-inspect* Tire wear-inspect* Battery-inspect Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect D j • D • D • • • D • • • D D • • D D • • hrs. MAINTENANCE...
...,000 miles of miles of use OPERATION CHASSIS Steering-inspect Steering joint dust boots-inspect Brake pedal play-inspect* Brake fluid level-inspect Parking brake lever-inspect Brake hose and pipe-inspect Brake wear-inspect* Tire wear-inspect* Battery-inspect Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect D j • D • D • • • D • • • D D • • D D • • hrs. MAINTENANCE...
Owners Manual
Page 102
... it is hot, nor open the radiator cap. WARNING The cooling fan turns on automatically, even with the Periodic Maintenance Chart. 100 MAINTENANCE AND ADJUSTMENT 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 2.5 L (2.6 US qt) Cooling System WARNING The cooling system can get extremely hot during normal operation and cause serious burns...
... it is hot, nor open the radiator cap. WARNING The cooling fan turns on automatically, even with the Periodic Maintenance Chart. 100 MAINTENANCE AND ADJUSTMENT 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 2.5 L (2.6 US qt) Cooling System WARNING The cooling system can get extremely hot during normal operation and cause serious burns...
Owners Manual
Page 121
... Maintenance Chart. A. MAINTENANCE AND ADJUSTMENT 119 the brake forcefully for a few seconds and • Apply check for fluid leakage around the fittings. j Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Brake Light Switch When the brake pedal is excessive or the brake feels mushy, have an authorized Kawasaki dealer inspect it does not, check the bulb and, if necessary, • If adjust the brake light switch...
... Maintenance Chart. A. MAINTENANCE AND ADJUSTMENT 119 the brake forcefully for a few seconds and • Apply check for fluid leakage around the fittings. j Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Brake Light Switch When the brake pedal is excessive or the brake feels mushy, have an authorized Kawasaki dealer inspect it does not, check the bulb and, if necessary, • If adjust the brake light switch...
Owners Manual
Page 122
... parking brake lever functions properly. Parking Brake Lever B. Rubber Boot the parking brake lever up on the bottom. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. j Inspection • Pull the rubber boot up and to the rear. • Pull 8 to access for adjustment. 120 MAINTENANCE AND ADJUSTMENT Adjustment is best-performed by an authorized • Adjustment Kawasaki dealer since the brake light switch...
... parking brake lever functions properly. Parking Brake Lever B. Rubber Boot the parking brake lever up on the bottom. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. j Inspection • Pull the rubber boot up and to the rear. • Pull 8 to access for adjustment. 120 MAINTENANCE AND ADJUSTMENT Adjustment is best-performed by an authorized • Adjustment Kawasaki dealer since the brake light switch...
Owners Manual
Page 139
... work effectively until they will not operate properly and the affected parts must be taken to keep water off the following places. if water gets into the fuse boxes, it can ground out the electrical system. Power Steering System - cover with tape. cover with tape, or stuff in dusty areas. Under the front seat - close opening - Front and rear brakes - When this vehicle. Air cleaner intake...
... work effectively until they will not operate properly and the affected parts must be taken to keep water off the following places. if water gets into the fuse boxes, it can ground out the electrical system. Power Steering System - cover with tape. cover with tape, or stuff in dusty areas. Under the front seat - close opening - Front and rear brakes - When this vehicle. Air cleaner intake...