Owners Manual
Page 5
... the intake manifold. The blow-by gases are necessary to ensure compliance with a suitable air cleaner and exhaust system. You should also retain copies of maintenance work orders, bills, etc., as verification of this engine family is carried out according to this maintenance. Oil is necessary to ensure that consist of a modified injection pump and injection timing characteristics. Maintenance and Warranty Proper maintenance is...
... the intake manifold. The blow-by gases are necessary to ensure compliance with a suitable air cleaner and exhaust system. You should also retain copies of maintenance work orders, bills, etc., as verification of this engine family is carried out according to this maintenance. Oil is necessary to ensure that consist of a modified injection pump and injection timing characteristics. Maintenance and Warranty Proper maintenance is...
Owners Manual
Page 7
... this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. Please read this manual. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. All rights reserved. Motorcycle & Engine Company © 2011 Kawasaki Heavy Industries, Ltd. For those who plan to do their Mule, a Service Manual is available for your Mule, give it the proper care and maintenance...
... this Owner's Manual carefully before starting your vehicle's controls, its features, capabilities, and limitations. Please read this manual. To ensure a long, trouble-free life for purchase from any authorized Kawasaki Mule dealer. All rights reserved. Motorcycle & Engine Company © 2011 Kawasaki Heavy Industries, Ltd. For those who plan to do their Mule, a Service Manual is available for your Mule, give it the proper care and maintenance...
Owners Manual
Page 8
... 44 45 46 46 Parking Brake Warning Light...Seat ...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 ...SAFE OPERATION ...Unfamiliar Terrain ...Driving in Reverse ...Driving in "4WD" ...Turning the Vehicle...Hills...Climbing Hills...
... 44 45 46 46 Parking Brake Warning Light...Seat ...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 ...SAFE OPERATION ...Unfamiliar Terrain ...Driving in Reverse ...Driving in "4WD" ...Turning the Vehicle...Hills...Climbing Hills...
Owners Manual
Page 9
... AND ADJUSTMENT...Periodic Maintenance Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...Cooling System ...Valve Clearance ...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 ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ... 74...
... AND ADJUSTMENT...Periodic Maintenance Chart ...Engine Oil...Front Final Gear Case Oil ...Transmission Case Oil ...Cooling System ...Valve Clearance ...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 ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ... 74...
Owners Manual
Page 11
... make driving more comfortable and could increase the risk of injury in your vehicle. Check the tire pressure frequently. Use only the recommended tires for proper operation. Before Starting the Engine Three "musts" before getting out of injury, always keep arms and legs inside the cab frame while the vehicle is operated. Wearing proper protective gear can affect the vehicle's handling characteristics. Diesel fuel is...
... make driving more comfortable and could increase the risk of injury in your vehicle. Check the tire pressure frequently. Use only the recommended tires for proper operation. Before Starting the Engine Three "musts" before getting out of injury, always keep arms and legs inside the cab frame while the vehicle is operated. Wearing proper protective gear can affect the vehicle's handling characteristics. Diesel fuel is...
Owners Manual
Page 12
10 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Cylinder Numbering Method Firing Order Injection Pump Lubrication System 52 N·m (5.3 kgf·m, 38.3...(46.26 × 51.57 × 11.34 in.) Diesel, 3 cylinder, 4-stroke, liquid-cooled 953 cm³ (58.2 cu in.) 72.0 × 78.0 mm (2.83 × 3.07 in.) 24...
10 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Cylinder Numbering Method Firing Order Injection Pump Lubrication System 52 N·m (5.3 kgf·m, 38.3...(46.26 × 51.57 × 11.34 in.) Diesel, 3 cylinder, 4-stroke, liquid-cooled 953 cm³ (58.2 cu in.) 72.0 × 78.0 mm (2.83 × 3.07 in.) 24...
Owners Manual
Page 16
Front Cargo Hood 4. Front Cargo Compartment 5. Seat 7. Parking Brake 11. Handgrip Cab Frame 3. Seat Belts 8. Battery 12. Air Cleaner (Belt Drive Torque Converter) 14. Steering Wheel 6. Latch 13. Belt Drive Torque Converter 15. Front Bumper 9. Radiator 10. 14 LOCATION OF PARTS LOCATION OF PARTS 1. Headlights 2.
Front Cargo Hood 4. Front Cargo Compartment 5. Seat 7. Parking Brake 11. Handgrip Cab Frame 3. Seat Belts 8. Battery 12. Air Cleaner (Belt Drive Torque Converter) 14. Steering Wheel 6. Latch 13. Belt Drive Torque Converter 15. Front Bumper 9. Radiator 10. 14 LOCATION OF PARTS LOCATION OF PARTS 1. Headlights 2.
Owners Manual
Page 28
... to increases in weight and changes in weight distribution, you have followed these instructions. They may affect vehicle handling in the cargo bed. Before you operate it, make sure that the vehicle is sensitive to your vehicle be equally distributed from side to steer and may break. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design...
... to increases in weight and changes in weight distribution, you have followed these instructions. They may affect vehicle handling in the cargo bed. Before you operate it, make sure that the vehicle is sensitive to your vehicle be equally distributed from side to steer and may break. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design...
Owners Manual
Page 34
.... Do not install seating or carry passengers in handling which can lead to the ON position. A. 32 GENERAL INFORMATION j 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. Glow Plug Light The glow plug light goes on or go off after the flow heats fully. If it does...
.... Do not install seating or carry passengers in handling which can lead to the ON position. A. 32 GENERAL INFORMATION j 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. Glow Plug Light The glow plug light goes on or go off after the flow heats fully. If it does...
Owners Manual
Page 42
... battery power will drop temporarily. Key Number Write your Kawasaki UV. Record the key number in the space provided and store the number in "N" (neutral) position. START NOTICE Do not operate the starter continuously for the ignition switch, and one spare key. This switch prevents the electric starter from operating when the gear shift lever is used . Do not turn the main switch key to the "START" position with a starter...
... battery power will drop temporarily. Key Number Write your Kawasaki UV. Record the key number in the space provided and store the number in "N" (neutral) position. START NOTICE Do not operate the starter continuously for the ignition switch, and one spare key. This switch prevents the electric starter from operating when the gear shift lever is used . Do not turn the main switch key to the "START" position with a starter...
Owners Manual
Page 53
... on when the main switch is "ON", there may be adequate throttle pedal play and stop position. In addition, there must be a problem with the light itself. GENERAL INFORMATION 51 j Power Steering Warning Light The power steering warning light will momentarily illuminate when the main switch is first turned to the rest position when released. Power Steering Warning Light A. Stop driving immediately and see an authorized Kawasaki dealer to have the...
... on when the main switch is "ON", there may be adequate throttle pedal play and stop position. In addition, there must be a problem with the light itself. GENERAL INFORMATION 51 j Power Steering Warning Light The power steering warning light will momentarily illuminate when the main switch is first turned to the rest position when released. Power Steering Warning Light A. Stop driving immediately and see an authorized Kawasaki dealer to have the...
Owners Manual
Page 58
... foreign particles in serious damage or an accident. j WARNING Failure to a safe operating condition. Do not run the engine in the window. The time required is cold), no leaks. Check the restriction gauge for the red band in enclosed areas. Front Final Gear Case ...No oil leaks. Always perform daily safety checks before operation. Air pressure (when cold): Front Rear 69 kPa (0.7 kgf/cm², 10 psi) 167...
... foreign particles in serious damage or an accident. j WARNING Failure to a safe operating condition. Do not run the engine in the window. The time required is cold), no leaks. Check the restriction gauge for the red band in enclosed areas. Front Final Gear Case ...No oil leaks. Always perform daily safety checks before operation. Air pressure (when cold): Front Rear 69 kPa (0.7 kgf/cm², 10 psi) 167...
Owners Manual
Page 60
... the electric starter leaving the throttle open part way (pressing lightly on at that the glow plug NOTE żThe vehicle is equipped with a starter lockout switch. key in the main switch at the OFF the main switch key to the ON position, the glow plug light remains lit for the battery to recover power. NOTICE Do not operate the engine at slow idle until the engine idles • Run smoothly...
... the electric starter leaving the throttle open part way (pressing lightly on at that the glow plug NOTE żThe vehicle is equipped with a starter lockout switch. key in the main switch at the OFF the main switch key to the ON position, the glow plug light remains lit for the battery to recover power. NOTICE Do not operate the engine at slow idle until the engine idles • Run smoothly...
Owners Manual
Page 61
... 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 bracket until fuel flows from loosened air vent plug. Starting After Fuel System Service Air bleeding of the fuel filter. (It has a 10 mm wrench head. Tighten the air vent plug bolt using a 10 mm wrench. Finally, crank the engine to the ON position, lighting the glow plug light. It...
... 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 bracket until fuel flows from loosened air vent plug. Starting After Fuel System Service Air bleeding of the fuel filter. (It has a 10 mm wrench head. Tighten the air vent plug bolt using a 10 mm wrench. Finally, crank the engine to the ON position, lighting the glow plug light. It...
Owners Manual
Page 81
...; D • • • D • • • D D • • • • • hrs. MAINTENANCE AND ADJUSTMENT 79 FREQUENCY First Service OPERATION Coolant-change Cooling fan belt-inspect 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 2 years (D) D Regular Service Every Every Every After 50 Every 100 hrs.
...; D • • • D • • • D D • • • • • hrs. MAINTENANCE AND ADJUSTMENT 79 FREQUENCY First Service OPERATION Coolant-change Cooling fan belt-inspect 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 2 years (D) D Regular Service Every Every Every After 50 Every 100 hrs.
Owners Manual
Page 93
...·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 2.5 L (2.6 US qt) j WARNING Oil on the dipstick with new gasket. Transmission case oil is a toxic substance. When draining or filling the transmission case, be careful that no oil gets on the tires or rims. Clean off any oil that inadvertently...
...·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 2.5 L (2.6 US qt) j WARNING Oil on the dipstick with new gasket. Transmission case oil is a toxic substance. When draining or filling the transmission case, be careful that no oil gets on the tires or rims. Clean off any oil that inadvertently...
Owners Manual
Page 100
... are purged from the muffler. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. 98 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with the gear shift lever in the "N" • • Remove the drain plug from the muffler. (Neutral) position. Drain Plug the parking brake. • Apply In an open area away from combustible materials, • start the engine with a spark arrester approved for...
... are purged from the muffler. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. 98 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with the gear shift lever in the "N" • • Remove the drain plug from the muffler. (Neutral) position. Drain Plug the parking brake. • Apply In an open area away from combustible materials, • start the engine with a spark arrester approved for...
Owners Manual
Page 121
MAINTENANCE AND ADJUSTMENT 119 Suspension j A. Turn here with the following table. Adjusting Sleeve B. Adjusting Sleeve Rear Shock Absorber Spring Force Adjustment The spring adjusting sleeves on the shock absorbers to the desired position. • Spring Action Position 1 2 3 4 5 Spring Force | | | Ļ Stronger Setting Load Soft Ĺ | Ļ Hard Light Ĺ | Ļ Heavy Surface Good Ĺ | Ļ Bad Speed Low Ĺ | Ļ High Shock Absorber B. Turn the...
MAINTENANCE AND ADJUSTMENT 119 Suspension j A. Turn here with the following table. Adjusting Sleeve B. Adjusting Sleeve Rear Shock Absorber Spring Force Adjustment The spring adjusting sleeves on the shock absorbers to the desired position. • Spring Action Position 1 2 3 4 5 Spring Force | | | Ļ Stronger Setting Load Soft Ĺ | Ļ Hard Light Ĺ | Ļ Heavy Surface Good Ĺ | Ļ Bad Speed Low Ĺ | Ļ High Shock Absorber B. Turn the...
Owners Manual
Page 130
... Kawasaki dealer or perform it referring to salt air, or operated on rainy days, rough terrain, or in rags. 128 MAINTENANCE AND ADJUSTMENT General Lubrication In accordance with the Periodic Maintenance Chart, have dried out. Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the electrical system. cover with tape. if water gets into the fuse...
... Kawasaki dealer or perform it referring to salt air, or operated on rainy days, rough terrain, or in rags. 128 MAINTENANCE AND ADJUSTMENT General Lubrication In accordance with the Periodic Maintenance Chart, have dried out. Air cleaner intake (middle of your vehicle, wash it down immediately after it can ground out the electrical system. cover with tape. if water gets into the fuse...
Owners Manual
Page 132
... cylinder with a pilot light. Contact your local authorities for approved disposal methods. WARNING Motor oil is extremely flammable and can be used oil properly. Catch the fuel in fresh engine oil. • Put the fuel from the fuel tank, and remove the • Empty fuel from any appliance with 3 cc engine oil by loosening air vent plug and the drain cap. Turn the main switch OFF. Close the air vent plug and...
... cylinder with a pilot light. Contact your local authorities for approved disposal methods. WARNING Motor oil is extremely flammable and can be used oil properly. Catch the fuel in fresh engine oil. • Put the fuel from the fuel tank, and remove the • Empty fuel from any appliance with 3 cc engine oil by loosening air vent plug and the drain cap. Turn the main switch OFF. Close the air vent plug and...