Owners Manual
Page 5
.... 2. Exhaust Emission Control System The exhaust emission control system applied to the intake manifold. The blow-by gases. Evaporative Emission Control System The evaporative emission control system for this engine family is stopped. Instead, fuel vapors are routed into the atmosphere. High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of a catalytic converter in the muffler, a modified carburetor and ignition system having optimum ignition timing characteristics. A maintenance free ignition...
.... 2. Exhaust Emission Control System The exhaust emission control system applied to the intake manifold. The blow-by gases. Evaporative Emission Control System The evaporative emission control system for this engine family is stopped. Instead, fuel vapors are routed into the atmosphere. High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of a catalytic converter in the muffler, a modified carburetor and ignition system having optimum ignition timing characteristics. A maintenance free ignition...
Owners Manual
Page 6
... authorized Kawasaki dealer, or someone equally competent, can record the maintenance. Kawasaki will continue to ensure compliance with the dealership management and need to be performed by the Periodic Maintenance Chart are not considered to take it and any warranty issues. This Owner's Manual contains those maintenance recommendations for your vehicle. at the end of certain carburetor components and belt drive torque converter components...
... authorized Kawasaki dealer, or someone equally competent, can record the maintenance. Kawasaki will continue to ensure compliance with the dealership management and need to be performed by the Periodic Maintenance Chart are not considered to take it and any warranty issues. This Owner's Manual contains those maintenance recommendations for your vehicle. at the end of certain carburetor components and belt drive torque converter components...
Owners Manual
Page 8
...in this Owner's Manual carefully before starting your Mule at the time of a new Kawasaki Mule. Jan. 2011. (1). The Service Manual contains detailed disassembly and maintenance information. KAWASAKI HEAVY ...change without our prior written permission. All products are subject to it the proper care and maintenance described in this manual. This manual should remain with the proper operation of 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...
...in this Owner's Manual carefully before starting your Mule at the time of a new Kawasaki Mule. Jan. 2011. (1). The Service Manual contains detailed disassembly and maintenance information. KAWASAKI HEAVY ...change without our prior written permission. All products are subject to it the proper care and maintenance described in this manual. This manual should remain with the proper operation of 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...
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 (KAF400A)...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Keys ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF400A) ...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 (KAF400A)...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Keys ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF400A) ...Differential Shift Lever ...Parking Brake Lever...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch...
Owners Manual
Page 10
Cooling Fan ...Spark Plug...Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System ...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...YOUR WARRANTY/OWNER ...
Cooling Fan ...Spark Plug...Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System ...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...YOUR WARRANTY/OWNER ...
Owners Manual
Page 14
... Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Kawasaki Performance 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 Capacity DRIVE TRAIN Driving Type Transmission Type (A) Gear (2WD/4WD) (B) Gear (2WD) (A) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic SAE 10W-40 1.4 L (1.5 US qt) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm...
... Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil: Type Kawasaki Performance 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 Capacity DRIVE TRAIN Driving Type Transmission Type (A) Gear (2WD/4WD) (B) Gear (2WD) (A) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic SAE 10W-40 1.4 L (1.5 US qt) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm...
Owners Manual
Page 21
Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A) 37. Ignition Switch 38. Accessory Connector 39. 40. 41. 42. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Parking Brake Warning Light 33. 34. 35. 36. LOCATION OF PARTS 19 28. 29. 30. 31.
Glove Compartment Brake Fluid Level Brake Light Switch Light Switch Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A) 37. Ignition Switch 38. Accessory Connector 39. 40. 41. 42. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Parking Brake Warning Light 33. 34. 35. 36. LOCATION OF PARTS 19 28. 29. 30. 31.
Owners Manual
Page 30
...to increases in weight and changes in weight distribution, you add to side. All cargo should be genuine Kawasaki components. • • NOTICE The front body work and fenders are personally responsible for use on top of your vehicle be securely ...WARNING Incorrect loading, improper installation or use of accessories, or modification of the cab frame. Do not carry cargo on Kawasaki utility vehicles. Make sure the cargo will void the utility vehicle warranty. In some cases, improper installation or use of others. They may affect vehicle handling in the cargo bed...
...to increases in weight and changes in weight distribution, you add to side. All cargo should be genuine Kawasaki components. • • NOTICE The front body work and fenders are personally responsible for use on top of your vehicle be securely ...WARNING Incorrect loading, improper installation or use of accessories, or modification of the cab frame. Do not carry cargo on Kawasaki utility vehicles. Make sure the cargo will void the utility vehicle warranty. In some cases, improper installation or use of others. They may affect vehicle handling in the cargo bed...
Owners Manual
Page 35
... or arms, between the bed and cab frame or vehicle frame when lifting and lowering the bed. The choke knob located on (pulled out) after the engine has warmed up using the choke and throttle until the idle speed is left on the dashboard, to the left of the steering wheel, provides a rich mixture for detailed information. Follow guidelines provided in the cargo bed. Driving with...
... or arms, between the bed and cab frame or vehicle frame when lifting and lowering the bed. The choke knob located on (pulled out) after the engine has warmed up using the choke and throttle until the idle speed is left on the dashboard, to the left of the steering wheel, provides a rich mixture for detailed information. Follow guidelines provided in the cargo bed. Driving with...
Owners Manual
Page 43
... engine running, or damage to the starter can be used for more than 5 seconds, or the starter will overheat and the battery power will return to have a duplicate made. NOTE żThe vehicle is stamped on the key itself. This switch prevents the electric starter from operating when the gear shift lever is in "N" (neutral) position. START NOTICE Do not operate the starter continuously for the ignition switch...
... engine running, or damage to the starter can be used for more than 5 seconds, or the starter will overheat and the battery power will return to have a duplicate made. NOTE żThe vehicle is stamped on the key itself. This switch prevents the electric starter from operating when the gear shift lever is in "N" (neutral) position. START NOTICE Do not operate the starter continuously for the ignition switch...
Owners Manual
Page 55
... action required to return the vehicle to a safe operating condition. Front Final Gear Case ...No oil leaks (KAF400A). j WARNING Failure to the Service Manual for cuts, cracks, damage, or excessive wear. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Engine oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your...
... action required to return the vehicle to a safe operating condition. Front Final Gear Case ...No oil leaks (KAF400A). j WARNING Failure to the Service Manual for cuts, cracks, damage, or excessive wear. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Engine oil ...Oil level between "H" and "L" lines (when engine is minimal, and habitual performance of these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your...
Owners Manual
Page 56
... (0 a 0.8 in .). Brake fluid level between level lines, no leaks. Battery ...Electrolyte level between level lines in .). Steering ...Steering wheel free play 2 a 5 mm (0.1 a 0.2 in .). Engine Cooling Fan Screen ...Check for braking effectiveness (while test running). Action smooth without excessive play 2 a 5 mm (0.1 a 0.2 in each cell. Electrical Equipment ...All lights and horn work. Brakes ...Check for mud and other debris. Check for dirt on or damage to rest position when released. Throttle ...Throttle pedal...
... (0 a 0.8 in .). Brake fluid level between level lines, no leaks. Battery ...Electrolyte level between level lines in .). Steering ...Steering wheel free play 2 a 5 mm (0.1 a 0.2 in .). Engine Cooling Fan Screen ...Check for braking effectiveness (while test running). Action smooth without excessive play 2 a 5 mm (0.1 a 0.2 in each cell. Electrical Equipment ...All lights and horn work. Brakes ...Check for mud and other debris. Check for dirt on or damage to rest position when released. Throttle ...Throttle pedal...
Owners Manual
Page 66
... start the engine by rolling the vehicle if the battery is in the converter allowing the converter to protect the emission control parts, do not turn off . Do not idle or park your vehicle in property damage or severe personal injury. Never use leaded • Use gasoline. Do not operate the vehicle with the ignition switch • Do and/or engine stop . Under these conditions unburned air/fuel...
... start the engine by rolling the vehicle if the battery is in the converter allowing the converter to protect the emission control parts, do not turn off . Do not idle or park your vehicle in property damage or severe personal injury. Never use leaded • Use gasoline. Do not operate the vehicle with the ignition switch • Do and/or engine stop . Under these conditions unburned air/fuel...
Owners Manual
Page 76
... km of use of use 5 years (D) j Fuel hose-replace ż Evaporative emission control system-function* • • 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 • •...
... km of use of use 5 years (D) j Fuel hose-replace ż Evaporative emission control system-function* • • 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 87
... touch a hot muffler or exhaust pipe during normal operation and cause serious burns. 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 make them with the hook. • Lift • Remove the filler plug. MAINTENANCE AND ADJUSTMENT 85 WARNING The exhaust system can cause...
... touch a hot muffler or exhaust pipe during normal operation and cause serious burns. 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 make them with the hook. • Lift • Remove the filler plug. MAINTENANCE AND ADJUSTMENT 85 WARNING The exhaust system can cause...
Owners Manual
Page 93
... Plug B. A. Spark Arrester (inside the muffler) the parking brake. • Apply In an open area away from combustible materials, • start the engine with the 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. MAINTENANCE AND ADJUSTMENT 91 Spark Arrester This vehicle...
... Plug B. A. Spark Arrester (inside the muffler) the parking brake. • Apply In an open area away from combustible materials, • start the engine with the 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. MAINTENANCE AND ADJUSTMENT 91 Spark Arrester This vehicle...
Owners Manual
Page 98
... after adjustment. Cap 96 MAINTENANCE AND ADJUSTMENT Carburetor The idle speed adjustment should be performed in .) Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • proper amount of play. j Idle Speed Adjustment the parking brake. • Apply Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and the...
... after adjustment. Cap 96 MAINTENANCE AND ADJUSTMENT Carburetor The idle speed adjustment should be performed in .) Adjustment and turn the choke cable mounting nuts • Loosen next to the starter lever until the cable has the • proper amount of play. j Idle Speed Adjustment the parking brake. • Apply Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and the...
Owners Manual
Page 109
... brake feel mushy or soft. The brake light switch should • Depress go on . Inspection Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. j A. Brake Light Switch When the brake pedal is depressed, the brake light goes on after about 10 mm (0.4 in.) of pedal travel is located above the brake The brake light should be inspected in .) it immediately. MAINTENANCE AND ADJUSTMENT 107 WARNING Air in an accident. Brake...
... brake feel mushy or soft. The brake light switch should • Depress go on . Inspection Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. j A. Brake Light Switch When the brake pedal is depressed, the brake light goes on after about 10 mm (0.4 in.) of pedal travel is located above the brake The brake light should be inspected in .) it immediately. MAINTENANCE AND ADJUSTMENT 107 WARNING Air in an accident. Brake...
Owners Manual
Page 110
108 MAINTENANCE AND ADJUSTMENT j A. Brake Light Switch B. A. Brake Light Switch Adjusting Nut Lights sooner. Lights later. B. C. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. D. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut.
108 MAINTENANCE AND ADJUSTMENT j A. Brake Light Switch B. A. Brake Light Switch Adjusting Nut Lights sooner. Lights later. B. C. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. D. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut.
Owners Manual
Page 126
... . Turn the engine over several times with a pilot light. WARNING Gasoline is a toxic substance. Turn the ignition switch "OFF". j WARNING Fuel stabilizers may be explosive under certain conditions and cause severe burns. Install the spark plugs. 124 STORAGE STORAGE Preparation for approved disposal methods or possible recycling. NOTE żAs an alternative to warm the oil, shut it off and drain the engine oil. • • WARNING Gasoline...
... . Turn the engine over several times with a pilot light. WARNING Gasoline is a toxic substance. Turn the ignition switch "OFF". j WARNING Fuel stabilizers may be explosive under certain conditions and cause severe burns. Install the spark plugs. 124 STORAGE STORAGE Preparation for approved disposal methods or possible recycling. NOTE żAs an alternative to warm the oil, shut it off and drain the engine oil. • • WARNING Gasoline...