Owners Manual
Page 5
... with your use . Passenger(s) should be hazardous. Choose a helmet most appropriate for your new Kawasaki vehicle. Habitual performance of this vehicle change depending upon cargo load and driving modes. Even drugs prescribed by placing both feet firmly on public roads and paved surfaces is especially important for your satisfaction with back against seat, feet flat on floor, and hands on...
... with your use . Passenger(s) should be hazardous. Choose a helmet most appropriate for your new Kawasaki vehicle. Habitual performance of this vehicle change depending upon cargo load and driving modes. Even drugs prescribed by placing both feet firmly on public roads and paved surfaces is especially important for your satisfaction with back against seat, feet flat on floor, and hands on...
Owners Manual
Page 8
... increase in noise level. Among those maintenance recommendations for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it with effective intake and exhaust silencing systems. They are necessary to ensure compliance with the original emission related parts: Throttle body and internal parts Spark plugs Magneto or electronic battery ignition system Fuel filter/Fuel injector/Fuel pump Air cleaner element...
... increase in noise level. Among those maintenance recommendations for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it with effective intake and exhaust silencing systems. They are necessary to ensure compliance with the original emission related parts: Throttle body and internal parts Spark plugs Magneto or electronic battery ignition system Fuel filter/Fuel injector/Fuel pump Air cleaner element...
Owners Manual
Page 9
... to do their Mule, a Service Manual is available for your purchase of a new Kawasaki Mule. The Service Manual contains detailed disassembly and maintenance information. For those who plan to change without our prior written permission. Motorcycle & Engine Company © 2014 Kawasaki Heavy Industries, Ltd. FOREWORD Congratulations on their own work should remain with the proper operation of your Mule at the time of printing.
... to do their Mule, a Service Manual is available for your purchase of a new Kawasaki Mule. The Service Manual contains detailed disassembly and maintenance information. For those who plan to change without our prior written permission. Motorcycle & Engine Company © 2014 Kawasaki Heavy Industries, Ltd. FOREWORD Congratulations on their own work should remain with the proper operation of your Mule at the time of printing.
Owners Manual
Page 10
... to 6-Persons Mode ...Cargo Bed ...Tailgate ...Loading Cargo Bed ...Lifting & Lowering the Cargo Bed...Fuel ...Glove Compartment ...Cupholders ...Front Access Cover...Ignition Switch ...Keys ...Gear Shift Lever ...Selectable 2WD/4WD Shift Switch ...Selectable DIFF-LOCK Shift Switch ...Belt Drive Transmission...Parking Brake Lever ...Doors ...Seats ...Seat Belts ...Throttle Pedal ...Trailer Hitch Bracket ...BREAK-IN ...HOW TO OPERATE ...Daily Checks ...Starting the Engine...Jump Starting ...Moving Off ...Braking ...Stopping the Engine ...Parking the Mule ...Shifting Gears...50 52 52 52 53...
... to 6-Persons Mode ...Cargo Bed ...Tailgate ...Loading Cargo Bed ...Lifting & Lowering the Cargo Bed...Fuel ...Glove Compartment ...Cupholders ...Front Access Cover...Ignition Switch ...Keys ...Gear Shift Lever ...Selectable 2WD/4WD Shift Switch ...Selectable DIFF-LOCK Shift Switch ...Belt Drive Transmission...Parking Brake Lever ...Doors ...Seats ...Seat Belts ...Throttle Pedal ...Trailer Hitch Bracket ...BREAK-IN ...HOW TO OPERATE ...Daily Checks ...Starting the Engine...Jump Starting ...Moving Off ...Braking ...Stopping the Engine ...Parking the Mule ...Shifting Gears...50 52 52 52 53...
Owners Manual
Page 11
... ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Hose ...Fuel Tank Vent...Belt Drive Transmission (CVT) ...Brakes ...Brake Pedal...Brake Disc and Brake Pad ...Brake Light Switch... 89 90 92 93 93 94 94 95 95 96 97 98 98 99 100 102 102 107 110 113 116 119 119 120 123 125 126 127 127 128 129 129 131 132 Parking Brake Lever...Steering Wheel...Power Steering System (KAF820B/C/D)...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam ...Battery ...Fuse...
... ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Idle Adjustment...Fuel Hose ...Fuel Tank Vent...Belt Drive Transmission (CVT) ...Brakes ...Brake Pedal...Brake Disc and Brake Pad ...Brake Light Switch... 89 90 92 93 93 94 94 95 95 96 97 98 98 99 100 102 102 107 110 113 116 119 119 120 123 125 126 127 127 128 129 129 131 132 Parking Brake Lever...Steering Wheel...Power Steering System (KAF820B/C/D)...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Cargo Bed Latches...Headlight Beam ...Battery ...Fuse...
Owners Manual
Page 34
... installation or use of accessories, or modification of your vehicle be securely anchored. Braking • Reduce distance is not overloaded and that extends beyond the rear of others. Carrying cargo and pulling a trailer can make your own safety and the safety of the vehicle. Avoid carrying cargo that you add to steer and may result in weight distribution, you are personally...
... installation or use of accessories, or modification of your vehicle be securely anchored. Braking • Reduce distance is not overloaded and that extends beyond the rear of others. Carrying cargo and pulling a trailer can make your own safety and the safety of the vehicle. Avoid carrying cargo that you add to steer and may result in weight distribution, you are personally...
Owners Manual
Page 39
... or minute continuously. ○The clock works normally from the back-up power while the ignition switch is turned off. ○When the battery is running, it in. Odometer: The odometer shows the total distance in kilometers or miles traveled since it was last reset to 0.0, and then starts counting when the vehicle is connected. Minute Display the Right button...
... or minute continuously. ○The clock works normally from the back-up power while the ignition switch is turned off. ○When the battery is running, it in. Odometer: The odometer shows the total distance in kilometers or miles traveled since it was last reset to 0.0, and then starts counting when the vehicle is connected. Minute Display the Right button...
Owners Manual
Page 41
... load caused by hard usage such as engine revving up while the wheels are stuck and unable to turn or exceeding maximum vehicle loads. ○The KAF820A model does not have the EPS sys- Red Parking Brake Indicator Light E. Red CVT Belt Check Indicator Light: This vehicle is activated, the CVT belt check indicator light will go on when the ignition switch is in three seconds.
... load caused by hard usage such as engine revving up while the wheels are stuck and unable to turn or exceeding maximum vehicle loads. ○The KAF820A model does not have the EPS sys- Red Parking Brake Indicator Light E. Red CVT Belt Check Indicator Light: This vehicle is activated, the CVT belt check indicator light will go on when the ignition switch is in three seconds.
Owners Manual
Page 42
... to make sure that passengers have buckled their seat belts. The light is free from overheating. ○When you touch the fan, NOTE be a problem with the temperature warning indicator light continuously illuminated. If it stays on, stop the engine and check the coolant level in the "ON" position, the parking brake indicator light illuminates. Be sure to check that the radiator fan is a reminder to...
... to make sure that passengers have buckled their seat belts. The light is free from overheating. ○When you touch the fan, NOTE be a problem with the temperature warning indicator light continuously illuminated. If it stays on, stop the engine and check the coolant level in the "ON" position, the parking brake indicator light illuminates. Be sure to check that the radiator fan is a reminder to...
Owners Manual
Page 45
... position setting of the steering will be adversely affected and will cause serious driving problems. If such components need service, contact an authorized Kawasaki dealer. LED Sub Headlight (KAF820C/D) A. If the steering becomes more difficult than usual or you feel a steering problem, refer to the "Steering Wheel" section in the "MAINTENANCE AND ADJUSTMENT" chapter. A. Do not tamper with an electric power steering system. The system...
... position setting of the steering will be adversely affected and will cause serious driving problems. If such components need service, contact an authorized Kawasaki dealer. LED Sub Headlight (KAF820C/D) A. If the steering becomes more difficult than usual or you feel a steering problem, refer to the "Steering Wheel" section in the "MAINTENANCE AND ADJUSTMENT" chapter. A. Do not tamper with an electric power steering system. The system...
Owners Manual
Page 47
... its original position. Roof After the cargo bed is lowered and latched, return the rear of the sun top roof to slow or stop the vehicle. Hook the rubber retaining straps on both sides to secure the rear of the cargo bed when it is the left pedal on the floor board. Brake Pedal A. Sun Top Roof (Equipped Model) The rear of the sun...
... its original position. Roof After the cargo bed is lowered and latched, return the rear of the sun top roof to slow or stop the vehicle. Hook the rubber retaining straps on both sides to secure the rear of the cargo bed when it is the left pedal on the floor board. Brake Pedal A. Sun Top Roof (Equipped Model) The rear of the sun...
Owners Manual
Page 55
Plastic Seat base A. Holding the handgrip, raise the cargo bed carefully. ○Do not lift the rear seat using the plastic seat base as shown. Handgrips C. Rear Seat Frame (Stored Position) 4. Hold the handgrip as it will break the plastic seat base. Rear Seat Cushion D. 54 GENERAL INFORMATION 2. Push the rear seat frame forward into the stored position. j A. Cargo Bed Latch (Both Sides) B. Lift the rear seat by holding the handgrip on either side, and turn the rear seat forward. 3. NOTE
Plastic Seat base A. Holding the handgrip, raise the cargo bed carefully. ○Do not lift the rear seat using the plastic seat base as shown. Handgrips C. Rear Seat Frame (Stored Position) 4. Hold the handgrip as it will break the plastic seat base. Rear Seat Cushion D. 54 GENERAL INFORMATION 2. Push the rear seat frame forward into the stored position. j A. Cargo Bed Latch (Both Sides) B. Lift the rear seat by holding the handgrip on either side, and turn the rear seat forward. 3. NOTE
Owners Manual
Page 59
... proce- On models equipped with a supporting rod whenever lifting the cargo bed. Before lowering the bed, check to its original position. Be sure to restore the seat as a strong wind, slope angle or cold weather. ○Support the cargo bed with a sun top roof, return the rear of the cargo bed becomes heavier as it lowers into position. Lowering the Cargo Bed j WARNING The front...
... proce- On models equipped with a supporting rod whenever lifting the cargo bed. Before lowering the bed, check to its original position. Be sure to restore the seat as a strong wind, slope angle or cold weather. ○Support the cargo bed with a sun top roof, return the rear of the cargo bed becomes heavier as it lowers into position. Lowering the Cargo Bed j WARNING The front...
Owners Manual
Page 105
... h, or h, or Every h, or 200 1 000 2 000 km 4 000 km 1 000 year of km (120 (2 500 km (600 km (600 (1 200 use mile) of mile) of mile) of mile) of mile) of use use use use use D or every year whichever comes first at Dealer OPERATION j Oil filter - change Radiator - change * Converter drive belt wear - inspect * Drive pulley coupling - check * Coolant - apply grease CHASSIS Brake pad wear -
... h, or h, or Every h, or 200 1 000 2 000 km 4 000 km 1 000 year of km (120 (2 500 km (600 km (600 (1 200 use mile) of mile) of mile) of mile) of mile) of use use use use use D or every year whichever comes first at Dealer OPERATION j Oil filter - change Radiator - change * Converter drive belt wear - inspect * Drive pulley coupling - check * Coolant - apply grease CHASSIS Brake pad wear -
Owners Manual
Page 113
... and water. A. Contact your local authorities for approved disposal methods or possible recycling. Front Final Gear Case Oil Oil Capacity 0.43 L (0.45 US qt) Oil Type Viscosity API "GL-5" Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Drain Plug j WARNING Oil on them slippery which can cause an accident and injury. 112 MAINTENANCE AND ADJUSTMENT Oil Change...
... and water. A. Contact your local authorities for approved disposal methods or possible recycling. Front Final Gear Case Oil Oil Capacity 0.43 L (0.45 US qt) Oil Type Viscosity API "GL-5" Hypoid gear oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Drain Plug j WARNING Oil on them slippery which can cause an accident and injury. 112 MAINTENANCE AND ADJUSTMENT Oil Change...
Owners Manual
Page 133
... in accordance with the Periodic Maintenance Chart. Pad wear inspection and pad replacement should be done by an authorized Kawasaki dealer in .) Brake Hoses: Brake hoses, pipes, and other components should • go on . j A. The brake light switch should be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. A. 132 MAINTENANCE AND ADJUSTMENT brake caliper, if the thickness of...
... in accordance with the Periodic Maintenance Chart. Pad wear inspection and pad replacement should be done by an authorized Kawasaki dealer in .) Brake Hoses: Brake hoses, pipes, and other components should • go on . j A. The brake light switch should be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. A. 132 MAINTENANCE AND ADJUSTMENT brake caliper, if the thickness of...
Owners Manual
Page 134
... parking brake cable adjusted • If by an authorized • Adjustment Kawasaki dealer since the brake light switch is best performed by an authorized Kawasaki dealer. Parking Brake Lever the parking brake lever to the rear. • Pull After to adjust. In accordance with the Periodic Maintenance Chart, check that the switch body does not turn during adjustment. Inspection j A. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked...
... parking brake cable adjusted • If by an authorized • Adjustment Kawasaki dealer since the brake light switch is best performed by an authorized Kawasaki dealer. Parking Brake Lever the parking brake lever to the rear. • Pull After to adjust. In accordance with the Periodic Maintenance Chart, check that the switch body does not turn during adjustment. Inspection j A. Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked...
Owners Manual
Page 157
... in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. j ○(KAF820C/D) Condensation may form on the headlight. To remove the moisture, start the engine and turn on the inside of debris or flammable materials. Allow the engine to collect in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Cleaning...
... in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. j ○(KAF820C/D) Condensation may form on the headlight. To remove the moisture, start the engine and turn on the inside of debris or flammable materials. Allow the engine to collect in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Cleaning...
Owners Manual
Page 162
... freezes. WARNING An air/oil mist may be forcibly ejected from the tire rubber. If you do get into each cylinder. oil on all the cables as indicated in the General Lubrication section in your eyes. DO NOT run the engine in a well-ventilated area. Turn the engine over the engine when performing this procedure. boards under the front and rear wheels to keep...
... freezes. WARNING An air/oil mist may be forcibly ejected from the tire rubber. If you do get into each cylinder. oil on all the cables as indicated in the General Lubrication section in your eyes. DO NOT run the engine in a well-ventilated area. Turn the engine over the engine when performing this procedure. boards under the front and rear wheels to keep...
Owners Manual
Page 164
... Power Engine overheated Too much idling or low speed running (not enough air flow) Overloaded Wrong spark plug Radiator clogged Coolant level too low Coolant deteriorated Cooling fan breaker functioned Engine oil level too low Compression leakage Valve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel Drive belt slipping Water in belt drive torque converter housing • Engine Cranks, But Won't Start No fuel in tank Water in fuel Air filter clogged or intake blocked Engine flooded Fuel tank vent clogged Spark plug wire...
... Power Engine overheated Too much idling or low speed running (not enough air flow) Overloaded Wrong spark plug Radiator clogged Coolant level too low Coolant deteriorated Cooling fan breaker functioned Engine oil level too low Compression leakage Valve clearance insufficient Air filter clogged or intake blocked Spark plug dirty or worm Engine oil incorrect Water in fuel Drive belt slipping Water in belt drive torque converter housing • Engine Cranks, But Won't Start No fuel in tank Water in fuel Air filter clogged or intake blocked Engine flooded Fuel tank vent clogged Spark plug wire...