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Do not drive in - Arizona Kawasaki

1. 158 TRANSPORTING AND STORAGE 159 Transporting the Vehicle 159 Storage c ecrire bees 160 TROUBLESHOOTING GUIDE 163 YOUR WARRANTY OWNER SATISFACTION i 165 ENVIRONMENTAL PROTECTION 169 MAINTENANCE RECORD 170 Maximum Torque Minimum Turning Radius Differential Mode Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread Ground Clearance Dry Mass Curb Mass SPECIFICATIONS 11 SPECIFICATIONS KAF820A B D KAF820C Front Rear KAF820A KAF820B KAF820C KAF820D KAF820A KAF820B KAF820C KAF820D 65 N m 6 6 kgf m 48 ft lb 3 500 r min rpm 4 8 m 15 7 ft Front 3 persons Rear 3 persons 3 385 mm 133 3 in 1 625 mm 63 98 in 1 970 mm 77 56 in 2 020 mm 79 53 in 2 345 mm 92 32 in 1 389 mm 54 68 in 1 321 mm 52 01 in 260 mm 10 2 in 806 kg 1 777 Ib 816 kg 1 799 Ib 825 kg 1 819 Ib 818 kg 1 804 Ib 841 kg 1 854 Ib 852 kg 1 879 Ib 861 kg 1 899 Ib 854 kg 1 883 Ib 12 SPECIFICATIONS Cargo Bed L x W x H ENGINE Type Displacement Bore x Stroke Compression Ratio Starting System Cylinder Numbering Method Firing Order Carburetion System Ignition System Ignition Timing Spa
2. GENERAL INFORMATION 47 Converting Rear Seat and Cargo Bed This vehicle can be converted to accommodate more passengers and less cargo or fewer passen gers and more cargo The seats and the cargo bed can be converted in the following way A WARNING The latches must be unlocked during the converting operation allowing the possi bility for the cargo bed to suddenly lift and cause serious injury To prevent the cargo bed from suddenly lifting do not convert the rear seat with the cargo bed loaded NOTICE Be careful not to pinch your finger between the movable components when converting the rear seat and cargo bed From 6 Persons to 3 Persons Mode 1 Open the rear doors and release the cargo bed latches on both sides 48 GENERAL INFORMATION EH 2 Lift the rear seat by holding the handgrip on 3 Pushthe rear seat frame forward into the stored x either side and turn the rear seat forward position SS A Cargo Bed Latch Both Sides A Rear Seat Frame Stored Position B Handgrips 4 On both sides pull the lower end of the screen C Rear Seat Cushion lock arms to release it from the cargo bed frame D Plastic Seat base NOTICE Do not lift the rear seat using the plastic seat base as it will break the plastic seat base 5 Turn the screen lock arms upward until lower locking arm is released from the lock pin in the cargo bed base A Screen Lock Ar
3. 79 Daily Checks aner AN 79 Starting the 82 Jump Starting 83 Moving Off 85 Braking eite eeu 86 Stopping the Engine 86 Parking the Mule 87 Shifting Gedis 88 2WD AWD Shifting ssesssss 89 Shifting the Differential 90 Catalytic 92 SAFE 93 Unfamiliar Terrain 93 Driving in Reverse 94 Driving in AWD 94 Turning the Vehicle 95 Hills 1 rtm tet er IRR 95 Climbing Hills esses 96 Descending 97 Traversing Hillsides 98 Sliding and 98 Driving through 99 Operator and Passenger Requirements 100 MAINTENANCE AND ADJUSTMENT Z 102 Periodic Maintenance 102 Erigirie Oil i ice Ete lee ean 107 Front Final Gear Case 110 Transmission Case
4. 113 Cooling System s 116 Spark 95 119 Valve Clearance 119 Engine Air 120 Spark 123 Throttle 125 Idle Adjustment sene 126 uoo tetti reis 127 Fuel Tank Vent ioan aan aeaaeai ata 127 Belt Drive Transmission CVT 128 Brak6S 2nd eds 129 Brake 129 Brake Disc and Brake Pad 131 Brake Light Switch 132 Parking Brake 133 Steering Wheel 134 Power Steering System KAF820B C D 134 Wheels aiite 135 RN 135 Wheel Nuts 135 i erase p eiie died 135 Joint Boots a ete ade acea 137 5 1 138 Seat 140 Cargo Bed 141 Headlight 142 Battery e dpt tet dde 142 PUSS bttaes 151 A 155 General 156 norn e eec hae cef a 156 Bolt and Nut
5. A WARNING Fuel stabilizers may contain poisonous sub stances Heed the manufacturer s warnings for use e Remove the spark plugs and spray fogging oil di rectly into each cylinder Turn the engine over sev eral times with the ignition switch key to coat the cylinder walls Install the spark plugs A WARNING An air oil mist may be forcibly ejected from the spark plug holes and could get into your eyes Do not lean over the engine when per forming this procedure If you do get oil in your eyes wash them immediately with lib eral amounts of clean fresh water and con sult a physician as soon as possible e Put boards under the front and rear wheels to keep dampness away from the tire rubber e Spray oil on all unpainted metal surfaces to pre vent rusting Avoid getting oil on rubber parts or in the brakes e Lubricate all the cables as indicated in the General Lubrication section in the MAINTENANCE AND ADJUSTMENT chapter TRANSPORTING AND STORAGE 161 e Remove the battery and store it where it will not be exposed to direct sunlight moisture or freezing temperatures During storage it should be given a slow charge one ampere or less about once a month NOTICE Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery The more discharged a battery becomes the more easily it freezes Never remove the sealing strip or the battery
6. oma Red CVT Belt Check Indicator Light Yellow Engine Warning Indicator Light Red EPS Warning Indicator Light Speedometer Fuel Level Gauge Red Parking Brake Indicator Light Red Reverse Indicator Light Green Neutral Indicator Light Right Button Odometer Trip Meter Hour Meter Clock Left Button 2WD Indicator Symbol Red Seat Belt Use Reminder Red Coolant Temperature Warning Indicator Light Red Pressure Warning Indicator Light 4WD Indicator Symbol Pushing the left button shifts the display in the odometer trip meter hour meter through the 4 modes odometer trip meter A and B and hour meter When the ignition switch is turned on all the LCD segments and LED lights are displayed for a sec ond then the clock and meters operate normally de pending on the mode selected 36 GENERAL INFORMATION Speedometer The speedometer shows the speed of the vehicle 120468 6 A Speedometer mph km h Display mph km h Display can alternate between U S and metric modes mph and km h in the digital meter Make sure that mph or km h is correctly displayed according to local regulations before riding Shift the mph km h display in the digital meter as follows NOTE not operate the vehicle with the digital meter displaying in the wrong unit mph or km h e Display the odometer in the digital meter e The mph km h display shifts by pushing and hold
7. U S A Here is some important information regarding your vehicle s lim ited warranty Frequently Asked Questions What is a Limited Warranty The most important thing to know about your warranty is that it protects you from manufacturing defects in material or workmanship during the warranty period You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale The warranty does not cover the cost of regularly scheduled maintenance The warranty also does not apply to the normal wear of items such as tires brake pads transmission drive belts chains sprockets etc What is the Good Times Protection Plan Much of the warranty coverage offered by the limited warranty can be extended by purchasing Kawasaki s Good Time Protection Plan GTPP See your Kawasaki dealer or go to Kawasaki com for more information if you don t already have the GTPP What Am I Responsible For You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner s manual You are responsible for notifying your dealer immediately if there is a problem and you as the owner will need to authorize the dealer to inspect the unit 166 YOUR WARRANTY OWNER SATISFACTION You will be responsible for paying for routine maintenance including the first scheduled service You can have the required servicing done by your Kawasaki dealer recommended or an equally
8. ing the vehicle WARNING Adjusting the steering wheel position while driving could cause loss of control and an accident resulting in serious injury or death To prevent loss of control do not adjust the steering wheel position unless the vehicle is GENERAL INFORMATION 45 stopped e Move the steering wheel up or down while pulling up the tilt lock lever under the steering wheel e Release the tilt lock lever to lock the steering wheel in position A Tilt Lock Lever B Pull Up C Adjust Steering Wheel NOTE Make sure you have securely locked the steering wheel in place by moving it up and down 46 GENERAL INFORMATION Brake Pedal Sun Top Roof Equipped Model The brake pedal is the left pedal on the floor board Depress the pedal to slow or stop the vehicle A Brake Pedal The rear of the sun top roof can be raised and flipped forward after unhooking the rubber retaining straps on both sides so that it does not interfere with the front of the cargo bed when it is lifted in extended condition Sf A Rubber Retaining Strap B Roof After the cargo bed is lowered and latched return the rear of the sun top roof to its original position Hook the rubber retaining straps on both sides to secure the rear of the roof CH0SED4B P NOTICE Do not drive the Mule with the rear of the sun top flipped forward as it could damage the hinge of the sun top roof
9. porn Refer to the Multifunction Meter section in this chapter together with the 2WD 4WD Shifting sec gt P tion in the HOW TO OPERATE chapter A Selectable 2WD 4WD Shift Switch A WARNING SUD EL The handling characteristics of this vehicle differs between 2WD and 4WD accord The current operating condition is indicated with ing to terrain Changing the operating mode the 2WD AWD indicator symbols in the multifunction while moving can cause sudden changes in meter handling performance which can cause the operator to lose control and have an acci dent Always stop the vehicle before chang ing from 2WD to 4WD and vice versa GENERAL INFORMATION 69 NOTICE Shifting from 2WD to 4WD or AWD to Selectable DIFF LOCK Shift Switch 2WD when the vehicle is in motion could cause drive train damage You can select differential LOCK locked rear axle or UNLOCK unlocked rear axle modes to suit various driving conditions The selectable DIFF LOCK shift switch is located on the dashboard Selectable DIFF LOCK Shift Switch LOCK Position Locked Rear Axle Mode UNLOCK Position Unlocked Rear Axle Mode DIFF LOCK Indicator Light The LOCK locked rear axle condition is indi cated by a light in the switch as a reminder Refer to the Shifting the Differential section in the HOW TO OPERATE chapter gt
10. B Spark Arrester Bolts C Spark Arrester e Remove the spark arrester and clean in a bath of high flash point solvent and if necessary use a fine wire brush to gently remove any particles in the Screen 124 MAINTENANCE AND ADJUSTMENT A Spark Arrester e Inspect the screen and replace it if it is damaged e In an open area away from combustible materials start the engine with the transmission in neutral WARNING Hot carbon particles are emitted when the spark arrester is cleaned and can cause a fire resulting in severe burns and damage Do not clean the spark arrester or run the engine with the spark arrester disassembled near combustible materials e Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon parti cles are purged from the muffler A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death Do not run the engine in enclosed areas Op erate only in a well ventilated area e Stop the engine e Install the new gasket and paste it on the muffler with grease before installing the spark arrester ji A Muffler B Gasket e Install the spark arrester in place and tighten the bolts to the specified torque Tightening Torque Spark Arrester Mounting Bolts 13 N m 1 3 115 1 MAINTENANCE AND ADJUSTMENT 12
11. Engine No A Frame Number A Engine Number Label 16 LOCATION OF PARTS LOCATION OF PARTS 6 persons mode T p i T 9 O0 1 Headlights 8 Rear Seat 16 Front Door 2 LED Sub Headlight 9 Rear Seat Belts 17 Handhold for Rear Seat KAF820C D 10 Screen Lock Arm Passengers 3 Front Access Cover 11 Cargo Bed 18 Rear Door 4 ROPS Roll Over Protective 12 Front Guard 19 Cargo Bed Handgrip Structure 13 Brake Fluid Reservoir 20 Cargo Bed Latch 5 Steering Wheel 14 Parking Brake Lever 21 Muffler Spark Arrester 6 Front Seat 15 Steering Wheel Tilt Lock 22 Trailer Hitch Bracket T Front Seat Belts Lever KAF820B C D LOCATION OF PARTS 17 3 persons mode 01 045 5 1 Tailgate Latch Handle 6 Handgrip for Front Right 11 Battery 2 Tailgate Seat Passenger 12 Rear Seat folded position 3 Sun Top Roof KAF820C 7 Tail Brake Light 13 Fuel Tank Cap 4 Screen 8 Rear Shock Absorber 14 Dashboard 5 Handgrip for Front Center 9 Cargo Bed Side Plate 15 Front Shock Absorber Seat Passenger 10 Air Cleaner 16 Radiator 18 LOCATION OF PARTS 1 Parking Brake Lever 2 Selectable DIFF LOCK Shift Switch 3 Selectable 2WD 4WD Shift Switch 4 Headlight Switch 6 0 5 LED Sub Headlight Switch KAF820C D 6 Multifunction Meter 7 Power Outlet Sockets 8 Glove Compartment 9 Cupholders 501804 5 10 Steering Wheel Tilt Lock Lever KAF820B C D
12. In the differential mode if either rear wheel leaves the ground it will spin freely and the wheel on the ground will transmit very little power When a spinning wheel touches the ground it may grab abruptly causing the op erator to lose control Do not make sharp turns even in the differential mode in order to avoid loss of control or tipping Remember e Slow down before entering the turn e Maintain an even speed through the turn As with any motor vehicle loading of the vehicle and the surface and steepness of the hill are among the critical considerations in climbing descending or traversing hills Use extreme caution on hills Keep in mind that loading changes a vehicle s center of gravity and that the higher the center of gravity the more likely the vehicle is to tip on uneven surfaces Slippery loose or bumpy surfaces on hills are es pecially hazardous Some hills are just too steep to climb Always use common sense and practice good judgement 96 SAFE OPERATION Climbing Hills Do not attempt to climb hills or steep inclines until you have mastered the controls and basic operating maneuvers of this vehicle Always go straight uphill and if the incline is steep and or the surface is loose use AWD with the differential locked for greater traction and in low range for maximum torque Avoid hills with slippery sides that will cause you to lose traction Do not climb hills where you cannot see far en
13. Q2X01B 6 Tire Depth Gauge Minimum Tread Depth 4 mm 0 16 in e Visually inspectthe tire for cracks and cuts replac ing the tire in case of bad damage Swelling or high spots indicate internal damage requiring tire replacement e Remove any imbedded stones or other foreign particles from the tread MAINTENANCE AND ADJUSTMENT 137 Joint Boots In accordance with the Periodic Maintenance Chart inspect the joint boots on the front axles tie rod ends steering knuckles and rear axle shafts for cracks holes damage or deterioration If there is any one of them have the joint boot replaced by an authorized Kawasaki dealer A Steering Knuckle B Tie Rod C Front Axle D Joint Boots 138 MAINTENANCE AND ADJUSTMENT A Rear Axle B Joint Boots Suspension Shock Absorber Spring Force Adjustment The spring adjusting sleeves on the shock ab Sorbers have 5 positions so that the springs can be adjusted for different riding and loading conditions On the California model the rear shock absorbers are not adjustable CL23019BM2 C A Rear Shock Absorber Except for California Model B Adjusting Sleeve C Rear Shock Absorber California Model A Adjusting Sleeve Turn with a hook wrench If the spring action feels too soft or too stiff have the sleeves adjusted by an authorized Kawasaki dealer in accordance with the following table e Turn the ad
14. e Do not tow more than 907 kg 2 000 Ib trailer weight trailer plus cargo weight e Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the ve hicle and have an accident 78 BREAK IN BREAK IN The first 20 hours or 200 km 120 mi of vehicle operation is designated as the break in period Do not exceed 1 2 throttle during the break in period If the vehicle is not used carefully during this period you may end up with a broken down instead of broken in vehicle Maximum Throttle Break in Period Position First 20 hours or 200 km 120 mi 1 2 Throttle NOTE O Do not start moving or race the engine immedi ately after starting it even if the engine is already warm O Do not race the engine while the transmission is in neutral Olt is important to perform the initial service after the first 20 hours or 200 km 120 mi of opera tion as described in this manual and the service manual for this vehicle See the Periodic Main tenance Chart in the MAINTENANCE AND AD JUSTMENT chapter HOW TO OPERATE 79 HOW TO OPERATE Daily Checks Check the following items each day before operation The time required is minimal and habitual performance of these checks will help ensure safe reliable operation If any irregularities are found during these checks refer to the MAINTENANCE AND ADJUSTMENT chap ter see your dea
15. 70 GENERAL INFORMATION EH NOTE OThe DIFF LOCK indicator light remains illumi nated when the DIFF LOCK shift switch is acti vated and the ignition switch is turned off When the engine has not been started the DIFF LOCK indicator light will remain illuminated for approxi mately 5 6 seconds When the ignition switch is turned off after the engine has been running the DIFF LOCK indicator light will remain illuminated for approximately 50 60 seconds Belt Drive Transmission This vehicle is equipped with a belt driven Contin uously Variable Transmission CVT This automatic drive system although simple to operate does re quire periodic inspection Refer to the MAINTE NANCE AND ADJUSTMENT chapter Parking Brake Lever The parking brake lever is located at the left side of the steering wheel Pull the lever rearward to apply the parking brake To release push in and hold the knob on the end of the lever and push the lever all the way forward Spring pressure helps return the lever to the re leased position Be sure to release the parking brake before driving off Failure to do so may result in poor performance and premature wearing of the rear brakes and belt converter system A Parking Brake Lever B Knob GENERAL INFORMATION 71 WARNING If the vehicle should move after it is parked it might be damaged or cause injury Be sure to apply the parking brake before leaving the vehicl
16. GENERAL INFORMATION 43 A High Beam Position B Low Beam Position C Off Position D High Beam Indicator Light E Headlight Switch F LED Sub Headlight Switch KAF820C D The KAF820C D models are equipped with LED sub headlights The operation of the LED sub head light switch is similar with the headlight switch 44 GENERAL INFORMATION eee A Headlight B LED Sub Headlight KAF820C D Steering Wheel The KAF820B C D models are equipped with an electric power steering system The system does not require regular maintenance by users Do not tamper with the electronic control unit ECU or loosen the fittings of steering actuator or the neutral position setting of the steering will be adversely affected and will cause serious driving problems If such components need service contact an autho rized Kawasaki dealer If the steering becomes more difficult than usual or you feel a steering problem refer to the Steer ing Wheel section in the MAINTENANCE AND AD JUSTMENT chapter A Steering Wheel The power steering system functions only when engine is running Olf you install wireless equipment on board contact an authorized Kawasaki dealer Installing such equipment improperly may affect the ECU Steering Position Adjustment KAF820B C D The steering wheel position can be adjusted to suit the operator Make any steering wheel adjustment before start
17. Hour Meter The hour meter shows the total hours that the vehi cle has been operated This meter cannot be reset NOTE OWhen the figures come to 99999 9 they are stopped and locked FAN A 348 190248 6 A Hour Meter GENERAL INFORMATION 39 2WD 4WD Indicator This Vehicle can be driven in either 2WD or AWD When the selectable 2WD 4WD shift switch is in AWD the 4WD indicator symbol will appear After shifting there is a momentary delay before the indicators change CHIBMIB A 2WD Indicator Symbol B 4WD Indicator Symbol 40 GENERAL INFORMATION CH180498 G A Red CVT Belt Check Indicator Light B Yellow Engine Warning Indicator Light C Red EPS Warning Indicator Light D Red Parking Brake Indicator Light E Red Reverse Indicator Light F Green Neutral Indicator Light G Red Seat Belt Use Reminder H Red Coolant Temperature Warning Indicator Light 1 Red Oil Pressure Warning Indicator Light Red CVT Belt Check Indicator Light This vehicle is equipped with a drive belt protection system that protects the drive belt from wear tear and damage from excessive load caused by hard usage such as engine revving up while the wheels are stuck and unable to turn or exceeding maximum vehicle loads When the protection mode is activated the CVT belt check indicator light will start flashing Avoid such hard usage to prot
18. can be damaged e Tie a plastic bag over the exhaust pipe to prevent moisture or small animals from entering e Put a cover over the vehicle to keep dust and dirt from collecting on it Removal from Storage A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas _Inhal ing carbon monoxide can cause serious brain injury or death DO NOT run the en gine in enclosed areas Operate only in a well ventilated area e Remove the plastic bags from the exhaust pipe e Clean the terminals of the battery charge the bat tery if necessary and install it in the vehicle 162 TRANSPORTING AND STORAGE e Make sure the spark plugs are tight e Lubricate as indicated in the General Lubrication e Fill the fuel tank with fuel section in the MAINTENANCE AND ADJUST e Check all the points listed in the Daily Checks MENT chapter section in the HOW TO OPERATE chapter TROUBLESHOOTING GUIDE 163 TROUBLESHOOTING GUIDE Starter Motor Won t Turn e Fuse failed be sure to check for cause of failure e Battery cables do not make good electrical contact with battery terminals e Battery discharged Engine Cranks But Won t Start e No fuel in tank e Water in fuel e Air filter clogged or intake blocked e Engine flooded e Fuel tank vent clogged e Spark plug wire not on spark plug e Valve Clearance incorrect e Spark plug dirty Engine Stops e No fuel in tank e Water in fuel e Ai
19. e Lubricate as indicated in the General Lubrication section e Test the brakes before operation e Start the engine and run it for 5 minutes to dry it thoroughly 158 MAINTENANCE AND ADJUSTMENT Bolt and Nut Tightening In accordance with the Periodic Maintenance Chart have the tightness of the bolts nuts and fas teners checked by an authorized Kawasaki dealer TRANSPORTING AND STORAGE 159 TRANSPORTING AND STORAGE Transporting the Vehicle Note the following points NOTICE e To avoid damage and the wind adversely affecting the vehicle transport it in an en closed truck or trailer e If an enclosed transporter is not available remove the plastic hard top and position the vehicle facing forward e Never tow the vehicle or use a car type dolly with the front or rear wheels on the dolly as this could damage the differential and or transmission e Secure the fuel tank cap e Make sure that the cargo bed is latched and the tail gate is closed e Before loading the vehicle on the transporter se lect a firm level surface e Secure loading ramps to the transporter when loading and unloading e Always position the vehicle level when transport ing e Set the parking brake e Stop the engine and remove the ignition switch key to prevent loss during transport e Fasten the vehicle to the transporter with a heavy duty strap or rope using tie down points on front A and rear B of the vehicl
20. have followed the instructions in the LOAD ING INFORMATION chapter Unfamiliar Terrain Before driving in a new area be sure to check for hidden obstacles or hazards Keep your speed down until you know the area well You must know the terrain you intend to drive on and be familiar with your machine and its handling characteristics Use existing trails and stay away from hazardous areas Such as steep rocky slopes or swamps Be cautious when visibility is limited as you may not be able to see obstacles in your path 94 SAFE OPERATION Driving in Reverse Driving in 4WD Start the engine following the procedure in the Starting the Engine section Before shifting into reverse stop the vehicle completely Refer to the Gear Shift Lever in the GENERAL INFORMA TION chapter and Shifting Gears section in the HOW TO OPERATE chapter Turn around and look behind you before backing up to be sure there are no obstacles or people in your way Gradually open the throttle and begin backing up cautiously To stop while driving in reverse close the throttle and gradually apply the brake Avoid sudden appli cation of the brake NOTICE Do not operate the gear shift lever to change gears while driving the vehicle in reverse or the transmission may be damaged Remember e Look behind you before backing up e Open the throttle gradually e To stop gradually apply the brake NOTE O This
21. have seen any significant level of commercial use Gasoline Alcohol Blends Gasoline containing up to 10 ethanol alcohol produced form agricul tural products such as corn also known as gaso hol is approved for use NOTICE Avoid using blends of unleaded gasoline and methanol wood alcohol whenever possible and never use gasohol containing more than 5 methanol Fuel system damage and performance problems may result Gasoline Ether Blends The most common ether is methyl tertiary butyl ether MTBE You may use gasoline containing up to 1596 MTBE NOTE O Other oxygenates approved for use in unleaded gasoline include TAME up to 16 7 and ETBE up to 17 296 Fuel containing these oxygenates can also be used in your Kawasaki GENERAL INFORMATION 61 NOTICE Never use gasoline with an octane rat ing lower than the minimum specified by Kawasaki Never use gasohol with more than 10 ethanol or more than 5 methanol Gaso line containing methanol must also be blended with cosolvents and corrosion inhibitors Certain ingredients of gasoline may cause paint fading or damage Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling When not operating your Kawasaki for 30 to 60 days mix a fuel stabilizer such as STA BIL with the gasoline in the fuel tank Fuel stabilizer additives inhibit oxidation of the fuel which minimizes gummy deposits Never store this
22. in the tilted position with the sup porting damper provided on the bottom of the cargo bed Do not drive the vehicle with the front end of the cargo bed raised or unlatched To lower the bed check to be sure the area un der the front of the cargo bed is clear then carefully lower the bed into position Check that both latches have locked the bed into place Do not leave the cargo bed unlatched Lifting the Cargo Bed while in Short Configuration 1 Open the rear doors and release the cargo bed latch on both sides 54 GENERAL INFORMATION 2 Lift the rear seat by holding the handgrip on either side and turn the rear seat forward A Cargo Bed Latch Both Sides B Handgrips C Rear Seat Cushion D Plastic Seat base NOTE O Do not lift the rear seat using the plastic seat base as it will break the plastic seat base 3 Push the rear seat frame forward into the stored position 4 A Rear Seat Frame Stored Position Hold the handgrip as shown Holding the hand grip raise the cargo bed carefully Handgrip B Cargo Bed WARNING Reduced clearance between the cargo bed and the ROPS can cause arm injury when lift ing or lowering the cargo bed To avoid in jury grasp cargo bed at the handle and do not hold the ROPS when lifting or lowering the cargo bed GENERAL INFORMATION 55 5 Pull the supporting rod out of its clip and attach the curved portion of the
23. obstacles which may cause you to overturn or become stuck or submerged Observe the following rules for operating the vehi cle in water CJ118004 P A Axle Cap SAFE OPERATION 99 WARNING Operating the vehicle in rivers or streams where water is flowing quickly can cause the tires to lose traction and allow the vehicle to be swept into the current Never operate the vehicle in fast flowing water or in water deeper than the bottom edge of the axle caps After prolonged exposure to water the wheel bear ings may require lubrication or replacement Wash the vehicle in fresh water if it has been ex posed to salt water or operated in muddy conditions WARNING Wet brakes provide greatly reduced effi ciency and could lead to an accident and injury After operation in water always apply the brakes long enough for friction to dry the linings Also the brake that gets wet may wear out faster Check for brake wear more frequently if the vehicle is used in water Remember e Avoid driving through water whenever possible e Don t drive in deep and fast moving water e Dry out the brakes 100 SAFE OPERATION Operator and Passenger Requirements All operators of this vehicle should possess a valid driver s license The operator and passenger s must be able to place both feet flat on the floorboards while seated upright with their backs against the seatbacks when firmly holding th
24. owner or general manager to request a review of the issue If you are unable to resolve a problem after consulting with the dealership management and need further as sistance contact Kawasaki Motors Corp U S A at the address below Please be certain to provide the model vehicle identification number VIN mileage or hours of use accessories dates that events occurred and what action has been taken by both you and your dealer Include the name and address of the dealership To assist us in resolving your inquiry please include copies of related receipts and any other pertinent informa tion including the name of the dealership personnel with whom you have been working Upon receipt of your correspondence Kawasaki Motors Corp U S A will contact the dealership and work with it in resolving your problem 168 YOUR WARRANTY OWNER SATISFACTION Want to Contact Kawasaki This owner s manual should answer most of your questions about your Kawasaki Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you Please send your correspondence to Consumer Services Kawasaki Motors Corp U S A P O Box 25252 Santa Ana CA 92799 5252 949 460 5688 ENVIRONMENTAL PROTECTION 169 ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly a program dedicated to protecting the great outdoors through education and fostering responsible enjoyme
25. product with gasohol in the fuel system Before storage it is recom mended that you drain all fuel from the fuel tank See the STORAGE chapter in this manual 62 GENERAL INFORMATION Glove Compartment Cupholders A glove compartment is provided at the right side Cupholders are provided at the left and right sides of the dashboard Store only light items to avoid of the dashboard damage to the inside of the compartment Do not 7 store items which must not get wet or dirty A Cupholder A Glove Compartment GENERAL INFORMATION 63 ee e Pull the front access cover forward to disengage p Front Access Cover the tabs from the slits of the front hood The front access cover can be removed for main tenance such as a coolant level inspection NOTICE Do not store items under the front access cover This area is not designed for storage Cover Opening e Turn the knobs counterclockwise 90 to release the locks e Pull front of the front access cover up and open the cover A Front Access Cover B Tabs C Slits Cover Closing e Insert the tabs on the front access cover to the slits of the front hood Lower the front access cover and turn the knobs clockwise until they stop to lock the front access cover A Front Access Cover B Knob 64 GENERAL INFORMATION A Front Access Cover B Knob e Pull up the front ends of the access cover to
26. qualified service facility You can also do your own maintenance work if you have the proper tools service references and mechanical skills However if a failure is found to be caused by improper servicing it would not be covered by the limited warranty You may purchase a Kawasaki Service Manual and any necessary special tools directly from your Kawasaki dealer You will be responsible for paying for repairs needed because of an accident to replace worn parts such as tires chains brakes and for repairs needed because of a lack of maintenance misuse or racing Whether you do it yourself or take your vehicle to a Kawasaki dealer be sure to record your service in the Maintenance Record section of this Owner s Manual Keep all receipts for the service and or items necessary to perform the maintenance so that in the event of a failure you can document the service history What Are The Dealership s Responsibilities Your Kawasaki dealer offers a wide range of services parts accessories and information on your product and on Kawasaki Each dealer is independently owned and operated and is responsible for the dealership s operations its repair warranty and service work and its personnel Your dealer is responsible for completing the set up and pre delivery service of your new Kawasaki vehicle The dealership should also explain its operation maintenance and warranty provisions so you understand them at the time of purchase or at an
27. seat Use only fresh gasoline with the rec ommended octane rating from an uncontaminated Source to insure proper running of your vehicle Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contami nated A Fuel Tank Cap Never fill the tank completely to the top As the fuel expands in a warm tank it may overflow from the vent line After refueling make sure the fuel tank cap is closed securely 60 GENERAL INFORMATION NOTICE Always clean dirt mud debris water from the fuel tank cap and surrounding area prior to filling the tank to prevent dirt mud debris wa ter from entering the fuel tank Accumulation of moisture or sediment in the fuel system can restrict the flow of fuel and cause fuel pump and or engine damage WARNING Gasoline is extremely flammable and can be explosive under certain conditions creating the potential for serious burns Turn the ig nition switch off Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Never fill the tank completely to the top If the tank is filled com pletely to the top heat may cause the fuel to expand and overflow through the vents in the tank cap After refueling make sure the tank cap is closed securely If gasoline is spilled on the fuel tank wipe it off immediately Fuel Requirements Fuel Type This vehicle i
28. suddenly lifting be sure the conversion is complete and the cargo bed latches are firmly locked NOTICE Do not carry more than the maximum load stated here in the convertible cargo bed Short bed mode 158 kg 350 Ib Long bed mode Except for California Model 453 kg 1 000 Ib California Model 272 kg 600 Ib WARNING Overloading failure to properly secure cargo or improper use of the cargo bed can cause changes in handling which can lead to an accident Follow guidelines pro vided in the LOADING INFORMATION chapter Passengers riding in the cargo bed can be tossed about or even thrown out causing serious injury or death Do not install seat ing or carry passengers in the cargo bed Driving with the cargo bed tilted may be hazardous Failure to lower and lock the bed into place may cause severe injury or death Always lower and latch the bed after tilting Lifting and lowering the bed could be dan gerous Be careful not to catch any part of your body such as hands or arms be tween the bed and ROPS or vehicle frame when lifting and lowering the bed GENERAL INFORMATION 53 Lifting amp Lowering the Cargo Bed The cargo bed can be tilted by releasing the latches on each side and then lifting the bed with the handgrips Before tilting the cargo bed park on a firm level surface and set the parking brake Empty the cargo bed prior to raising the cargo bed Support the bed
29. t c 4 CH18027BM1 C A Minute Display e Push the Right button Both the hour and minute displays start blinking again e Push the Left button The displays stop blinking and the clock starts working NOTE Pushing the Left button momentarily advances the hour or minute step by step Pushing and holding the button advances the hour or minute continu ously O The clock works normally from the back up power while the ignition switch is turned off O When the battery is disconnected the clock resets to 1 00 and starts working again when the battery is connected Odometer The odometer shows the total distance in kilome ters or miles that the vehicle has been ridden The meter cannot be reset NOTE OWhen the figures come to 999999 they are stopped and locked AN gt OOOO cH150028 6 A Odometer Trip Meters A B The trip meter shows the distance in kilometers or miles traveled since it was last reset to zero To reset the trip meter e Push the Left button to display the trip meter A or B e Push the Right button and hold it in e After two seconds the figure display turns to 0 0 and then starts counting when the vehicle is oper ated The meter counts until it is next reset NOTE O When the trip meter reaches 9999 9 when the ve hicle is running it turns back to 0 0 and starts counting again 09190238 6
30. the vehicle near flammable materials can cause a fire and can result in property damage or severe personal injury Do not idle or park your vehicle in an area where tall or dry vegetation or other flammable materials could come into con tact with the muffler or exhaust pipe ex A Parking Brake Lever WARNING The engine and exhaust system get ex A WARNING tremely hot during normal operation and can cause serious burns Never touch a hot engine exhaust pipe or muffler during operation or after stopping the engine If the vehicle should move after it is parked it might be damaged or cause injury Be sure to apply the parking brake before leaving the vehicle e Remove the ignition switch key to prevent unau e Stop the vehicle on a level surface iharized use NOTICE e When parking inside a garage or other structure be sure the structure is well ventilated and the ve Avoid parking on steeply inclined surfaces hicle is not close to any source of flame or sparks This includes any appliance with a pilot light e When the engine has stopped apply the parking brake to help prevent the vehicle from rolling 88 HOW TO OPERATE A WARNING Gasoline is extremely flammable and can be explosive under certain conditions creat ing the potential for serious burns Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any applia
31. 0 e Install the oil filler cap and tighten itto the specified torque Tightening Torque Oil Filler Cap 16 N m 1 6 kgf m 12 10 MAINTENANCE AND ADJUSTMENT 113 Transmission Case Oil In order for the transmission differential pinion and ring gears to function properly check the oil level and change the oil in accordance with the Periodic Maintenance Chart WARNING Vehicle operation with insufficient deterio rated or contaminated oil causes acceler ated wear of the transmission differential pinion and ring gears and may result in seizure Seizure can lock the rear wheels and skid the rear tires causing loss of control To prevebt seizure check the trans mission case oil according to the periodic maintenance chart Oil Level Inspection e Park the vehicle on level ground 114 MAINTENANCE AND ADJUSTMENT A Transmission Case B Oil Filler Cap NOTICE Be careful not to allow any dirt or foreign ma terials to enter the transmission case e Remove the oil filler cap and check the oil level view from the slit of the rib The oil level should be between the high and low levels on the rib as shown A Slit B Rib C High Level D Low Level e If the oil level is too high remove the excess oil using a syringe or other suitable device through the oil filler opening e If the oil level is too low add the correct amount of oil NO
32. 0 L 2 1 US qt Steel tube ladder type Rack and Pinion Rack and Pinion with Electric Power Steering EPS System 14 SPECIFICATIONS Caster Tire Size Rim Size Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight High Beam Low Beam Brake Tail Light LOAD CAPACITY Maximum Vehicle Load Including occupants cargo and accessories Maximum Cargo Bed Load Front Rear Front Rear KAF820A B KAF820C D KAF820A B KAF820C D Except for California Model California Model Except for California Model California Model 44 26 9 00812 26 x 11 00R12 4PR 12 x 7 0AT 12 x 8 0AT 30 L 7 9 US gal 12 V 32 Ah 20 HR 12V 60W x2 12 V 60 W x2 LED x 2 12V 55 2 12 V 55 W x 2 LED x 2 12V 21 5 W x2 748 kg 1 650 Ib 590 kg 1 300 Ib Short Bed Mode 158 kg 350 Ib Long Bed Mode 453 kg 1 000 Ib Long Bed Mode 272 kg 600 Ib Specifications are subject to change without notice SERIAL NUMBER LOCATIONS 15 SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the vehicle They are the only means of identifying your particular machine from others of the same model type These serial numbers may be needed by your dealer when ordering parts In the event of theft the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it Frame No
33. 03065C 5 18 Except for California Model A WARNING Overloading or failure to properly secure cargo can cause loss of control of the vehicle Loss of control of the vehicle can result in severe injury or death Cargo bed capacity Short bed mode 158 kg 350 105 Cargo bed capacity Long bed mode 453 kg 1000 105 Follow the Loading Information and Cargo Bed sections in the owner s manual Driving with passenger in the cargo bed can result in Severe injury or death ever carry passengers in the cargo bed 56071 0478 CF030700 S 30 LOCATION OF LABELS 18 California Model Only A WARNING 19 Overloading or failure to properly secure cargo can cause loss of control of the vehicle Loss of control of the vehicle can result in severe injury or death Cargo bed capacity Short bed mode 158 kg 350 Ibs Cargo bed capacity Long bed mode 272 kg 600 105 Follow the Loading Information and Cargo Bed sections in the owner s manual Driving with a passenger in the cargo bed can result in Severe injury or death ever carry passengers in the cargo bed 56071 0480 CF03071C 5 20 Except for California Model A WARNING Tire replacement improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Load conditon LT including occupants and cargo C00 tre pressure Tre siz
34. 11 Ignition Switch 12 Brake Pedal 13 Throttle Pedal 14 Gear Shift Lever LOCATION OF LABELS All warning labels which are on your vehicle are repeated here Read labels on your vehicle and un derstand them thoroughly They contain information which is important for your safety and the safety of anyone else who may operate your vehicle There fore it is very important that all warning labels be on your vehicle in the locations shown If any label is missing damaged or worn get a replacement from your Kawasaki dealer and install it in the correct po sition NOTE OThe sample warning labels in this section have part numbers to help you and your dealer obtain the correct replacement O Refer to the actual vehicle label for model specific data grayed out in the illustration LOCATION OF LABELS 19 gt SS Sess 1 Warning General 2 Certification ANSI OPEI 3 Power Outlet Socket Information 4 Notice Shifting 20 LOCATION OF LABELS CF0 BI69 P 5 Specification ROPS 6 Notice No Storage Area 7 Specification Model 8 Danger Radiator Cap 9 Brake Fluid Warning LOCATION OF LABELS 21 x EL E ue 10 Danger Poison Battery 11 Warning Refueling 12 Warning Cargo Bed Lifting both sides own 22 LOCATION OF LABELS CF028175 13 Warning Trailer Towing 14 Important Information Air Cleaner 15 Important In
35. 5 Throttle Pedal If the throttle pedal has excessive play due to ei ther cable stretch or misadjustment it will cause a delay in throttle response especially at low engine speed Also the throttle may not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart Throttle Pedal Play Inspection e Apply the parking brake e Putthe gear shift lever in the N Neutral position e Start the engine and warm it up thoroughly e Measure the distance the throttle pedal moves be fore the engine begins to pick up speed Free play should be 2 10 mm 0 08 0 39 in If the free play is out of specification have your authorized Kawasaki dealer adjust the throttle pedal play 126 MAINTENANCE AND ADJUSTMENT A Throttle Pedal B 2 10 mm 0 08 0 39 in Idle Adjustment Idle adjustment is controlled by the ECU elec tronic control unit and cannot be adjusted If the idle speed is unstable or out of specification have your authorized Kawasaki dealer inspect the fuel in jection system Specified Idle Speed 1 050 50 rpm High Altitude Use High altitude adjustment is not required as the ECU controls the air fuel mixture automatically Fuel Hose MAINTENANCE AND ADJUSTMENT 127 Fuel Tank Vent Fuel hose and connections should be chec
36. LN NE The ROPS meets the performance reauremerts of 150 3471 CF03858B 5 6 CFO31208 NOTICE This is not a storage area Items placed in this area can shift and melt if they touch hot surfaces 56033 0825 9 030676 5 10 A DANGER POISON IPELIGRO VENENO AI FUT OF PHL MACH OL DI 02 UO T pa BET Orte GATTI OE POLL ERI ERTS Pes Pus Cowen Ls rman I WE li S Se 0SA0A Bp CF03079 S LOCATION OF LABELS 27 11 WARNING Gasoline is flammable Fire can cause severe injury or death Refuel in well ventilated area Shut engine off Keep away from flame or sparks 96071 0292 12 WARNING Reduced clearance setween the cargo bed and the ROPS ray trap an while lifting or lowerng the cargo bed This may result in injury To avoid 005906 always use the lift handle provided and do rot place hands or the 30PS the area of the cargo bed when lifting or lowering the cargo bed 56071 0494 CFO030600 S 28 LOCATION OF LABELS 13 14 A WARNING imoroperly towing a trailer can cause an accident and injury Use extra care when towing a trailer IMPORTANT AIR CLEANER INFORMATION Prevent premature engine wear Service the air filter element regularly and correctly Service the elem
37. MULE PRO FXT Utility Vehicle OWNER S MANUAL N Read this manual carefully It contains safety information Quick Reference Guide This Quick Reference Guide will assist you in finding the information you re looking for A Table of Contents is included after the Foreword GENERAL INFORMATION BREAK IN HOW TO OPERATE SAFE OPERATION MAINTENANCE AND ADJUSTMENT TRANSPORTING AND STORAGE TROUBLESHOOTING GUIDE Whenever you see the symbols shown below heed their instructions Always follow safe operat ing and maintenance practices A DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE NOTICE is used to address practices not re lated to personal injury NOTE O NOTE indicates information that may help or guide you in the operation or service of the vehicle WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of Cali fornia to cause cancer and birth defects or other reproductive harm BASIC SAFE DRIVING Knowing and following these rules for safe oper ation will increase your satisfaction with your new Kawasaki vehicle Perform the Daily Checks Refer to the Daily Checks section for a list of items to check
38. RAL INFORMATION chapter HOW TO OPERATE 85 Moving Off e Make sure that all doors are properly closed e Depress the brake pedal e Put the gear shift lever into the H High or L Low position e Release the parking brake e Gradually increase engine speed by pressing on the throttle pedal NOTE O Practice starting and stopping using the brakes until you are familiar with the controls 86 HOW TO OPERATE Braking Stopping the Engine NOTE OWhen the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking This is caused by the ve hicle s automatic transmission which releases the engine at very low speed to prevent it from stalling Employ the brakes to control the vehicle s speed e Release the throttle pedal completely e Press on the brake pedal evenly and firmly WARNING Carrying cargo or towing a trailer will in crease braking distances Failure to allow for increased braking distance may result in accident and injury Always allow more dis tance to stop when carrying cargo or towing a trailer e Release the throttle pedal completely e Put the gear shift lever into the N Neutral posi tion e Apply the parking brake to help prevent the vehicle from rolling e Turn the ignition switch key to the OFF position HOW TO OPERATE 87 Parking the Mule WARNING Operating or parking
39. Regular Service After 50 Every Every Every After 20 h or 50 h or 100 h or 200 h or c kn 120 1 000 1 000 2 000 km 4 000 km AU 600 600 1 200 2 500 mile of il f il f il f il use ise mile of mile of mile o mile o OPERATION use use use use Steering inspect D D Steering joint dust boots inspect General lubrication perform D Bolts nuts and fasteners tightness D D inspect Seat belts inspect Cables inspect Cargo bed latch inspect Engine Oil In order for the engine to function properly main tain the engine oil atthe proper level and change the oil and oil filter in accordance with the Periodic Main tenance Chart Not only do dirt and metal particles collect in the oil but the oil itself loses its lubricative quality if used too long A WARNING Vehicle operation with insufficient deterio rated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart in the owner s manual Oil Level Inspection e If the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil reaches ev ery part can cause en
40. TE O Use the same type and brand of oil that is already in the transmission case O When adding oil do not exceed the high level of rib e Install the oil filler cap and tighten itto the specified torque Tightening Torque Oil Filler Cap 20 N m 2 0 kgf m 15 10 Oil Change NOTE O Before draining the oil warm it up by running the vehicle Warm oil drains easily and picks up any sediment e With the vehicle level place an oil pan beneath the transmission case e Remove the drain bolt A Transmission Case B Drain Bolt MAINTENANCE AND ADJUSTMENT 115 WARNING The exhaust system can get extremely hot during normal operation and cause serious burns To avoid a serious burn never touch a hot muffler or exhaust pipe during oil drain ing e Remove the oil filler cap WARNING Oil on tires can make them slippery which can cause an accident and injury 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 them with soap and water e After the oil has completely drained install the drain bolt with a new gasket Tighten itto the spec ified torque e Fill the transmission case to the high level on the rib with a high quality oil as specified in the table Tightening Torque Drain Bolt 20 N m 2 0 15 ft Ib Transmission Case Oil Type API GL 5 Hypoid gear oil
41. above 5 C 41 F SAE 90 below 5 C 41 F SAE 80 116 MAINTENANCE AND ADJUSTMENT Transmission Case Oil Capacity 2 0 L 2 1 US qt e Install the oil filler cap and tighten it to the specified torque Tightening Torque Oil Filler Cap 20 N m 2 0 kgf m 15 ft lb Cooling System A WARNING The cooling system is pressurized and can get extremely hot during normal operation and cause serious burns To prevent burns do not touch the radiator when it is hot Do not attempt to open the radiator cap when hot since steam and hot coolant can forcefully erupt when the cap is even loosened slightly Radiator and Cooling Fan Check and clean the screen and radiator fins for obstruction by insects or mud in accordance with the Periodic Maintenance Chart In dusty areas the radiator should be cleaned more frequently than the recommended interval A WARNING To avoid injury keep your hands and cloth ing away from the fan blades at all times 100011 P b A Screen B Radiator e Clean the screen and radiator fins of any obstruc tions with a stream of low pressure water e If insects or mud can not be completely removed it should be cleaned by an authorized Kawasaki dealer NOTICE Using high pressure water as from a car wash facility could damage the radiator fins and impair the radiator s effectiveness Do not obstruct or deflect airflow through the radiator by installi
42. ay raise and and the ROPS can cause arm injury when lift lower more quickly increasing the risk of ing or lowering the cargo bed To avoid in arm injury To prevent injury use extra care jury grasp cargo bed at the handle and do when raising or lowering the bed in extended not hold the ROPS when lifting or lowering mode the cargo bed 3 Hold the handgrip as shown Holding the hand grip raise the cargo bed carefully NOTE ODo not hold ROPS when lifting or lowering the cargo bed 4 Pullthe supporting rod out of its clip and attach the curved portion of the supporting rod into the bar of the ROPS to support the cargo bed A Handgrip B Cargo Bed 58 GENERAL INFORMATION A Supporting Damper B Cargo Bed Raised Position C Supporting Rod NOTE O Using only the bed supporting damper for support may allow the cargo bed to suddenly lower under particular situations such as a strong wind slope angle or cold weather O Support the cargo bed with a supporting rod when ever lifting the cargo bed Lowering the Cargo Bed Before lowering the bed check to be sure the area under the front of the cargo bed is clear Hold the handgrip and carefully lower the bed into position Check that both latches have locked the bed into place Do not leave the cargo bed unlatched A WARNING The front of the cargo bed becomes heavier as it lowers into position and can suddenly lower trapping arms between
43. belt will self adjust to the seat occupant so that it is snug 76 GENERAL INFORMATION around both the occupant s waist and shoulder Un der rough driving situations the dual mode latch plate will lock the seat belt in place To release the lock e Move the slider in the direction of the arrow mark A Slider B Arrow Mark Throttle Pedal The throttle pedal is the right pedal on the floor board Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throt tle pedal returns normally before starting the engine In addition there must be adequate throttle pedal play and correct throttle stop position adjustment Refer to the MAINTENANCE AND ADJUSTMENT chapter for the throttle pedal adjustment procedure GENERAL INFORMATION 77 Trailer Hitch Bracket This vehicle is equipped with a bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage observe the following precautions WARNING Improper towing of a loaded trailer could cause an accident resulting in serious injury or death e Never carry a passenger in a trailer e Never load more than 68 1 kg 150 Ib A Trailer Hitch Bracket tongue weight on the towing bracket e Do not operate the vehicle faster than 16 km h 10 mph when towing Remember that towing a trailer increases braking dis tance
44. cle Do not carry cargo on top of the ROPS e Do not carry more than maximum cargo bed load as follows Short Cargo Bed Mode 158 kg 350 Ib Long Cargo Bed Mode 453 kg 1 000 Ib Except for California Model 272 kg 600 Ib California Model e Cargo should be securely anchored Make sure the cargo will not move around while the vehicle is moving Recheck cargo security as often as possible while the vehicle is stopped and adjust as necessary 34 LOADING INFORMATION NOTICE The front body work and fenders are not designed to carry cargo or to support your weight They may break e Always subtract trailer tongue weight from the Maximum Load capacity Refer to the Trailer Hitch Bracket section in the GENERAL INFOR MATION chapter Maximum Vehicle Load e Weight of operator passenger s cargo and ac cessories must not exceed following limits Except for California Model 748 kg 1 650 Ib California Model 590 kg 1 300 Ib e This vehicle is not designed to carry passengers in the cargo bed Installing additional passenger seating or carrying passengers in the cargo bed can cause changes in vehicle handling A WARNING Passengers riding in the cargo bed can be tossed about or even thrown out causing se rious injury or death Do not install seating or carry passengers in the cargo bed Multifunction Meter GENERAL INFORMATION 35 GENERAL INFORMATION O
45. cle completely e Push the selectable 2WD AWD shift switch to se lect the drive modes A Selectable 2WD 4WD Shift Switch B 2WD Position C 4WD Position NOTE O The 4WD operating mode is indicated with the AWD indicator symbol Refer to the Multifunc tion Meter section in the GENERAL INFORMA TION chapter OWhen the shift switch is changed from 4WD to 2WD and vice versa the transmission shifts when the vehicle has rolled a short distance 90 HOW TO OPERATE Drive off slowly to allow 4WD to engage or disengage As it engages the 4WD indicator symbol will appear Olt is normal to hear a small clanking noise when 4WD engages or disengages while rolling on hard surfaces such as hard packed dirt A WARNING The handling characteristics of this vehicle differs between 2WD and 4WD accord ing to terrain Changing the operating mode while moving can cause sudden changes in handling performance which can cause the operator to lose control and have an acci dent Always stop the vehicle before chang ing from 2WD to 4WD and vice versa NOTICE Shifting from 2WD to 4WD or 4WD to 2WD when the vehicle is in motion could cause drive train damage Shifting the Differential e Stop the vehicle completely e Push the selectable DIFF LOCK shift switch to LOCK position Selectab
46. ctual product and illustrations and text in this manual All products are subject to change without prior notice or obligation KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company 2014 Kawasaki Heavy Industries Ltd Apr 1 2014 3 11 SERIAL NUMBER 15 LOCATION OF PARTS 16 LOCATION OF LABELS 19 LOADING 33 GENERAL 35 Multifunction 35 36 Fuel Level Gauge Symbol 36 Clock auicm ttem ie ed 37 Genre 38 Trip Meters 38 Hour Meter 39 2WD AWD 39 Red CVT Belt Check Indicator Light 40 Yellow Engine Warning Indicator Light 40 Red EPS Warning Indicator Light 40 Red Parking Brake Indicator Light 41 Red Reverse Indicator Light 41 Green Neutral Indicator Light 41 Red Seat Belt Use Reminder 41 Red Coolant Temperature Warning Indicator LiQht ra 41 R
47. down as indicated on the embossed mark next to the shift lever Refer to the Shifting Gears section in the HOW TO OPERATE chapter GENERAL INFORMATION 67 low gearing for maximum torque at low speeds for climbing hills pulling a trailer or keeping constant low speeds The high gearing raises the speed range for ordinary off highway use Stop the vehicle before moving the gear shift lever NOTICE Use of the high range for heavy loads climb ing hills and pulling a trailer can lead to pre mature wear of the torque converter belt and pulleys Use low range for these conditions Refer to the Shifting Gears section in the HOW TO OPERATE chapter Gear Shift Lever L Low Position H High Position Neutral Position R Reverse Position NOTICE Do not shift from High or L Low to Reverse and vice versa when the vehicle is moving or with the engine run ning above idling speed or the transmission could be damaged moom This vehicle is equipped with a sub transmission to allow maximum transmission efficiency Use the 68 GENERAL INFORMATION Selectable 2WD AWD Shift Switch You can select 2WD or 4WD to suit various driving conditions The selectable 2WD AWD shift Switch is located on the dashboard cer CHIBMIB G A 2WD Indicator Symbol B 4WD Indicator Symbol
48. e 72 GENERAL INFORMATION Doors Pull the door handle outward to open the door Push or pull the door inward until the latch clicks to close the door After closing the door be sure to check that the latch is securely locked If a door is damaged or does not close securely contact an au thorized Kawasaki dealer for repair or replacement A Door Handle B Door C Latch NOTE O Make sure that the all doors are properly closed before starting the vehicle NOTICE The doors are not designed to bear weight Never lean on or place excessive weight on the doors or they will be damaged Seats There are front and rear seats on this vehicle It can be transformed from 3 persons to 6 persons by unfolding the rear seat 3 Persons Mode 258000 P A Rear Seat Stored Position GENERAL INFORMATION 73 6 Persons Mode 25801 A Rear Seat NOTE O Converting the rear seat must be made in com bination with cargo bed conversion Refer to the Converting Rear Seat and Cargo Bed section in this chapter 74 GENERAL INFORMATION Seat Belts The vehicle is equipped with retractable three point seat belts for all occupants opera tor and two passengers for the front seat and three passengers for the rear seat Always wear the seat belts when operating and riding in the vehicle A Seat Belt B Latch Plate C Buckle A WARNING Not wear
49. e xao rese ine eco dae oid I IDCBTUIITT RR Selling Dealer Name nennen trennen erp nennt rein Ea nuo t ro uuo Eae Addfess E E E citer ree RIXA Dez quo cuir EpL ORE NN END ERREUR AE VAR E Pour ras T FEDES AER Phone eO YE ET a a a Warranty Start Date eicere etre Cor ber te or Eno Eo crura opua Note Keep this information and a spare key in a secure location Date Traveled Distance Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 171 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address 172 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address MAINTENANCE RECORD 173 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address 174 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address KAF820AF BF CF DF TIBI UONI 99987 1813 Kawasaki Heavy Industries Ltd Motorcycle amp Engine Company Printed in Japan
50. e Do not attach tie straps or ropes to the A arms other suspension parts or drive shafts Straps must be directed downwards and outwards from the vehicle Front Tie Down Points A Tie down points on the front of vehicle 160 TRANSPORTING AND STORAGE Rear Tie Down Points B Tie down points on rear of vehicle e Equip the transporter with all the necessary lights and signs required by local state provincial or federal laws Storage Preparation for Storage e Clean the entire vehicle thoroughly e Run the engine for about five minutes to warm the oil shut it off and drain the engine oil A WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local author ities for approved disposal methods or pos sible recycling e Put in fresh engine oil e Empty the fuel from the fuel tank A WARNING Gasoline is extremely flammable and can be explosive under certain conditions and cause severe burns Do not smoke Turn the ignition switch off Make sure the area is well ventilated and free from any source of flame or sparks including any appliance with a pilot light A WARNING Gasoline is a toxic substance Dispose of fuel properly Contact your local authorities for approved disposal methods OAs an alternative to draining the fuel system a fuel stabilizer such as STA BIL may be used Follow the manufacturer s instructions for use
51. e Front Up to 748 kg load 78 4 kPa 1650 105 0 80 kat cm 114 psi 26X9 00R 12 Up to 590 kg load 110 kP a 1300 105 112 kgf cm 160 090 Real OVER 590 Up to 748 kg 1080 130 ga 1300 1650 Ibs 1 33 189 psi e Maximum weight capacity 748 kg 1650 105 Includi ng occupants and cargo 56071 0488 20 California Model Only A WARNING Tire replacement improper tire pressure or over oading can cause loss of control Loss of control can result in severe injury or death Load conditon including occupants and cargo COO tre pressure Te sie Front Up to 590 kg load 1300 105 78 4 kPa 080 kaf cm 11 4 psi 26x9 00R 12 Rear Up to 590 ka load 1300 105 110 kPa 112 kaf cm 160 psi 26x11 00R 12 Maximum weight capacity 590 kg 1300 05 Including occupants and cargo 56071 0489 LOCATION OF LABELS 31 CF03073C 5 CFO3074C 5 32 LOCATION OF LABELS Q1 Use the handarip to lift the rear seat 56033 0829 Cr03083C S LOADING INFORMATION 33 LOADING INFORMATION WARNING Incorrect loading improper installation or use of accessories or modification of your vehicle may result in an unsafe operating condition Before you operate it make sure that the vehicle is not overloaded and that you have followed these instructions With the exception of genuine Kawa
52. e brake feels mushy have an authorized Kawasaki dealer inspect it immediately Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer Brake Disc and Brake Pad Disc and brake pad wear is automatically compen sated for and has no effect on the brake pedal ac tion There are no parts that require adjustment on the brake A WARNING Air in brake line can make the brake feel mushy or soft This may cause reduced braking performance or brake failure and result in an accident If brake lever travel is excessive or the brake feels mushy have an authorized Kawasaki dealer inspect it immediately Brake Wear Inspection In accordance with the Periodic Maintenance Chart inspect the brakes for wear For each disc 132 MAINTENANCE AND ADJUSTMENT brake caliper if the thickness of either pad is less than 1 mm 0 04 in replace both pads in the caliper as a set Pad wear inspection and pad replacement should be done by an authorized Kawasaki dealer CL19014BM2 C A Lining Thickness B 1 mm 0 04 in Brake Hoses Brake hoses pipes and other components should be checked and replaced periodically by an autho rized Kawasaki dealer in accordance with the Peri odic Maintenance Chart Brake Light Switch When the brake pedal is depressed the brake light goes on The brake light switch should be inspected in accordance with the Periodic Maintenance Chart Inspec
53. e is released freely and the belt is wound into the retractor freely Also check the belt web bing for wear cuts or damage If any irregularities are found have the seat belt system checked or re placed by an authorized Kawasaki dealer A Retractor B Seat Belt C Latch Plate MAINTENANCE AND ADJUSTMENT 141 Cargo Bed Latches Depending on the cargo loading and or passenger riding conditions latch lever compression needs to be adjusted Release the latch lever bolts and adjust the posi tion of the latch assembly so that the latch lever will be secured without rattling and tighten the bolts A Latch Assembly B Latch Lever C Latch Lever Bolts NOTE Adjustment should be made for both sides 142 MAINTENANCE AND ADJUSTMENT Headlight Beam Battery The headlight beams can be adjusted vertically e Remove the front access cover Refer to the Front Access Cover section in the GENERAL INFORMATION chapter e Turn the adjusting screw on each headlight rim in or out to adjust the headlight vertically A Adjusting Screws B Headlight C LED Sub Headlight KAF820C D The battery is located under the right end of the rear seat A DANGER Battery contains sulfuric acid and produces hydrogen gas Sulfuric acid can cause burns and hydrogen gas can cause an explosion Read and heed the battery safety label Battery Removal e Push the locking tab to clear the hook e Unlatch t
54. e steering wheel handgrips or hand hold A WARNING To avoid injury in the event of a roll over keep arms and legs inside the vehicle at all times The operator should firmly grip the steering wheel at all times and the front pas senger should hold onto the handgrips The rear passengers should hold the handhold firmly with both hands Close all the doors Wear the seat belts for an operator and passenger s The doors handgrips and handhold are not a substitute for the seat belts A Front Center Handgrip B Front Right Handgrip C Rear Handhold SAFE OPERATION 101 This vehicle is designed for an operator and up to five passengers Never carry persons in the cargo bed Refer to the LOADING INFORMATION chapter before operat ing this vehicle 102 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor dance with the Periodic Maintenance Chart to keep the Mule in good running condition The initial mainte nance is vitally important and must not be neglected If you are in doubt as to any adjustment or vehicle operation please ask your authorized Kawasaki dealer to check the Mule Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect mainte nance or improper adjustment done by the owner Periodic Maintenance Chart In addition
55. each day before use Habitual performance of these checks will help to insure safer more re liable usage Be sure that any irregularities found during these checks are corrected before operating the vehicle Drive Carefully and with Good Judgement We want you to be satisfied with your new Kawasaki vehicle so drive carefully safely and ex ercise good judgement Practice basic maneuvers SO you can drive confidently and safely Improper use of this vehicle can be hazardous Never operate at speeds too fast for your skills or conditions Handling characteristics of this vehicle change depending upon cargo load and driving modes Read the Owner s Manual Read and understand this Owner s Manual This is especially important for inexperienced drivers Refer to this Owner s Manual if you have any ques tions Off Highway Use Only This vehicle is not an all terrain vehicle it is de signed and equipped to be a multiuse utility vehicle for off highway use only Use of this vehicle on pub lic roads and paved surfaces is hazardous Do not operate this vehicle on public roads or paved sur faces Occupant Capacity Make sure operators are 16 years or older with a valid driver s license Each occupant must be able to sit with back against seat feet flat on floor and hands on steer ing wheel handgrip or handhold The operator should be tall enough to wear the seat belt properly and reach all controls Passenger s should also be
56. ealer or perform it referring ter or exposed to salt air or operated on rainy days to the Service Manual for this vehicle rough terrain or in dusty areas A WARNING Build up of debris or flammable material in and around the vehicle chassis engine and exhaust can cause mechanical problems and increase the risk of fire When operating the vehicle in conditions that allow debris or flammable material to collect in and around the vehicle inspect the engine electrical component and exhaust areas frequently If debris or flammable materials have col lected park the vehicle outside and stop the engine Allow the engine to cool then remove any collected debris Do not park or store the vehicle in an enclosed space prior to inspecting for build up of debris or flammable materials NOTE O KAF820C D Condensation may form on the in side of the LED sub headlight lens after riding in the rain washing the vehicle or humid weather To remove the moisture start the engine and turn on the headlight Gradually the condensation on the inside of the lens will clear off Preparation for Washing Before washing precautions must be taken to keep water off the following parts e Muffler rear opening cover with a plastic bag e Ignition switch cover the key hole with tape Where to be Careful Avoid spraying water with any great force near the following places e Disc brake master cylinder and caliper e Under the rear sea
57. ect the drive belt and take actions to escape from such conditions Refer to the When Stuck section in the HOW TO OPERATE chapter and Belt Drive Transmission CVT section in the MAINTENANCE AND ADJUSTMENT chap ter NOTE O This indicator light will go on when the ignition switch is turned on and go off in three seconds Yellow Engine Warning Indicator Light The engine warning indicator light goes on when engine parts fail to function properly Ifthis light goes on have your authorized Kawasaki dealer to check the vehicle for the problem Red EPS Warning Indicator Light The EPS warning indicator light will momentarily il luminate when the engine starts then go off in a sec ond if the system is in order If this warning indicator light illuminates any other time it indicates the ECU or actuator has malfunctioned or the wiring harness has become disconnected Stop driving immediately and contact an authorized Kawasaki dealer to have the system checked NOTE O The KAF820A model does not have the EPS sys tem on it Therefore the EPS warning indicator light does not go on except for a second when the ignition switch is turned on Olf this warning indicator light does not go on when the ignition switch is turned on there may be a problem with the light itself Contact an authorized Kawasaki dealer for inspection Red Parking Brake Indicator Light When the parking brake is applied with the ignition Switch i
58. ed Use the Parking Brake Always apply the parking brake before getting out of your vehicle Obey Local Laws Know and obey all laws and regulations govern ing the use of off highway vehicles in your area Re spect private property Always try to preserve nature and the environment Refueling Before refueling the vehicle shut the engine off and make sure the area is well ventilated and free of any source of flame or sparks Gasoline is very flammable Tire Air Pressure Tire inflation and type can affect the vehicle s han dling characteristics Check the tire pressure fre quently Use only the recommended tires for re placement Maximum Seating Capacity Do not exceed seating capacity 6 occupants Occupants shall only ride in designated seating positions and with maximum 3 persons in each front and rear seat Do not carry small children on lap EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 exhaust emission 2 and evaporative emission 3 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the cylinder head Then it is led to the combustion chamber through the air c
59. ed Oil Pressure Warning Indicator Light 41 Lighting Electrical Accessory Socket 42 Light Switches doe tei 43 Steering Wheel sess 44 Brake 46 Sun Top Roof Equipped Model 46 Converting Rear Seat and Cargo Bed 47 From 6 Persons to 3 Persons Mode 47 TABLE OF CONTENTS From 3 Persons to 6 Persons Mode 50 Cargo Bed dn Heer bep 52 Tailgate 52 Loading Cargo Bed 52 Lifting amp Lowering the Cargo Bed 53 oai 59 Glove 62 Cupholdets urere 62 Front Access 63 Ignition Switch sene 64 E 65 Gear Shift 66 Selectable 2WD AWD Shift Switch 68 Selectable DIFF LOCK Shift Switch 69 Belt Drive 70 Parking Brake 71 odd metuens tont 72 RICCA 73 Seat Belts 52 ied ee eges 74 Throttle Pedal 76 Trailer Hitch 7T BREAKIN tope teda 78 HOW TO
60. eels must be installed so that the valve stems are on the outside of the vehicle Wheel Nuts Check for wheel nut tightness in accordance with the Periodic Maintenance Chart Tightening Torque 120 N m 12 2 kgf m 88 5 ft lb Tires The front and rear tires are knobby tubeless tires When replacing tires check the valve stems and cores for damage Take care not to damage the tire sealing surfaces of the rims MAINTENANCE AND ADJUSTMENT 135 Standard Tire Tubeless Make Type DURO FRONTIER DI2037 Size 26 x 9 00R12 4PR Tubeless Make Type DURO Rear FRONTIER DI2037 Size 26 x 11 00R12 4PR Tubeless Tire Air Pressure when cold Except for California Model Up to 748 kg 1 650 78 4 kPa 0 80 Front i Load kgf cm 11 4 psi Up to 590 kg 1 300 110 kPa 1 12 R Ib Load kgf cm 16 0 psi ear 590 748 kg 1 300 130 kPa 1 33 1650 Ib Load kgf cm 18 9 psi Tire Air Pressure when cold California Model Up to 590 kg 1 300 78 4 kPa 0 80 Ib Load kgf cm 11 4 psi Front Up to 590 kg 1 300 110 kPa 1 12 Ib Load kgf cm 16 0 psi 136 MAINTENANCE AND ADJUSTMENT NOTE Tires are an important part of the suspension of the vehicle Tire construction characteristics and tire inflation pressure can greatly influence vehicle handling Kawasaki recommends that you always replace tires with standard replacement tires as shown above It is also ve
61. ent every 50 hrs of use or more often in muddy dusty or other harsh conditions Refer to your owner s manual for complete service information Operate in low range gear 56033 0724 only allow for increased braking distance and use extreme caution when operating on hills Follow towing hitch guidelines in the Owner s Manual 15 eMax trailer tongue weight 68 1 kg 150 105 eMax trailer weight 907 kg 2000 lbs trailer olus cargo weight IMPORTANT DRIVE BELT INFORMATION Neglect abuse or failure to maintain the iransmission can result in belt damage and failure Inspection of the transmission drive belt is required at least every 100 hours or 2000km 1200mi since drive belts wear with normal use More frequent inspection is necessary if the vehicle is Subjected to hard usage If excessive belt slippage occurs do not ride the vehicle until damaged components are repaired Refer to your Owner s Manual ae 3b mm L MAX 93 INCH 236 56033 0831 CF030930 S 56071 0436 0030768 5 LOCATION OF LABELS 29 16 KAF820C D 17 Do Not Exceed 120 w Total 4 WARNING Fages 0 Panis cculd oc pinched during carco bed convors on when Using One or Both Sockets wher conversing tre 3 00 oed be rot 19 calch incers hards 0 any ct er cody parts between zhe fc ding carco bec sice walls 56033 0814 56071 0471 030626 5 CF
62. er steering system in the front access cover A 40 A Fuse B Hook If the fuse is blown steering becomes heavy Re place the blown fuse with a fuse of the same specific amperage and type If a replaced fuse blows again there can be trouble with the ECU or harness con nectors Contact an authorized Kawasaki dealer for inspection e You can check the 40 A fuse if it is blown at the top of the fuse When replacing the fuse release the hook of fuse 40 A Fuse WARNING The electrical system can produce painful electrical shocks When replacing the 40 A fuse first remove the cables from the battery terminals to avoid electric shock MAINTENANCE AND ADJUSTMENT 155 Breaker The breaker for the radiator fan is located in the front access cover If the fan does not function in spect the breaker In order to reset the breaker push the button atthe side of the breaker case Before re setting however check that the radiator fan is free from mud or other obstacle as well as the wiring har ness and electrical equipment for bare wires or other possible causes for the tripped breaker B Reset Button 156 MAINTENANCE AND ADJUSTMENT General Lubrication Cleaning In accordance with the Periodic Maintenance To prolong the life of your vehicle wash it down Chart have the general lubrication performed by an immediately after it has been splashed with sea wa authorized Kawasaki d
63. ery Removal NOTE O If there is dust or mud around the battery and air cleaner housing clean them using compressed air e Free the drain hose from the clamps e Pull up the snaps and remove the air cleaner hous ing cap e Pull the air cleaner element and adapter out of the housing e Remove the element from the adapter e Push a clean lint free towel into the air cleaner housing to keep dirt or other foreign material from entering WARNING If dirt or dust is allowed to pass through into the fuel injection system the throttle may stick or become inoperable resulting in a hazardous operating condition NOTICE If dirt gets into the engine excessive engine wear and possible engine damage may oc cur A Paper Element B Adapter MAINTENANCE AND ADJUSTMENT 121 NOTE O Element installation is performed in the reverse order of removal Element Cleaning e Remove the element see Element Removal e Clean the paper element by tapping it lightly to loosen dust e Blow away the remaining dust by applying com pressed air from the inside to the outside from the clean side to the dirty side e Inspect the element material for damage If any part of the element is damaged the element must be replaced Element Installation e If there is dust and mud in the air cleaner housing blow out the inside of the air cleaner housing with compressed air e Install the air filte
64. formation Drive Belt 16 Power Outlet Socket Information KAF820C D LOCATION OF LABELS 23 CF0 8104 17 Warning Cargo Bed Operation 18 Warning Cargo Bed Loading 19 Certification Emission 20 Important Information Tires Max Load 24 LOCATION OF LABELS 21 Instruction Rear Seat LOCATION OF LABELS 25 1 A WARNING Be Presared Fasten seal bells Wear approved helmet and ovotective gear Each occupant must be able to sil gack against seat feet fat loor ard hands steering wheel o nandorips Stay completely inside the ve iclo Be sure doors are securely closed before drivirg this vehicle Drive Responsibly Avoid loss of control and rollovc5 Avic abrupt maneuvers sideways sliding skidding fishlail na and never do dents Slow dowr before entering turn Avoic harc ecceleration wren turning even fron 5100 or hills rough terrain ruts and athe charges traction anc errain Avoid Davec sur aces side hillina riding acress slopes Rollovers have caused severe injuries and ceath ever on flat open areas Toroper Jse cf Off Highway Vehicles Can Cause Severe or Death He sure Occupants Pay Attention and Plan 1 you link or feel ihe vehicle may tip or reduse your risk of injury Keep a firm grip or che steering wheel hendarins and brace y
65. ght safe path for descent to avoid any ob stacles Normally you should descend straight down a hill since driving at an angle could cause the vehi cle to lean to one side and possibly tip over Proceed slowly and cautiously Apply the brake as necessary Be careful if the surface is loose because the tires are more likely to skid and braking effectiveness will be reduced Turning while descending a slope must be done very carefully and gradually to avoid tipping the ve hicle over WARNING Riding sideways across a hill may cause the vehicle to overturn causing severe injury or death Do not turn sideways to the hill Remember e Stop and look for obstacles before descending a hill e Go straight downhill e Go slowly e If you must turn do so carefully and gradually SAFE OPERATION 97 NOTE OWhen the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking This is caused by the ve hicle s automatic transmission which releases the engine at very low speed to prevent it from stalling Use the brakes to control the vehicle s speed 98 SAFE OPERATION Traversing Hillsides Sliding and Skidding When driving across the side of a hill reduce vehi cle speed and exercise extreme caution to prevent tipping or loss of control Avoid hills with slippery sides that will cause you to lose traction Also avoid traversing hillsides covered with roc
66. ght will remain illuminated for approxi mately 5 6 seconds When the ignition switch is turned off after the engine has been running the DIFF LOCK indicator light will remain illuminated for approximately 50 60 seconds If the indicator light in the DIFF LOCK shift switch does not go off the electric shifting mechanism may have a failure Contact an authorized Kawasaki dealer for inspection 92 HOW TO OPERATE Catalytic Converter This vehicle is equipped with a catalytic converter in the exhaust system The converter reacts with carbon monoxide hydrocarbons and nitrogen ox ides to convert them into carbon dioxide water nitro gen and oxygen resulting in much cleaner exhaust gases to be discharged into the atmosphere For proper operation of the catalytic converter the following cautions must be observed A WARNING Operating or parking the vehicle near flammable materials can cause a fire and can result in property damage or severe personal injury Do not idle or park your vehicle in an area where tall or dry vegetation or other flammable materials could come into con tact with the muffler or exhaust pipe A WARNING The engine and exhaust system get ex tremely hot during normal operation and can cause serious burns Never touch a hot engine exhaust pipe or muffler during operation or after stopping the engine e Use only unleaded gasoline Never use leaded gasoline Leaded gaso
67. gine damage MAINTENANCE AND ADJUSTMENT 107 e If the vehicle has just been used wait several min utes for all the oil to drain down e Park the vehicle on level ground e Remove the battery cover see Battery Removal e Pull up the dipstick out of the dipstick tube wipe it dry and insert the dipstick till it bottoms into the tube securely A Dipstick e Pull out the dipstick and check the oil level The oil level should be between the F Full and L Low holes on the dipstick 108 MAINTENANCE AND ADJUSTMENT 2031049 P A Dipstick B Full Hole C L Low Hole e Reinsert the dipstick until it bottoms into the tube securely e the oil level is too high remove the excess oil using a syringe or other suitable device e f the oil level is too low unscrew the oil filler cap and add the correct amount of oil Use the same type and brand of oil that is already in the engine e Install the oil filler cap Oil and or Oil Filter Change e Lift the cargo bed and support it with the support ing rod e Warm up the engine thoroughly and then stop the engine e Remove the oil filler cap A Oil Filler Cap e Place an oil pan beneath the engine e Remove the drain bolt 0039051 P A Drain Bolt e Let the oil completely drain with the vehicle on level ground WARNING Engine oil is a toxic substance Dispose of used oil properly Contact your local auth
68. he START position with the engine running or damage to the starter can result CH16008BM2 NOTE A Key OThe vehicle is equipped with a starter lockout B ey Number switch This switch prevents the electric starter Write your key number here from operating when the gear shift lever is in the H High L Low or R Reverse position unless the brake is applied In the event you lose your keys you will need the key number to have a duplicate made If you cannot locate your key number contact the dealer where 66 GENERAL INFORMATION you purchased your Kawasaki UV It s possible the dealer may have the number in its records If the key number is lost completely you will need to replace the ignition switch Contact your Kawasaki dealer to purchase addi tional spare keys either using your original key as a master or using the key code on the tag or your key Store one key at home and keep another spare in your wallet or riding gear in case the original is lost Gear Shift Lever The gear shift lever is located on the dashboard to the right side of the steering wheel The gear shift lever has four positions L Low H High Neutral and Reverse Make certain that the vehicle is completely stopped and the engine is idling before shifting from High or L Low to Reverse or vice versa Move the gear shift lever up or
69. he latch as shown right side MAINTENANCE AND ADJUSTMENT 143 A Battery Cover A Battery Cover B Latch B Latch C Locking Tab C Locking Tab 1 Push the locking tab 1 Push the locking tab 2 Pull 2 Pull 3 Slide 3 Slide 4 Open 4 Open e Unlatch the latch as shown left side e Clear the hooks upward on the battery cover 144 MAINTENANCE AND ADJUSTMENT _ m QOO A Hooks A Battery Cover B Battery Cover B Tabs 1 Slide 2 Pull NOTE e Clear the tabs on the battery cover and remove O If there is dust or mud around the battery and air the battery cover right ward cleaner housing clean them using compressed air e Remove the screws and washers MAINTENANCE AND ADJUSTMENT 145 A Screws and Washers e Remove the battery holder A Battery Holder B Red Cap C Terminal D Terminal e Disconnect the negative cable from the ter minal e Remove the red cap e Disconnect the positive cable from the ter minal NOTE O There is no need to separate the smaller cables clamped with the positive cable e Take the battery out e Clean the battery using a solution of baking soda and water Be sure that the lead connections are clean 146 MAINTENANCE AND ADJUSTMENT e Perform a visual inspection Inspect for defective or cracked case and cover and loose or damaged terminal posts or cables Replace battery and or cables immediately if any damage
70. hen released The latch plate should click securely with the buckle and release when the release button is pushed firmly DO6OIS dut teat tle Make sure there is no damage to the structure or loose bolts and all doors are latched securely they are closed 82 HOW TO OPERATE Starting the Engine A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas _Inhal ing carbon monoxide can cause serious brain injury or death DO NOT run the en gine in enclosed areas Operate only in a well ventilated area e Close all doors e Wear the seat belts for an operator and passen ger s e Make sure the parking brake is applied e Putthe gear shift lever in the N Neutral position e Put the ignition switch key in the switch e Turn the ignition switch key to the START posi tion to activate the electric starter Repeat until the engine starts NOTICE Do not operate the electric starter continu ously for more than 5 seconds or the starter may overheat and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and for battery power to recover NOTE O The vehicle is equipped with a starter lockout sys tem This switch prevents the electric starter from operating when the gear shift lever is in the H High L Low or R Reverse position un less the brake is applied Jump Starting If your vehicle
71. hicle use or 2 000 km 1 200 miles whichever comes first since drive belt wear with normal use More frequent inspection is necessary if the vehicle is subjected to hard us age such as pulling a trailer operating in mud or deep water or in extremely dusty conditions If excessive belt slippage occurs do not drive the vehicle until damaged components are re paired Causes of accelerated Belt Wear Avoid these hard usage conditions to obtain maxi mum belt life and prevent accelerated belt wear and deterioration e Operating the vehicle in high range while climbing hills carrying heavy loads or pulling a trailer e Exceeding maximum vehicle load or trailer weight e Operating in mud or water deeper than recom mended e Operating in extremely dusty conditions e Continued operation with excessive belt slippage e Failure to apply the brake controls while descend ing hills Indications of Excessive Belt Slippage Excessive slippage will accelerate belt wear and lead to failure Recognize these symptoms of ex cessive belt slippage If excessive slippage occurs do not continue to drive the vehicle until all damaged components are repaired e Smell of burning rubber e Visible white smoke e Sluggish initial acceleration or loss of power e Engine rpm is higher for the same vehicle speed e Engine vibration When Swamped If a large amount of water accidentally has entered the CVT housing it will cause drive belt
72. ile of mile of OPERATION use use use use D or ev ery year Cil filter replace D whichever comes first at Dealer Radiator hoses and connections check Coolant change Converter drive belt wear inspect Converter drive belt deflection inspect Converter drive pulley shoe inspect Drive pulley coupling apply grease CHASSIS Brake pad wear inspect Brake light switch inspect MAINTENANCE AND ADJUSTMENT 105 FREQUENCY First Service Regular Service After 50 Every Every Every After 20 h 50h or 100 h or 200 h or p Y 120 1 000 1 000 2 000 4 000 km pu km 600 km 600 1 200 2 500 y mile of il use ise mile of mile of mile of mile of OPERATION use use use use Brake fluid change 2 years D Brake master cylinder cup and dust seal 2 years D replace Brake caliper piston seal and dust seal replace 2 years D Brake hoses replace 4 years D Brake fluid level inspect e Brake pedal play inspect e Brake hoses and pipes inspect D Parking brake lever inspect Tire wear inspect e Wheel nuts tightness inspect e Wheels inspect D Wheel hub bearings inspect D Joint boots inspect Shock absorbers inspect D Suspension arms inspect D 106 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service
73. iller opening no leaks Coolant Coolant level between level lines when engine is cold no leaks Air Cleaner Element Check for dirt clean or replace as required Drain the oil and water in the drain hose if necessary Screen at Belt Drive Transmission CVT Air Check and clean the screen for obstruction by insects mud or foreign object Throttle chien dae Throttle pedal free play 2 10 mm 0 08 0 39 in Throttle pedal operates smoothly and returns to rest position when released HOW TO OPERATE 81 Steering Steering wheel free play 0 20 mm 0 0 79 in Action smooth without excessive play rough spots or strange noises Brakes testet p bets Check for braking effectiveness while test running Brake pedal free play 2 10 mm 0 08 0 39 in Brake fluid level between level lines no leaks Parking brake Stops vehicle completely Parking Brake Indicator Make sure the parking brake indicator light illuminates when the parking brake is applied with the ignition switch in the ON position Electrical Equipment All lights work Check for dirt on or damage to lights ROPS uiii eerie Make sure there is no damage to the structure or loose bolts Seat BeltS Make sure that all seat belts are in good condition and operate prop erly The belt should pull smoothly and retract w
74. iming NOTICE If valve clearance is left unadjusted wear will eventually cause the valves to remain partly open which lowers performance burns the valves and valve seats and may cause seri ous engine damage Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Main tenance Chart Inspection and adjustment should be done by an authorized Kawasaki dealer Valve Clearance Engine Cold Intake 0 13 0 23 mm 0 0051 0 0091 in 0 20 0 30 mm 0 0079 0 0118 in Exhaust 120 MAINTENANCE AND ADJUSTMENT Engine Air Cleaner A clogged engine air cleaner restricts the engine s air intake increasing fuel consumption reducing en gine power and causing spark plug fouling A WARNING A clogged air cleaner may allow dirt and dust to enter the fuel injection system and the throttle may stick resulting in a haz ardous operating condition Clean the air filter according to the periodic maintenance chart more often if the vehicle is used in extremely dusty conditions NOTICE A clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and possible engine damage The air filter element should be cleaned in ac cordance with the Periodic Maintenance Chart In dusty areas the element should be cleaned more frequently than the recommended interval Element Removal e Remove the battery cover see Batt
75. ing C Bottom of Filler Opening e Install the oil filler cap and tighten itto the specified torque Tightening Torque Oil Filler Cap 16 N m 1 6 kgf m 12 ft lb NOTE Use the same type and brand of oil that is already in the gear case 112 MAINTENANCE AND ADJUSTMENT Oil Change NOTE O Before draining the oil warm it up by running the vehicle Warm oil drains easily and picks up any sediment e With the vehicle level place an oil pan beneath the gear case e Remove the oil filler cap and drain plug A WARNING Gear case oil is a toxic substance Dispose of used oil properly Contact your local au thorities for approved disposal methods or possible recycling A WARNING Oil on tires can make them slippery which can cause an accident and injury When draining or filling the gear case be careful that no oil gets on the tires or rims Clean off any oil that inadvertently gets on them with soap and water A Drain Plug e After the oil has completely drained install the drain plug with a new O ring Tighten itto the spec ified torque Tightening Torque Drain Plug 16 N m 1 6 kgf m 12 16 e Fill the gear case to the bottom thread of the filler opening with a high quality oil as specified in the table Front Final Gear Case Oil Oil Capacity 0 43 L 0 45 US qt Oil Type API GL 5 Hypoid gear oil Viscosity above 5 C 41 F SAE 90 below 5 C 41 F SAE 8
76. ing a seat belt or wearing one im properly can result in serious injury or death in the event of an accident Make certain the operator and all passengers always wear their seat belts properly A WARNING Operator and all passengers must be able to place both feet flat on the floorboards while seated upright with their backs against the seatbacks To wear the seat belt properly follow this proce dure 1 Place the belt across your lap and chest taking care that the belt is not twisted 2 Pushthelatch plate into the buckle until it clicks Pull up on the latch plate to make sure it is se cure A Seat Belt B Latch Plate C Buckle D Red Button Put the lap portion of the belt low on your hips Push down on the buckle end of the belt as you pull up on the shoulder part so the belt is snug across your hips GENERAL INFORMATION 75 4 Place the shoulder belt over your shoulder and across your chest The shoulder belt should fit against your chest If it is loose pull the belt out all the way and then let it retract Fg 268000 5 Lap Portion of Belt B Shoulder Belt 5 Tounfasten the belt press the red button in the buckle WARNING Too much seat belt slack could reduce its protection effectiveness in an accident Al ways verify that the belt is at a SNUG FIT The seat belt is equipped with a dual mode latch plate Under normal driving conditions the
77. ing the left button and pushing the right button within two seconds G A mph km h Display B Left Button C Right Button e The mph km h display shifts as follows km h lt gt mph 120606 6 NOTE O The data is maintained even if the battery is dis connected Fuel Level Gauge Symbol The fuel in the fuel tank is shown in segments All 6 segments are displayed when the fuel tank is full As fuel is consumed the segments go out accordingly When the bottom segment is reached it will begin blinking to warn of a low fuel level When it begins blinking 6 8 liters 1 8 U S gal of fuel remain Fill the fuel tank as soon as possible because there is no reserve tank in this vehicle see the Fuel Tank section A Blinking to warn of low fuel level Clock To adjust hours and minutes e Turn the ignition switch on e The odometer is displayed e Push the Right button for more than two seconds Both the hour and minute displays start blinking GENERAL INFORMATION 37 ii CH18025BM1 C A Hour Display B Minute Display e Push the Right button The hour display only blinks Push the Left button to advance the hours CH18026BM1 A Hour Display e Push the Right button The hour display stops blinking and the minute display starts blinking Push the Left button to advance the minutes 38 GENERAL INFORMATION 1 3 3
78. is found Battery Installation e Check that the rubber dampers on the battery holder and the floor board are properly in place e Put the battery in place on the rubber damper e Connect the three positive cables to the termi nal and then connect the negative cable to the terminal e Put a light coat of grease on the terminals to pre vent corrosion e Install the red cap e Install the battery holder and tighten its nut e Install the screws and washers e Insert the hooks into the slots as shown _ A Battery Cover B Hooks C Slots e Insert the tabs into the slots as shown MAINTENANCE AND ADJUSTMENT 147 A Battery Cover A Battery Cover B Tabs B Tabs C Slots C Slots e Insert the tabs into the slots as shown e Lock the latch as shown 148 MAINTENANCE AND ADJUSTMENT A Latch A Latch B Battery Cover B Battery Cover 1 Close 3 Push 2 Pull WARNING Loose battery cables can create sparks which can cause a fire or explosion resulting in injury or death Make sure the battery terminal screws are tightened securely and the covers are in stalled over the terminals Battery Characteristics The battery installed in this vehicle is a sealed type and the sealing strip should not be removed at any time after the specified electrolyte has been installed in the battery for initial service It is not essary to check the battery electrolyte level o
79. justing sleeves on the shock absorbers to the desired position Spring Action Front Shock Absorber Up to 590 kg 1 300 Ib Load Posi Spring tion Force Setting Load MAINTENANCE AND ADJUSTMENT 139 Spring Action Front Shock Absorber 590 748 kg 1 300 1 650 Ib Load Except for California Model Posi Spring tion Force Weak Setting Load Spring Action Rear Shock Absorber Up to 590 kg 1 300 Ib Load Except for California Model Spring Force 140 MAINTENANCE AND ADJUSTMENT Spring Action Rear Shock Absorber 590 748 kg 1 300 1 650 Ib Load Except for California Model Posi tion Spring Force Weak Setting Load A WARNING Improper shock absorber adjustment can cause poor handling and loss of stability which could lead to an accident Always adjust the shock absorbers on the left and right side to the same setting Seat Belts In accordance with the Periodic Maintenance Chart check that each seat belt functions properly Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle The click sound indicates it is securely latched Pull the belt vigorously to make sure the retractor locks the seat belt A Seat Belt B Buckle C Red Button Push the red button in the buckle to make sure the latch plat
80. ked and replaced periodically by an authorized Kawasaki dealer in accordance with the Periodic Maintenance Chart The fuel tank vent hoses must be routed as spec ified The engine may stall or lose power if the fuel tank ventis plugged orifthe venthose is pinched Inspect the vent hose before riding and whenever the engine seems to lose power If the fuel tank is full but the engine feels as if it is running out of fuel check the vent and vent hose A Fuel Tank Vent Hose B Check Valve C Fuel Tank 128 MAINTENANCE AND ADJUSTMENT Belt Drive Transmission CVT This vehicle is equipped with a belt driven Contin uously Variable Transmission CVT This automatic drive system although simple to operate does re quire periodic inspection since the drive belt wears with normal use Inspection should be done by an authorized Kawasaki dealer 7 2 172007 P A Belt Drive Transmission CVT Periodic Drive Belt Inspection Requirements Drive belt wears with normal use Inspection of the drive belt is required at least every 100 hours of vehicle use or 2 000 km 1 200 miles whichever comes first More frequent inspection is necessary if the vehicle is subjected to hard usage IMPORTANT INFORMATION Neglect abuse or failure to maintain the trans mission can result in a severely worn or dam aged drive belt locking up the transmission and wheels Inspect the drive belt at least every 100 hours of ve
81. ks or other ob stacles which may cause you to lose your balance or tip over When driving on soft terrain steer slightly uphill to keep the vehicle on a straight line across the hillside Ifthe vehicle begins to tip steer downhill if possible to regain control Obviously on slippery or loose surfaces special care is required Sliding any vehicle may be haz ardous because the wheels may suddenly regain traction and cause the vehicle to tip or overturn Therefore never drive over your head or when you are unsure or unprepared for the surface Often you can correct a skid by turning the wheels in the direction of the skid Do not apply heavy brak ing force or accelerate when skidding since this may cause further loss of control Use caution and maintain low speeds to avoid un controlled skidding on areas covered with clay mud ice or snow Use 4WD and low range gearing effi ciently These conditions are particularly hazardous when descending a hill or making a turn Remem ber that this vehicle is not for use on public streets roads or highways Remember e Be especially careful on very slippery surfaces e Don t drive on public streets roads or highways Driving through Water Avoid driving through water whenever it is possi ble When driving across shallow water choose a location to enter and exit the water where the banks are not too steep or slippery Check before entering for rocks holes or other
82. le DIFF LOCK Shift Switch LOCK Position Locked Rear Axle Mode UNLOCK Position Unlocked Rear Axle Mode DIFF LOCK Indicator Light e After crossing the obstacle push the shift switch to UNLOCK Unlocked Rear Axle position com WARNING Shifting to Locked Axle Mode while turning or before entering a turn can reduce steering response increasing the effort to turn An unexpected change in direction can cause the operator to lose control resulting in an accident and injury Do not shift to Locked Axle Mode while turning or before entering a turn NOTE OBy pushing the shift switch to LOCK position driving force to both wheels is equalized thereby increasing traction Shifting to Differential Unlocked Rear Axle Mode e Stop the vehicle completely e Turn the selectable DIFF LOCK shift switch to UNLOCK position If the indicator light in the DIFF LOCK shift switch does not go off do one of the following procedures to cancel the indicator light e Push the selectable DIFF LOCK shift switch to the LOCK position while stopping the vehicle e Turn the ignition switch to OFF position while stopping the vehicle Then turn on the ignition Switch HOW TO OPERATE 91 NOTE OThe DIFF LOCK indicator light remains illumi nated when the DIFF LOCK shift switch is acti vated and the ignition switch is turned off When the engine has not been started the DIFF LOCK indicator li
83. leaner Oil is separated from the gases while passing through the inside of the breather chamber from the cylinder head 2 Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a catalytic converter in the muffler a fuel injection system and ignition system having optimum ignition timing characteristics The fuel injection system has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thor ough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere 3 Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank Maintenance and Warranty Proper maintenance is necessary to ensure that your vehicle will continue to have low emission levels This Owner s Manual contains those maintenance recommendations for your vehicle Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards As the owner of this vehicle you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner s Manual at your own expense Yo
84. ler or refer to the Service Manual for the action required to return the vehicle to a safe operating condition WARNING Failure to perform these checks before operation may result in serious damage or an accident Al ways perform daily checks before operation A DANGER Exhaust gas contains carbon monoxide a colorless odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Op erate only in a well ventilated area Fiel nemen et Enough fuel in tank no leaks Engine Oil asneira Oil level between F and L holes on the dipstick when engine is cold no leaks 80 HOW TO OPERATE TIES ce cete pete Air pressure when cold Except for California Model Tire Load Cold Tire Pressure Front to 748 kg 1 650 Ib Sn RPO RU Koren dq 2 Up to 590 kg 1 300 Ib i kPa 1 12 kgf cm 16 0 Rear 590 748 kg 1 300 1 650 130 kPa 1 33 kgf cm 18 9 Ib psi California Model Tire Load Cold Tire Pressure 2 Front Up to 590 kg 1 300 Ib RP aD SO RAUCH Td 2 Up to 590 kg 1 300 Ib 110 kPa 1 12 kgf cm 16 0 psi Check for cuts cracks damage or excessive wear Check for any imbedded stones or other foreign particles in tread Front Final Gear Case No oil leaks Transmission Case Oil Oil level between high and low levels on the rib in the oil f
85. line significantly reduces the capability of the catalytic converter e Do not operate the vehicle with the engine or any one cylinder misfiring Under these conditions unburned air fuel mixture flowing out of engine excessively accelerates reaction in the converter allowing the converter to overheat and become damaged when the engine is hot or reduces converter performance when the engine is cold SAFE OPERATION 93 SAFE OPERATION Safety is an attitude Your common sense and good judgement are your best defenses against ac cident and injury in everything you do Your safety and the safety of others depends on you and your common sense Use good judgement in the opera tion of this or any other motor vehicle This vehicle is designed for an operator and two passengers for 3 persons mode or an operator and five passengers for 6 persons mode Never carry persons in the cargo bed Refer to the LOADING INFORMATION chapter before operating this vehi cle Novice operators should practice braking and turn ing in an open off highway area away from other vehicles and persons The terrain should be flat and free of obstacles with either a loose or hard dirt sur face but not a mixture of both WARNING Incorrect loading improper installation or use of accessories or modification of your vehicle may result in an unsafe operating condition Before operation make sure that the vehicle is not overloaded and that you
86. long time Do not mix two types and brands of fluid for use in the brakes Don t leave the reservoir cap off for any length of time to avoid moisture con tamination of the fluid Don t add or change brake fluid in the rain or during conditions of blowing dust or debris NOTICE Brake fluid quickly ruins painted surfaces Wipe up any spilled fluid immediately Fluid Level Inspection e With the vehicle on level ground check through the cover that the fluid level in the reservoir is be tween the upper marked MAX and lower marked MIN level lines Brake Fluid Reservoir B Upper Level Line MAX C Lower Level Line MIN e f the fluid level is lower than the lower level line check for fluid leaks in the brake lines and fill the reservoir to the upper level line WARNING Mixing two types and brands of fluid for use in the brake lowers the brake fluid boiling point and could reduce brake effectiveness Change the fluid in the brake system com pletely if the fluid level is low but the type and brand of the fluid already in the reservoir are unknown e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings MAINTENANCE AND ADJUSTMENT 131 WARNING Air in brake line can make the brake feel mushy or soft This may cause reduced braking performance or brake failure and result in an accident If brake lever travel is excessive or th
87. m Both Sides B Lower Locking Arm Both Sides C Lock Pin Both Sides 6 GENERAL INFORMATION 49 Slide the cargo bed screen forward in conjunc tion with pushing the hinge between the cargo bed side plates on both sides A Cargo Bed Screen B Cargo Bed Side Plates NOTE O To move the screen smoothly push both cargo T bed side plates evenly as much as possible After fully extending the cargo bed side plates lower both screen lock arms aligning their lower locking arms with the lock pins in the cargo bed base Push the screen lock arms into the brackets on the side plates on both sides until you hear a click Secure the cargo bed side plates with the cargo bed latches on both sides 50 GENERAL INFORMATION EH 10 Close the rear doors NOTE O Pull the screen lock arms lightly to check if they are locked securely WARNING Failure to properly lock the cargo bed or screen may allow them to move suddenly while driving causing loss of control and an accident resulting in serious injury or death To prevent the cargo bed from sud denly moving make sure that the cargo bed and screen has been locked properly after handling them A Cargo Bed Side Plates B Screen Lock Arm C Bracket D Lower Locking Arm E Handgrip F Cargo Bed Latch From 3 Persons to 6 Persons Mode NOTICE Be careful not to pinch your finger between the movable components when converting the rear
88. make sure the cover is locked securely A WARNING An open front access cover can distract or impair visibility of the operator causing loss of vehicle control and potential serious in jury or death Lock the front access cover securely before operating the vehicle Ignition Switch This is a three position key operated switch The key can be removed from the switch only when it is in the OFF position Ignition Switch OFF Position Position START Position GENERAL INFORMATION 65 OFF off All electrical circuits off Keys All electrical equipment can be used Hour meter works ON This UV comes with two keys Use one for the Electric starter is engaged by holding ignition switch and keep the other in a secure place ignition switch key in this position only to use as a spare A key number is stamped on START when gear shift lever is in N neutral the key itself Record the key number in the space position or applying brake pedal Upon provided and store the number in a safe place release key will return to ON position NOTICE Do not operate the starter continuously for more than 5 seconds or the starter will overheat and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power Do not turn the ignition switch key to t
89. n the front access cover The main power fuses are located under the rear seat If the electrical systems do not function inspect the fuses Before replacing a fuse check the wiring harness and electrical equip ment for bare wires or other possible causes for the blown fuse NOTICE Do not use a fuse of a higher capacity than the specified fuse rating or damage to the electrical system could result Refer to the Fuse Location label on the other side fuse case lid Fuse e Remove the front access cover Refer to Front Access Cover section in the GENERAL INFOR MATION chapter A Cover B Projections C Pull Forward 152 MAINTENANCE AND ADJUSTMENT A Fuse Boxes A Fuse Box Lids B ECU Fuse Box B Fuses C Main F Open the fuse box lids and check the fuse element D EU Eire If it is blown out replace the fuse E Spare Fuses MAINTENANCE AND ADJUSTMENT 153 PF Normal Failed BL29015BM2 Main Power Fuse A Fuse Box e Remove the battery cover see Battery Removal Open the fuse box lid and check the fuse element If itis blown out replace the fuse A Battery Cover 154 MAINTENANCE AND ADJUSTMENT A Fuse Box Lid B Main Power Fuses Before replacing a fuse check the wiring harness and electrical equipment for bare wires or other pos sible causes for blown fuse Power Steering System Fuse KAF820B C D There is 40 A fuse for the pow
90. n the ON position the parking brake indica tor light illuminates Red Reverse Indicator Light When the transmission is in reverse gear the re verse indicator light illuminates Green Neutral Indicator Light When the transmission is in neutral the neutral indicator light illuminates Red Seat Belt Use Reminder When the ignition switch is turned on the seat belt use reminder light will illuminate and stay on for ap proximately 8 seconds even if the operator s belt is buckled The light is a reminder to the operator to make sure that passengers have buckled their seat belts Red Coolant Temperature Warning Indicator Light The coolant temperature warning indicator light il luminates whenever the coolant temperature rises GENERAL INFORMATION 41 too high while the vehicle is in operation If it stays on stop the engine and check the coolant level in the coolant reserve tank after the engine cools down Be sure to check that the radiator fan is free from mud and other obstacles Refer to the Breaker sec tion in the MAINTENANCE AND ADJUSTMENT chapter NOTICE Do not continue running the engine with the temperature warning indicator light continu ously illuminated Prolonged engine opera tion can result in engine damage from over heating NOTE O When you touch the fan be sure to disconnect the negative battery cable since the fan can operate automatically even with the ignition swi
91. n withstand sub freezing temper atures with no damage Battery Sulfation A common cause of battery failure is sulfation Sulfation occurs when the battery is left in a dis charged condition for an extended time Sulfate is a normal by product of the chemical reactions within a battery But when continuous discharge allows the sulfate to crystallize in the cells the battery plates become permanently damaged and will not hold a charge Battery failure due to sulfation is not war rantable Battery Maintenance It is the owner s responsibility to keep the battery fully charged Failure to do so can lead to battery failure and leave you stranded 150 MAINTENANCE AND ADJUSTMENT If you are riding your vehicle infrequently inspect the battery voltage weekly using a voltmeter If it drops below 12 6 volts the battery should be charged using an appropriate charger check with your kawasaki dealer or visit by kawasaki com If you will not be using your vehicle for longer than two weeks the battery should be charged using an appropriate charger Do not use an automotive type quick charger that may overcharge the battery and damage it NOTE OLeaving the battery connected causes the electri cal components to make the battery discharged resulting the over discharge of the battery In this case the repair or replacement of the battery is not included in the warranty If you do not drive for four weeks or more disconnect the batter
92. nce with a pilot light Shifting Gears e Stop the vehicle completely e Move the shift lever into the H High or L Low position e If you intend to operate the vehicle in reverse move the gear shift lever into the R Reverse position Refer to the Driving in Reverse section in the SAFE OPERATION chapter e Gradually increase engine speed by depressing the throttle pedal Gear Shift Lever L Low Position H High Position N Neutral Position R Reverse Position A B C D E NOTICE Shifting to high or low range when the vehi cle is in motion could cause engine damage Do not shift from High or L Low to R Reverse and vice versa when the vehicle is moving or with the engine run ning above idling speed or the transmission could be damaged NOTICE Use of the high range for heavy loads climb ing hills pulling a trailer and sustained low speed riding can lead to premature wear of the torque converter belt and pulleys Use the low range for these condition WARNING Shifting the transmission while the vehicle is moving can cause abrupt changes in speed and direction resulting in loss of control and accident with severe personal injury or death Do not shift the transmission while the vehi cle is moving Stop the vehicle to shift the transmission HOW TO OPERATE 89 2WD AWD Shifting e Stop the vehi
93. ng unauthorized ac cessories in front of the radiator or behind the cooling fan Interference with the ra diator airflow can lead to overheating and consequent engine damage MAINTENANCE AND ADJUSTMENT 117 Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator If the coolant level becomes low the engine overheats and may suffer damage Check the coolant level each day before operating the vehicle and replenish coolant if the level is low Change the coolant in accordance with the Periodic Maintenance Chart NOTE OA permanent type of antifreeze is installed in the cooling system when shipped It is colored green and contains ethylene glycol It is mixed at 5096 with water and has a freezing point of 35 C 31 F Coolant Level Inspection e Situate the vehicle on level ground e Remove the front access cover Refer to the Front Access Cover section in the GENERAL INFORMATION chapter e Check the coolant level through the coolant level gauge on the reserve tank The coolant level should be between the F Full and L Low marks NOTE O Check the level when the engine is cold room or atmospheric temperature Coolant Capacity 5 9 L 6 2 US qt 118 MAINTENANCE AND ADJUSTMENT Reserve Tank F Full Mark L Low Mark Cap com e If the amount of coolant is insufficient unscrew the cap from the reserve ta
94. nge noises or the steering feels rough or catchy have the steering system checked by an authorized Kawasaki dealer A 0 20 mm 0 0 79 in Power Steering System KAF820B C D Steering may become more difficult than usual for the following reasons e The steering wheel was continuously turned or held to the full turn stops with torque applied by driver In this case the ECU works to protect the system from overheating by stopping the power assisting Stop turning the steering wheel and wait until the system temperature drops and the power Steering recovers e Fuses in the harness may have blown There are several reasons that the fuses may blow Refer to the Fuse section in this chapter for details e Battery voltage has dropped Voltage drop can happen when the engine starts inspect the battery voltage e Cable harness or connectors may have been disconnected Contact an authorized Kawasaki dealer for service NOTE the steering becomes irregular or unusual for any reason other than above have an authorized Kawasaki dealer check the steering and relevant components immediately In some cases the power steering s neutral position can be affected by an accident or bump Wheels Rims The rims are a drop center tubeless tire design Take care not to damage the sealing surfaces of the tire or rim when removing or installing tires Note that the rims like automotive rims are not symmetrical wh
95. nk and add coolant through the filler opening to the F Full mark Install the cap Recommended Coolant Solution Coolant Mixture Ratio Water 50 Antifreeze 50 1 1 Recommended Antifreeze Permanent type antifreeze ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiator NOTE an emergency you can add water alone to the coolant reserve tank however it must be returned to the correct mixture ratio by the addition of an tifreeze concentrate as soon as possible NOTICE If coolant must be added often or the reserve tank completely runs dry there is probably leakage in the system Have the cooling sys tem inspected by your authorized Kawasaki dealer Coolant Change Have the coolant changed by an authorized Kawasaki dealer Spark Plugs MAINTENANCE AND ADJUSTMENT 119 Valve Clearance The standard spark plug is shown in the table The spark plug should be taken out periodically in ac cordance with the Periodic Maintenance Chart for cleaning and inspection Spark plug cleaning and inspection should be done by an authorized Kawasaki dealer CLO7012BM2 C A 0 9 1 1 mm 0 035 0 043 in Spark Plug Standard Plug Zhuzhou torch spark plug 7026 0 9 1 1 mm 0 035 0 043 in Plug Gap Tightening Torque 20 N m 2 0 kgf m 15 ft Ib Valve and valve seat wear decrease valve clear ance upsetting valve t
96. nt of public lands When using your Kawasaki Utility Ve hicle UV please follow these Tread Lightly guidelines Tread Lightly Travel responsibly on designated roads and trails or in permitted areas Respect the rights of others including private property owners and all recreational trail users campers and others to allow them to enjoy their recreational activities undisturbed Educate yourself by obtaining travel maps and regulations from public agencies planning for your trip taking recreation skills classes and knowing how to use and operate your equipment safely Avi sensitive areas such as meadows lakeshores wetlands and streams unless on designated routes This protects wildlife habitat and sensitive soils from damage D your part by leaving the area better than you found it properly disposing of waste minimizing the use of fire avoiding the spread of invasive species restoring degraded areas and joining a local enthusiast organi zation Properly discard used batteries tires engine oil other vehicle components or the entire vehicle that you might dispose of in the future Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure 170 MAINTENANCE RECORD MAINTENANCE RECORD Owner EDI C LODICIIBCK MET EE Engine Nu umber
97. of the booster battery to the bracket bolt on the engine NOTICE Do not connect the booster battery to the fol lowing portions as a ground e Battery negative terminal e Electrical components or leads e Fuel line or fuel relative components A DANGER Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive e Do not make this last connection at the fuel system or battery e Take care not to touch the positive and negative cables together and do not lean over the battery when making this last con nection e Do not connect to a frozen battery It could explode e Do not reverse polarity by connecting pos itive to negative or a battery explo sion and serious damage to the electrical system may occur e Follow the standard engine starting procedure NOTICE Do not operate the starter continuously for more than 5 seconds or the starter overheat and the battery power will drop temporarily Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power e After the engine starts disconnect the jumper ca bles Disconnect the negative cable from the vehicle first e Reinstall the battery cover Refer to the Battery section in the MAINTENANCE AND ADJUST MENT chapter e Lowerthe cargo bed and secure it with the latches Refer to the Cargo Bed section in the GENE
98. or ities for approved disposal methods or pos sible recycling e The oil filter should be replaced periodically by an authorized Kawasaki dealer in accordance with the Periodic Maintenance Chart e Replace the gasket e Install the drain bolt with its gasket Tighten it to the specified torque Tightening Torque Drain Bolt 50 N m 5 1 kgf m 37 ft lb e Fill the engine up to the F Full hole on the dip Stick with high quality engine oil as specified in the table e Start the engine and check for oil leakage MAINTENANCE AND ADJUSTMENT 109 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 SAE 10W 40 Capacity 2 1 L 2 2 US qt when filter is not removed Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle Con sistent use of these products meets or exceeds war ranty and service requirements and can help to ex tend the life of your Kawasaki NOTE O Do not add any chemical additives to the oil Oils fulfilling the above requirements are fully formu lated and provide adequate lubrication for the en gine Although 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric condi
99. ough ahead If you cannot see what is on the other side of the crest of a hill slow down until you can get a clear view Don t apply power suddenly while climbing or the front wheels might rise off the ground If the vehicle does not have enough power to reach the top of the hill and stalls allow the vehicle to roll slowly straight back down the hill controlling its descent with the brakes Leave the gear shift lever in the H High or L Low position until you stop at the bottom of the hill A WARNING Riding sideways across a hill may cause the vehicle to overturn causing severe injury or death Do not turn sideways to the hill Remember e Some hills are too steep Use common sense e Never drive past your limit of visibility If you can t see what is on the other side of the crest of a hill slow down until you can get a clear view e Don t turn sideways to the hill e f you get stuck on a hill roll slowly straight back down using the brake with the gear shift lever left in the High or L Low position NOTE O When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking This is caused by the ve hicle s automatic transmission which releases the engine at very low speed to prevent it from stalling Use the brakes to control the vehicle s speed Descending Hills Slow down or stop at the top of a hill so you can pick a strai
100. ourself Da rot put any part cf your bedy outside o tne vehic e or ary reason Be Sure to Apply Parking Brake Before Leavirg the vehicle Rocurc Proboer Use of Your vehicle Dc your 20 prevent injuries 02 rot allow careless or reckless driving Moke sure operatcrs are 16 or o der with valid driver s license Do rot let 20901 drive or ride after using a corol of drugs Do rot allow coevation on oublie roads unless cesignated fcr off hignvay vehicle access collisions with cars and trucks can occur lt The front sea of tris vehicle is designed to carry the operator and 8 maximum 9 zwo passergers The rear seat is designed to carry maximum 5 chree passergors Read Owner s Manuel Follow Al Instructions and warnings Monufoclured by Kawasaki Motors Manufacturing Corp U S A Kawasaki Motors Manufacturing Corp U S A certifies that this vehicle complies with the American Notional Standard for Multipurpose Off Highway Utility Vehicles PE ANSI OPE 55 Standard CF03054 5 96071 0433 5 3 Not 120 Total when Using One or Both Sockets 56033 0814 6030626 5 26 LOCATION OF LABELS 4 7 MFD BY KAWASAKI MOTORS MFG CORP MODEL YEAR IOS CF03064 5 56033 0822 8 CFo30s6C 5 DANGER 5 T WARNUNG MFD BY KAWAZAXI MOTORS MFG CORP USA LINCO
101. r add distilled water However in order to maximize battery life and en sure that it will provide the power needed to start your vehicle you must properly maintain the battery s charge When used regularly the charging system in your vehicle helps keep the battery fully charged If your vehicle is only used occasionally or for short periods of time the battery is more likely to dis charge Due to their internal composition batteries contin ually self discharge The discharge rate depends on the type of battery and ambient temperature As temperatures rise so does the discharge rate Ev ery 15 C 59 F doubles the rate Electrical accessories such as digital clocks and computer memory also draw current from the bat tery even when the key is switched off Combine such key off draws with hot temperature and a battery can go from fully charged to completely dis charged in a matter of days Self discharge Approx Number of Days From 100 Charged to 100 discharged Battery Temperature Lead Calcium Battery 300 Days 600 Days 950 Days MAINTENANCE AND ADJUSTMENT 149 Current Drain 0 Charged o 50 Charged fo 100 ischarged Discharged 119 Days 83 Days 56 Days 42 Days 28 Days In extremely cold weather the fluid in an inade quately charged battery can easily freeze which can crack the case and buckle the plates A fully charged battery ca
102. r element to the adapter e Install the element and adapter in the air cleaner housing as shown 122 MAINTENANCE AND ADJUSTMENT A Element B Adapter C Tabs D Air Cleaner Housing e Clamp the air cleaner housing cap securely e Install the drain hose to the clamps e Clean inside of the battery cover and install it see Battery Installation Oil Draining e Inspect the transparent drain hose located under the air cleaner housing to see if any oil and water have run down A Drain Hose B Plug C Battery e f there are any oil and water the hose remove the plug from the lower end of the drain hose and drain the oil and water e Reinstall the plug to the drain hose Spark Arrester This vehicle is equipped with a spark arrester ap proved for off highway use by the U S Forest Ser vice It must be properly maintained to ensure its efficiency Clean the spark arrester in accordance with the Periodic Maintenance Chart A WARNING An incorrectly installed spark arrester can emit sparks and cause a fire Be sure the spark arrester and muffler are installed se curely Spark Arrester Cleaning and Inspection WARNING The muffler can become extremely hot dur ing normal operation and cause severe burns Since the engine must be running during this procedure wear heat resistant gloves while cleaning the spark arrester MAINTENANCE AND ADJUSTMENT 123 A Muffler
103. r filter clogged or intake blocked e Fuel tank vent clogged e Engine overheated e much idling or low speed running not enough air flow e Overloaded e Wrong spark plug e Radiator clogged e Coolant level too low e Coolant deteriorated e Cooling fan breaker functioned e Engine oil level too low No Power e Engine overheated e much idling or low speed running not enough air flow e Overloaded e Wrong spark plug e Radiator clogged e Coolant level too low e Coolant deteriorated e Cooling fan breaker functioned e Engine oil level too low e Compression leakage e Valve clearance insufficient e Air filter clogged or intake blocked e Spark plug dirty or worm e Engine oil incorrect e Water in fuel e Drive belt slipping e Water in belt drive torque converter housing Power Steering Won t Work KAF820B C D e ECU functioned to prevent overheating e Fuse failed e Battery discharged e Cable harness connectors disconnected 164 TROUBLESHOOTING GUIDE Selectable 2WD 4WD or DIFF LOCK Systems Malfunction e Actuators failed e ECU failed e Battery disconnected YOUR WARRANTY OWNER SATISFACTION 165 YOUR WARRANTY OWNER SATISFACTION Welcome to the Kawasaki family Congratulations on buying your Kawasaki vehicle You ve chosen a great high quality product with state of the art features and built to Kawasaki s high standards Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki Motors Corp
104. rk Plug Lubrication System Engine Oil Type Viscosity Capacity Coolant Capacity Long bed mode 1 085 x 1 363 x 279 mm 42 72 x 53 66 x 10 98 in Short bed mode 560 x 1 363 x 279 22 05 x 53 66 x 10 98 in 4 stroke DOHC 3 cylinder liquid cooled 812 49 5 cu in 72 0 x 66 5 mm 2 83 2 62 in 9 5 1 Electric starter Left to right 1 2 3 1 2 3 FI Fuel Injection Battery and Coil Transistorized Ignition 9 5 BTDC 1 700 r min rpm Zhuzhou torch spark plug 7026 Forced lubrication wet sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 2 4 L 2 5 US qt 5 9 L 6 2 US qt DRIVE TRAIN Driving Type Primary Final Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio Forward Reverse Transmission Gear Ratio Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Steering KAF820A KAF820B C D SPECIFICATIONS 13 Belt drive torque converter CVT 2WD AWD system with Drive Shafts 2 speed amp reverse Automatic 3 33 0 76 Belt drive torque converter 6 382 6 245 11 261 High 22 356 Low 17 359 1 803 High 3 580 Low 2 779 API GL 5 Hypoid gear oil SAE 90 above 5 C 41 F SAE 80 below 5 C 41 F 0 43 L 0 45 US qt API GL 5 Hypoid gear oil SAE 90 above 5 41 F SAE 80 below 5 C 41 F 2
105. ry important to have tires of the same type and size on all axles and at the same inflation pressure on each axle O Installation of non standard tires or use of differ ent tires on one axle can change or impair the handling of the vehicle O Installation of tubeless tires on rims requires com pressed air and is normally recommended as a dealer service operation Nevertheless a tube can be inserted into the tire by the operator as an emergency repair Maximum Tire Air Pressure for Seating Beads 250 kPa 2 5 kgf cm 36 psi Front and Rear Payload and Tire Pressure Failure to maintain proper inflation pressures or observe payload limits for your tires can change or impair handling and performance of the vehicle The maximum vehicle load as follows Except for California Model California Model 748 kg 1 650 Ib 590 kg 1 300 Ib Use a tire pressure gauge to accurately set tire pressure A WARNING Operating with unequally or improperly pres surized tires can adversely affect steering or handling Inflate both front tires to the same pressure and both rear tires to the same pressure Tire Wear Damage As tire tread wears down tires become more sus ceptible to puncture and failure In accordance with the Periodic Maintenance Chart measure the depth of the tread with a depth gauge and replace any tire that has worn down to the minimum allowable tread depth
106. s battery is run down it should be removed and charged If this is not practical a 12 volt booster battery and jumper cables may be used to start the engine A DANGER Battery acid generates hydrogen gas which is flammable and explosive under certain conditions It is present within a battery at all times even in a discharged condition Keep all flames and sparks cigarettes away from the battery Wear eye protection when working with a battery In the event of bat tery acid contact with skin eyes or clothing wash the affected areas immediately with water for at least 5 minutes Seek medical attention Connecting Jumper Cables e Make sure the ignition switch is turned off e Remove the battery cover located at the right side of the rear seat Refer to the Battery section in HOW TO OPERATE 83 the MAINTENANCE AND ADJUSTMENT chap ter 01008014 A Battery Cover e Lift the cargo bed and support it with the support ing rod Refer to the Cargo Bed section in the GENERAL INFORMATION chapter e Connect a jumper cable from the positive ter minal of the booster battery to the positive ter minal of the vehicle battery 84 HOW TO OPERATE E A Vehicle Battery Positive Terminal B From Booster Battery Positive Terminal C From Booster Battery Negative Terminal D Bracket Bolt e Connect another jumper cable from the negative terminal
107. s certified to operate on unleaded gasoline only Use clean fresh unleaded gasoline with an Anti knock index equal to or higher than that shown in the table The Antiknock Index is posted on service sta tion pumps in the U S A and Canada The octane rating of a gasoline is a measure of its resistance to detonation or knocking The Antiknock Index is an average of the Research Octane Number RON and the Motor Octane Number MON as shown in the table below Minimum Rating Octane Rating Method Antiknock Index RON 2 MON NOTICE If engine knocking or pinging occurs use a different brand of gasoline of a higher octane rating If this condition is allowed to continue it can lead to severe engine dam age Gasoline quality is important Fuels of low quality or not meeting standard industry specifications may result in unsatisfac tory performance Operating problems that result from the use of poor quality or nonrec ommended fuel may not be covered under warranty Fuels Containing Oxygenates Gasoline frequently contains oxygenates alco hols and ethers especially in areas of the U S A and Canada which are required to sell such refor mulated fuels as part of a strategy to reduce exhaust emissions The types and volume of fuel oxygenates ap proved for use in unleaded gasoline by the U S Environmental Protection Agency include a broad range of alcohols and ethers but only two compo nents
108. saki Parts and Accessories Kawasaki has no control over the de sign or application of accessories In some cases improper installation or use of accessories or vehi cle modifications will void the utility vehicle warranty In selecting and using accessories and in loading the vehicle you are personally responsible for your own safety and the safety of others NOTE OKawasaki Parts and Accessories have been spe cially designed for use on Kawasaki utility vehi cles We strongly recommend that all parts and accessories you add to your vehicle be genuine Kawasaki components Because any vehicle is sensitive to increases in weight and changes in weight distribution you must take care in carrying cargo The following general guidelines have been prepared to help you make your determinations e Reduce speed when carrying cargo Braking distance is increased Use extreme caution when climbing and descending hills and traversing slopes Carrying cargo and pulling a trailer can make the vehicle difficult to steer and may affect vehicle handling in an unpredictable manner e Do not operate this vehicle faster than 16 km h 10 mph when pulling a trailer e All cargo should be carried as low as possible to reduce the effect on the vehicle s center of gravity Cargo weight should be equally distributed from side to side This helps maintain stability by cen tralizing weight Avoid carrying cargo that extends beyond the rear of the vehi
109. seat and cargo bed e Reverse the procedure for 6 persons to 3 persons mode conversion O After folding the cargo bed side plates push both screen lock arms to the lock pin until you hear a click A Screen Lock Arm B Lock Pin GENERAL INFORMATION 51 WARNING Failure to properly lock the cargo bed or screen may allow them to move suddenly while driving causing loss of control and an accident resulting in serious injury or death To prevent the cargo bed from sud denly moving make sure that the cargo bed and screen has been locked properly after handling them 52 GENERAL INFORMATION Cargo Bed Tailgate The tailgate of the cargo bed can be lowered Be fore lowering the tailgate park on a firm level surface and set the parking brake To open the tailgate release the latches and lower the tailgate Cables hold the tailgate level with the cargo bed A Tailgate B Latch Handle To close the tailgate lift to the upright position and secure firmly with the latches Pull the tailgate latch handles to make sure the latches stay securely closed Do not drive the ve hicle with the tailgate lowered M A Tailgate B Cable Loading Cargo Bed A WARNING Loading the cargo bed before the conversion operation is completed and the cargo bed is unlocked may cause the bed to suddenly tilt resulting in serious injury To prevent the bed from
110. slippage and loss of power If this occurs consult an authorized Kawasaki dealer MAINTENANCE AND ADJUSTMENT 129 Brakes The vehicle is equipped with hydraulically acti vated disc brakes on all four wheels Brake Pedal Brake Pedal Free Play Inspection In accordance with the Periodic Maintenance Chart check the brake pedal free play e Before the brake pedal free play inspection check that the brake pedal lever contacts with the stop per CL20008BM2 C A Brake Pedal Lever B Stopper e Depress the brake pedal lightly by hand 130 MAINTENANCE AND ADJUSTMENT e There should be 2 10 mm 0 08 0 39 in of free play A Brake Pedal B 2 10 mm 0 08 0 39 in e If the brake pedal has more or less free play than specified or the pedal action feels rough or catchy have the brake system inspected imme diately by an authorized Kawasaki dealer Brake Fluid In accordance with the Periodic Maintenance Chart inspect the brake fluid level in the brake fluid reservoir and change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Fluid Requirement Use heavy duty brake fluid only from a fresh un opened container marked 4 A WARNING Over time brake fluid can absorb moisture lowering its boiling point and reducing brake effectiveness Do not use fluid from a con tainer that has been left unsealed or that has been open for a
111. supporting rod into the bar of the ROPS to support the cargo bed NOTE ODo not hold ROPS when lifting or lowering the cargo bed A Supporting Damper B Cargo Bed Raised Position C Supporting Rod NOTE O Using only the bed supporting damper for support may allow the cargo bed to suddenly lower under particular situations such as a strong wind slope angle or cold weather O Support the cargo bed with a supporting rod when ever lifting the cargo bed 56 GENERAL INFORMATION EH Lifting the Cargo Bed in Extended Configuration 2 Openthe rear doors Make sure the screen lock 1 On models equipped with a sun top roof un arms are locked properly then release the cargo hook the rubber retaining straps on both sides bed latches on both sides and raise the rear of the roof and flip it forward A Cargo Bed Latch A Rubber Retaining Strap B Screen Lock Arm B Roof A WARNING Failure to properly lock the screen lock arms could cause the cargo bed side plates to fold and allow the screen to slide down while lift ing the cargo bed resulting in serious injury To prevent the cargo screen from sliding down make sure that the screen lock arms are locked properly before lifting the cargo bed GENERAL INFORMATION 57 WARNING WARNING The front of the cargo bed becomes heavier Reduced clearance between the cargo bed in the extended mode and m
112. t if water gets into the ignition coils or into the spark plug caps it can ground out the spark When this happens the vehicle will not operate properly and the affected parts must be wiped dry e Power Steering System if water gets into the actuator or is sprayed over the ECU they may cause malfunction NOTICE Coin operated high pressure spray wash ers are not recommended Water may be forced into bearings and other components causing eventual failure from rust and cor rosion Some soaps are highly alkaline and may leave a residue or cause spotting NOTE O KAF820D Abrasive cleanser or high pressure washer will damage the paint finish or camouflage on the bodywork MAINTENANCE AND ADJUSTMENT 157 Flat Finish Flat finishes reflect light differently than traditional gloss paints and require some special care to main tain the flat effect Do not use soaps cleaners or wax designed for gloss paint These products can smooth the special flat finish coat which makes it more glossy To clean the flat finish e When washing the vehicle only use soap de signed specifically for flat or matte finishes e Use a spot cleaner especially formulated for flat paint to help remove tough dirt e Use only microfiber towels for drying e The flat finish effect may be lost when the finish is excessively rubbed e f any doubt consult an authorized Kawasaki dealer After Washing e Remove the plastic bag and tape
113. tall enough for the seat belt to fit properly and to be able to brace them selves as necessary by placing both feet firmly on the floor while gripping the handhold Stay com pletely inside the vehicle Never Drink and Drive Alcohol and drugs impair your judgement and slow your reactions Even drugs prescribed by a physi cian can be dangerous Check with your doctor Use Proper Riding Gear Proper protective gear can reduce the severity of injury in the event of an accident Choose a helmet most appropriate for your use of this utility vehicle A helmet can reduce the risk of head injuries Wear appropriate eye protection and protective clothing Wearing Seat Belts Both the operator and passenger s should al ways wear their seat belts properly Seat belts cannot completely protect you in every accident but in many cases a seat belt can reduce the risk of serious injury Also to avoid injury do not put any part of your body outside of the vehicle for any reason Close the Doors Be sure all doors are securely closed during oper ation and never remove a door The doors prevent branches gravel and debris from getting inside the passenger compartment Before Starting the Engine Three musts before starting the engine are 1 Apply the parking brake 2 Put the gear shift lever in the N neutral posi tion 3 Check the throttle pedal for proper operation It should return to its rest position when releas
114. tch off Red Oil Pressure Warning Indicator Light The oil pressure warning indicator light blinks to warn the operator whenever the oil pressure is dan gerously low or the ignition switch is in the po sition with the engine not running and goes off when the proper engine oil pressure is reached Refer to the MAINTENANCE AND ADJUSTMENT chapter for more detailed engine oil information 42 GENERAL INFORMATION Lighting Electrical Accessory Socket The lighting electrical accessory 12 volt sockets are located on the dashboard On KAF820C D mod els the rear power outlet sockets are located on the footwell of the rear seat An auxiliary light or an accessory may be con nected to these connectors A Power Outlet Sockets A Rear Power Outlet Sockets KAF820C D NOTICE Do not connect a light or load of more than 120 watts on one or both sockets or the bat tery may rapidly discharge Light Switches The light switches are 3 position type with a pi lot light which illuminates while the ignition switch is turned on The headlights can be turned on by pushing the headlight switch to the or position when the ignition switch is in the ON position a Low Beam gt High Beam When the headlight is on high beam the high beam indicator light in the switch comes on as a reminder The headlights go off when the headlight switch is pushed in OFF position
115. the bed and frame causing serious injury To prevent the bed from suddenly lowering use the handles to properly support the bed when lowering or lifting the bed On models equipped with a sun top roof return the rear of the sun top roof to its original position Hook the rubber retaining straps on both sides to secure the rear of the roof NOTE O To lower the cargo bed follow the reverse proce dure for lifting Be sure to restore the seat as be fore and put the latches on Never drive the Mule without locking the latches to the cargo bed WARNING e Overloading failure to properly secure cargo or improper use of the cargo bed can cause changes in handling which can lead to an accident Follow guidelines pro vided in the LOADING INFORMATION chapter e Passengers riding in the cargo bed can be tossed about or even thrown out causing serious injury or death Do not install seat ing or carry passengers in the cargo bed e Driving with the cargo bed tilted may be hazardous Failure to lower and lock the bed into place may cause severe injury or death Always lower and latch the bed after tilting e Lifting and lowering the bed could be dan gerous Be careful not to catch any part of your body such as hands or arms be tween the bed and ROPS or vehicle frame when lifting and lowering the bed GENERAL INFORMATION 59 Fuel The fuel tank is mounted under the right side of the front
116. tion e Turn the ignition switch to the ON position e Depress the brake pedal The brake light should go on after about 10 mm 0 39 in of pedal travel A Brake Pedal B 10 mm 0 39 in e If it does not check the bulb and if necessary adjust the brake light switch Adjustment e Adjustment is best performed by an authorized Kawasaki dealer since the brake light switch is hard to adjust NOTICE To avoid damaging the electrical connec tions inside the switch be sure that the switch body does not turn during adjust ment MAINTENANCE AND ADJUSTMENT 133 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 Inspection uw A Parking Brake Lever e Pull the parking brake lever to the rear e After 4 to 12 clicks of lever travel the vehicle should not roll while parked e If it does have the parking brake cable adjusted by an authorized Kawasaki dealer 134 MAINTENANCE AND ADJUSTMENT Steering Wheel In accordance with the Periodic Maintenance Chart check the steering wheel for the specified free play and smooth operation Free Play Inspection e Park the vehicle on level ground e Lightly turn the steering wheel left and right e There should be 0 20 mm 0 0 79 in of free play e If there is excessive free play or stra
117. tions in your driving area 110 MAINTENANCE AND ADJUSTMENT SAE 10W 50 SAE 10W 40 SAE 10W 30 SAE 20W 50 SAE 20W 40 20 10 0 10 20 40 0 LIII es ee aes ES 4 14 32 50 68 86 104 F L 1 1 BL03006BM2 C e Reinstall the removed parts as before e Run the engine for several minutes e Check the oil level Front Final Gear Case Oil In order for the differential pinion and ring gears to function properly check the oil level and change the oil in accordance with the Periodic Maintenance Chart A WARNING Vehicle operation with insufficient deterio rated or contaminated oil causes acceler ated wear of the differential pinion and ring gears and may result in seizure Seizure can lock the front wheels and skid the front tires cousing loss of control To prevent seizure check the differential oil according to the pe riodic maintenance chart Oil Level Inspection e With the vehicle level front to rear and side to side remove the oil filler cap from the front final gear case MAINTENANCE AND ADJUSTMENT 111 A Front Final Gear Case B Oil Filler Cap NOTICE Be careful not to allow any dirt or foreign ma terials to enter the gear case e Check the oil level The oil level should come to the bottom of the filler opening If itis low add oil through the oil filler opening as necessary A Front Final Gear Case B Filler Open
118. to the following items always perform the Daily Checks listed in the HOW TO OPERATE chapter e Clean adjust lubricate replace parts as necessary D Service to be performed by an authorized Kawasaki Dealer or someone equally competent Service more frequently when operated in mud dust or other harsh driving conditions Emission Related MAINTENANCE AND ADJUSTMENT 103 FREQUENCY First Service Regular Service After 50 Every Every Every After 20 h 50h or 100 h or 200 h or EIER 1000 1000 2000 14 000 km dd km 600 km 600 1 200 2 500 y mile of il f il f il f il f use ise mile of mile of mile o mile o OPERATION use use use use ENGINE O Throttle pedal play inspect e e Fuel hose and connections inspect D Fuel hose replace Idle speed inspect Spark plugs clean and gap inspect Air cleaner clean and inspect Valve clearance inspect Spark arrester clean and inspect or every 6 months whichever comes first Engine oil change 104 MAINTENANCE AND ADJUSTMENT case oil change Radiator clean Front final gear case oil and transmission FREQUENCY First Service Regular Service After 50 Every Every Every After 20 h or 50h or 100 h or 200 h or ES kn 120 1 000 1 000 2 000 4 000 km year of 600 600 1 200 2 500 mile of use ise mile of mile of m
119. u should keep a maintenance record for your vehicle To assist you in keeping this record we have pro vided space at the end of this manual where an authorized Kawasaki dealer or someone equally competent can record the maintenance You should also retain copies of maintenance work orders bills etc as verifica tion of this maintenance Tampering with Emission Control System Prohibited Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related parts e Throttle body and internal parts e Spark plugs e Magneto or electronic battery ignition system e Fuel filter Fuel injector Fuel pump e Air cleaner element e Electronic Control Unit ECU PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product Kawasaki has equipped it with effective intake and exhaust silencing systems They are designed to give optimum performance while maintaining a low noise le
120. vehicle is equipped with a reduced reverse speed system It limits the vehicle speed to 20 km h 12 mph AWD gives greater traction when you are climb ing steep inclines or driving on bumpy sandy or snowy surfaces It also helps break loose with the differential locked under certain circumstances for example when the vehicle is stuck in the mud If maximum torque is needed in these situations shift into the L Low position with the gear shift lever Refer to the Shifting Gears section 2WD 4WD Shifting and Shifting the Differential sections in the HOW TO OPERATE chapter NOTE O Do not drive 4WD on paved surfaces because itincreases tire and drive train wear and makes the steering feel tight Remember e Use 4WD on steep inclines or loose surfaces or when stuck in the mud with the differential locked if necessary e For maximum torque shift into low range e Do not drive 4WD on paved surfaces Turning the Vehicle SAFE OPERATION 95 Hills The vehicle will turn in a smaller radius with the differential unlocked in differential mode In this mode the rear wheels can turn at different speeds allowing the vehicle to turn tighter and more smoothly Even in this mode however avoid sharp turns to keep the vehicle from tipping Reduce vehicle speed before entering the turn and use the throttle to maintain an even speed through the turn WARNING
121. vel Please do not remove these systems or alter them in any way which results in an increase in noise level FOREWORD Congratulations on your purchase of a new Kawasaki Mule It is the result of Kawasaki s engineering exper tise and a tradition of manufacturing high quality consumer products Please read this Owner s Manual carefully before starting your new Mule so that you will be thoroughly familiar with the proper operation of your vehicle s controls its features capabilities and limitations To ensure a long trouble free life for your Mule give it the proper care and maintenance described in this manual For those who would like more detailed information on their Mule a Service Manual is available for purchase from any authorized Kawasaki Mule dealer The Service Manual contains detailed disassembly and mainte nance information Those who plan to do their own work should of course be competent mechanics and possess the special tools described in the Service Manual Keep this Owner s Manual aboard your Mule at all times so that you can refer to it whenever you need infor mation This manual should be considered a permanent part of the Mule and should remain with the Mule when it is sold All rights reserved No part of this publication may be reproduced without our prior written permission This publication includes the latest information available at the time of printing However there may be minor differences between the a
122. y from the vehicle Kawasaki recommended chargers are Battery Mate 150 9 OptiMate 4 Yuasa MB 2040 2060 Christie C10122S If the above chargers are not available use equiv alent one For more details ask your Kawasaki dealer Battery Charging e Remove the battery from the vehicle see Battery Removal e Attach the leads from the charger and charge the battery at a rate amperage x hours that is indi cated on the battery If it is not possible to read the rate charge the battery at an amperage that is about 1 10th of the battery capacity e The charger will keep the battery fully charged un til you are ready to reinstall the battery in the vehi cle see Battery Installation NOTICE Never remove the sealing strip or the battery can be damaged Do not install a conventional battery in this vehicle or the electrical system cannot work properly Make East Penn Manufacturing Type 426RMF NOTE Olf you charge the sealed battery never fail to ob serve the instructions shown on the label on the battery and charger A WARNING Battery posts terminals and related acces sories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Fuse MAINTENANCE AND ADJUSTMENT 151 e Pull the cover forward to clear the projections and remove the cover Fuses are arranged in the fuse boxes located i
123. y other time you have questions The dealership is responsible for inspecting your Kawasaki vehicle if there is a failure investigating the cause of the problem and getting any needed authorization from Kawasaki if the repair is one that will be covered by the limited warranty The dealership will also file all necessary paperwork The dealership is responsible for correctly completing any necessary repairs whether they are covered by the limited warranty or not YOUR WARRANTY OWNER SATISFACTION 167 How Do I Get Warranty Service If there is a problem with your vehicle within the limited warranty period you will need to schedule a service appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and diag nosis You can go to any Kawasaki dealer for warranty repairs Your Kawasaki dealer will inspect your vehicle and give you the results of the inspection The dealer will perform the repairs at no cost to you if it is determined that the problem is covered by the warranty Kawasaki will work with your dealer to resolve any warranty issues No authorization for warranty work can be given until your vehicle has been inspected by a Kawasaki dealer What if am not Satisfied With My Warranty Service If you aren t satisfied with your dealership s repair work or operations it is best to discuss the situation with the appropriate dealership manager If you have already done this then contact the dealership s

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