Kawasaki MULE SX 2017 Owner's manual

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ENGLISH

Utility Vehicle

Owner's Manual

Original instructions

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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

HOW TO OPERATE

SAFE OPERATION

MAINTENANCE AND ADJUSTMENT

TRANSPORTING AND STORAGE

TROUBLESHOOTING GUIDE

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Whenever you see the symbols shown below,

heed their instructions! Always follow safe operating

and maintenance practices.

DANGER

DANGER indicates a hazardous situation

which, if not avoided, will result in death or

serious injury.

WARNING

WARNING indicates a hazardous situation

which, if not avoi ded, could result in death or

serious injury.

NOTICE

NOTICE is used to address practices not re-

lated to personal injury.

NOTE

○

NOTE indicates information that may help or

guide you in the operation or service of the ve-

hicle.

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BASIC SAFE DRIVING

Knowing and following these rules for safe opera-

tion will increase your satisfaction with your new Ka-

wasaki vehicle.

Perform the Daily Checks

Refer to the Daily Checks section for a list of items

to check each day before use. Habitual perform-

ance of these checks will help to insure safer, more

reliable 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 Kawa-

saki vehicle, so drive carefully, safely, and exercise

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 operators.

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 surfa-

ces.

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 steering

wheel or handgrip.

The operator should be tall enough to wear the

seat belt properly and reach all controls.

Passenger should also be 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 handgrip. 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

physician can be dangerous. Check with your doc-

tor.

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

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head injuries. Wear appropriate eye protection and

protective clothing.

Wearing Seat Belts

Both the operator and passenger should always

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 seri-

ous injury. Also, to avoid injury, do not put any part

of your body outside of the vehicle for any reason.

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 released.

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 governing

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

replacement.

Maximum Seating Capacity

Do not exceed seating capacity: 2 occupants.

Occupants shall only ride in designated seating

positions and with maximum 2 persons in the seat.

Do not carry small children on lap.

Reduce Speed When Carrying Cargo, Passen-

ger, and/or Pulling a Trailer

Carrying cargo, passen ger and/or pulling a trailer

can make the vehicle difficult to steer and may affect

vehicle handling in an unpredictable manner.

Braking distance is increased when carrying car-

go, passenger, and/or pulling a trailer. Reduce

speed and allow greater distance for braking when

carrying cargo, passenger, and/or pulling a trailer.

Use extreme caution when climbing and descend-

ing hills, and traversing slopes.

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FOREWORD

Congratulations on you r 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 pos-

sess 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.

This publication includes the latest information available at the time of printing. However, there may be minor

differences betw een the actual product and illustrations and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

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TABLE OF CONTENTS

SPECIFICATIONS .............................................. 12

DECLARATION OF CONFORMITY ................... 16

SERIAL NUMBER LOCATIONS ........................ 18

LOCATION OF PARTS ....................................... 19

LOCATION OF LABELS .................................... 22

LOADING INFORMATION ................................. 34

GENERAL INFORMATION ................................ 36

Lighting/Electrical Accessory Socket ........ ....... 36

Light Switch ...................................................... 36

Steering Wheel ................................................. 38

Brake Pedal ...................................................... 39

Cargo Bed ........................................................ 39

Tailgate .......................................................... 39

Lifting and Lowering the Cargo Bed .............. 40

Loading Cargo Bed ....................................... 42

Choke Knob ...................................................... 43

Red Engine Oil Temperature Warning Indicator

Light (KAF400H) ...........................................

44

Fuel ................................................................... 45

Glove Compartment/Tool Kit ............................ 47

Cupholders ....................................................... 48

Front Cargo Compartment ............................... 49

Horn Switch ...................................................... 51

Ignition Switch .................................................. 51

Fuel Gauge/Hour Meter .................................... 53

Shift Lev ers ...................................................... 54

Gear Shift Lever .............................. .............. 54

2WD/4WD Shift Lever (KAF400H) ................ 55

Differential Shift Lever ................................... 55

Red Reverse Indicator Light ............................. 56

Belt Drive Transmission ................................... 57

Parking Brake Lever ......................................... 57

Red Parking Brake Indicator Light ................... 58

Seat .................................................................. 59

Seat Belts ......................................................... 59

Throttle Pedal ................................................... 61

Trailer Hitch Bracket (Accessory) ..................... 62

Winch Installation ............................ ................. 63

HOW TO OPERATE ........................................... 64

Daily Checks .................................................... 64

Starting the Engine ........................................... 66

Throttle-linked choke system ........................ 66

Jump Starting ................................................... 68

Moving Off ........................................................ 69

Braking ............................................................. 70

Stopping the Engine ......................................... 70

Parking the Mule .............................................. 71

Shifting Gears ................................................... 72

2WD/4WD Shifting (KAF400H) ........................ 74

Shifting the Differential ..................................... 75

When Stuck ...................................................... 76

SAFE OPERATION .............................. .............. 77

Unfamiliar Terrain ............................................. 77

Driving in Reverse ............................................ 78

Driving in “4WD” (KAF400H) ............................ 78

Turning the Vehicle ........................................... 79

Hills ................................................................... 79

Climbing Hills .................................................... 80

Descending Hills .............................................. 81

Traversing Hillsides .......................................... 82

Sliding and Skidding ......................................... 82

Driving through Water ...................................... 83

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Operator and Passenger Requirements ........... 84

NOISE AND VIBRATION CONTROL INFORMA-

TION ..................................................................

85

Control Information ............................................ 85

MAINTENANCE AND ADJUSTMENT ................ 86

Periodic Maintenance Chart .............................. 87

Engine Oil .......................................................... 90

Front Final Gear Case Oil (KAF400H) .............. 94

Transmission Case Oil ...................................... 97

Cooling Fan .......................................................100

Spark Plug .........................................................101

Valve Clearance ................................................103

Engine Air Cleaner ............................................103

Spark Arrester ...................................................106

Throttle Pedal ....................................................108

Choke Knob .......................................................110

Carburetor ....................................................... .. 112

Fuel System ...................................................... 115

Fuel Filter ........................................................116

Belt Drive Torque Converter ..............................117

Belt Drive Torque Converter Air Cleaner ........... 118

Brakes ...............................................................121

Brake Pedal ....................................................121

Brake Light Switch .............................................123

Parking Brake Lever ..........................................125

Steering Wheel ..................................................126

Wheels ..............................................................126

Rims ...............................................................126

Wheel Nuts .....................................................126

Tires ................................................................126

Joint Boots .........................................................129

Suspension ........................................................129

Seat Belts ..........................................................131

Headlight Beam .................................................132

Battery ...............................................................132

Fuse .............................. .....................................137

General Lubrication ...........................................138

Cleaning ............................................................138

General Precautions ......................................138

Where to be Careful .......................................140

Washing Your Vehicle ....................................140

Bolt and Nut Tightening ................................... ..141

TRANSPORTING AND STORAGE ....................142

Transporting the Vehicle ....................................142

Storage ..............................................................143

TROUBLESHOOTING GUIDE ............................146

ENVIRONMENTAL PROTECTION .....................147

MAINTENANCE RECORD ..................................148

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SPECIFICATIONS

PERFORMANCE

Maximum Torque (H) 29.7 N·m (3.0 kgf·m, 22 ft·lb) @2 400 r/min (rpm)

(J) 27.9 N·m (2.8 kgf·m, 21 ft·lb) @2 200 r/min (rpm)

Minimum Turning Radius

Differential Mode 3.3 m (10.8 ft)

DIMENSIONS

Overall Length 2 710 mm (106.7 in.)

Overall Width 1 335 mm (52.56 in.)

Overall Height (H) 1 800 mm (70.87 in.)

(J) 1 780 mm (70.08 in.)

Wheelbase 1 780 mm (70.08 in.)

Tread:

Front 1 055 mm (41.54 in.)

Rear 1 000 mm (39.37 in.)

Ground Clearance (H) 170 mm (6.69 in.)

(J) 155 mm (6.10 in.)

Curb Mass (H) 468 kg (1 032 lb)

(J) 439 kg (968 lb)

Cargo Bed (L × W × H) 905 × 1 040 × 245 mm

(35.6 × 40.94 × 9.65 in.)

ENGINE

Type OHV, 1-cylinder, 4-stroke, positive air-cooled

12 SPECIFICATIONS

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Displacement 401 cm³ (24.5 cu in.)

Bore × Stroke 82.0 × 76.0 mm (3.23 × 2.99 in.)

Compression Ratio

(H) 8.6 : 1

(J) 8.3 : 1

Starting System Electric starter

Carburetor NIKKI 6C1026

Ignition System Magneto and transi stor

Ignition Timing 20° constant.

Spark Plug NGK BPR5ES

Lubrication System Forced lubrication (wet sump)

Engine Oil:

Type

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity SAE 10W-40

Capacity 1.4 L (1.5 US qt)

DRIVE TRAIN

Driving Type

(H) Gear (2WD/4WD)

(J) Gear (2WD)

Transmission Type (H) 2-speed & reverse, automatic

(J) 1-speed & reverse, automatic

Primary Reduction Ratio 3.653 ~ 0.794 (Belt drive torque converter)

Final Reduction Ratio:

Front (H) 3.852

Rear 4.000

SPECIFICATIONS 13

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Overall Drive Ratio:

Forward 9.263 (High)

(H) 13.706 (Low)

Reverse 11.910

Transmission Gear Ratio:

Forward 2.916 (High)

(H) 4.315 (Low)

Reverse 3.750

Front Final Gear Case Oil (H) API GL-5 SAE 140 or API GL-6 SAE 90 Hypoid gear oil for Lim-

ited Slip Differentials.

Front Final Gear Case Oil Capacity (H) 0.35 L (0.37 US qt)

Transmission Case Oil

API GL-5 Hypoid gear oil

SAE 90 [above 5°C (41°F)]

SAE 80 [below 5°C (41°F)]

Transmission Case Oil Capacity

(H) 2.40 L (2.54 US qt)

(J) 2.20 L (2.33 US qt)

FRAME

Type Steel tube, ladder type

Caster 9°

Trail

(H) 45 mm (1.8 in.)

(J) 40 mm (1.6 in.)

Tire Size:

Front (H) 24 × 9.00-10

(J) 22 × 9.00-10

14 SPECIFICATIONS

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Rear (H) 24 × 11.00-10

(J) 22 × 11.00-10

Rim Size:

Front 10 × 7.0 AT

Rear 10 × 8.5 AT

Fuel Tank Capacity 16 L (4.2 US gal)

ELECTRICAL EQUIPMENT

Battery 12 V 14 Ah (10 HR)

Headlight:

High Beam 12 V 35 W × 2

Low Beam 12 V 35 W × 2

Brake/Tail Light 12 V 21/5 W

Reverse Light 12 V 10 W

LOAD CAPACITY

Maximum Vehicle Load (Including occu-

pants, cargo and accessories)

415 kg (915 lb)

Maximum Cargo Bed Load

181 kg (400 lb)

(H): KAF400H

(J): KAF400J

Specifications are subject to change without notice, and may not apply to every country.

SPECIFICATIONS 15

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DECLARATION OF CONFORMITY

16 DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY 17

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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 investigat ing 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.

A. Frame Number

Engine No.

A. Engine Number

18 SERIAL NUMBER LOCATIONS

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LOCATION OF PARTS

1. Outer Headlight

2. Front Cargo Compartment

3. Front Cargo Compartment

Cover

4. Steering Wheel

5. ROPS (Roll Over Protective

Structure)

6. Air Cleaner Intake

7. Seat

8. Seat Belt

9. Cargo Bed

10. Front Guard

11. Steering Wheel Tilt Lock Lever

12. Parking Brake Lever

13. Battery

14. Air Cleaner (Carburetor)

15. Muffler

16. Tail/Brake Light

LOCATION OF PARTS 19

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Kawasaki MULE SX 2017 Owner's manual

Kawasaki MULE SX 2017 Owner's manual

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