Kawasaki KAF400A General Owners 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

BREAK-IN

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.

NOTE

○

This general OM contains following models.

Please refer to where applicable to your MULE.

KAF400H .................... MULE SX

KAF400J ..................... MULE SX

KAF1000B .................. MULE PRO-DXT

KAF1000E .................. MULE PRO-DX

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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 licen se.

Each occupant must be able to sit with back

against seat, feet flat on floor, and hands on steering

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 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 or handhold.

Stay completely 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 Ridin g 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(s) should al-

ways wear their seat belts properly. Seat belts can-

not 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.

Close the Doors (KAF1000B/E)

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 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

(KAF400H/J) Before refueling the vehicle, shut

the engine off and make sure the area is well venti-

lated and free of any source of flame or sparks.

Gasoline is very flammable.

(KAF1000B/E) Before refueling the vehicle, shut

the engin e off and make sure the area is well venti-

lated and free of any source of flame or sparks. Die-

sel fuel 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

(KAF400H/J, KAF1000E) 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.

(KAF1000B) Do not exceed seating capacity: 4

occupants.

Occupants shall only ride in designated seating

positions and with maximum 2 persons in each front

and rear seat.

Do not carry small children on lap.

Reduce Speed When Carrying Cargo, Passen-

ger(s), and/or Pulling a Trailer

Carrying cargo, passenger(s) and/or pulling a

trailer can make the vehicle difficult to steer and

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may affect vehicle handling in an unpredictable

manner.

Braking distance is increased when carrying car-

go, passenger(s), and/or pulling a trailer. Reduce

speed and allow greater distance for braking when

carrying cargo, passenger(s), 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 General Owner's Manual offers only the standard descriptions from various models so some descrip-

tions shown may not apply to your particular model. For detailed information of your Mule (Mule handling, main-

tenance, service and technical data) refer to the English Owner's Manual. If not available, consult an

authorized Kawasaki dealer.

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

differences between the actual product and illustrations and text in this manual.

All pro ducts are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

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TABLE OF CONTENTS

SPECIFICATIONS .............................................. 15

DECLARATION OF CONFORMITY ................... 18

SERIAL NUMBER LOCATIONS .................... .... 22

LOCATION OF PARTS ....................................... 24

LOCATION OF LABELS .................................... 33

LOADING INFORMATION ................................. 56

GENERAL INFORMATION ................................ 58

Multifunction Meter (KAF1000B/E) .................. 58

Speedometer ................................................. 59

Fuel Lev el Gauge .......................................... 60

Clock .............................................................. 60

Odometer ...................................................... 61

Trip Meters (Trip Meter A/B) ... ....................... 61

Hour Meter ..................................................... 62

2WD/4WD Indicator Symbol ......................... 62

Amber Glow Plug Indicator Light ................... 63

Red EPS Warning Indicator Light .................. 64

Red Parking Brake Indicator Light ................ 64

Red Reverse Indicator Light .......................... 64

Green Neutral Indicator Light ........................ 64

Red Seat-Belt Use Reminder ........................ 64

Red Coolant Temperature Warning Indicator

Light ............................................................

64

Red Oil Pressure Warning Indicator Light ..... 65

Lighting/Electrical Accessory Socket ........ ....... 65

Light Switches ....................... ........................... 66

Steering Wheel ................................................ . 69

Brake Pedal ...................................................... 70

Converting Rear Seat and Cargo Bed

(KAF1000B) ........ ..........................................

71

From 4-Persons to 2-Persons Mode ............. 71

From 2-Persons to 4-Persons Mode ............. 74

Cargo Bed ........................................................ 75

Tailgate .......................................................... 75

Loading Cargo Bed ....................................... 75

Lifting and Lowering the Cargo Bed .............. 77

Choke Knob (KAF400H/J) ................................ 86

Red Engine Oil Temperature Warning Indicator

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

87

Fuel (KAF400H/J) ............................................. 88

Fuel (KAF1000B/E) .......................................... 91

Diesel Fuel Requirements ............................. 91

Cold Weather Information ............................. 91

Using Biodiesel Fuel .......... ........................... 91

Filling the Fuel tank ....................................... 92

Glove Compartment/Tool Kit ............................ 94

Cupholders ....................................................... 94

Front Cargo Compartment (KAF400H/J) ......... 95

Front Access Cover (KAF1000B/E) ................. 97

Horn Switch ...................................................... 98

Ignition Switch (K AF400H/J) ............................ 99

Main Switch (KAF1000B/E) ..............................101

Fuel Gauge/Hour Meter (KAF400H/J) .............102

Shift Levers (KAF400H/J) ................................103

Gear Shift Lever ............................................103

2WD/4WD Shift Lever (KAF400H) ................104

Differential Shift Lever ..... ..............................104

Red Reverse Indicator Light (KAF400H/J) .......105

Gear Shift Lever (KAF1000B/E) .......................106

Selectable 2WD/4WD Shift Switch

(KAF1000B/E) ...............................................

107

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Selectable DIFF-LOCK Shift Switch

(KAF1000B/E) ................................................

109

Belt Drive Transmission ....................................109

Parking Brake Lever .......................................... 110

Red Parking Brake Indicator Light (KAF400H/J)

111

Doors (KAF1000B/E) ........................................ 111

Seats .................................................................112

Seat Belts ..........................................................116

Throttle Pedal ....................................................120

Trailer Hitch Bracket ..........................................120

Winch Installation (KAF400H/J) ........................122

BREAK-IN ............................................................123

HOW TO OPERATE ............................................124

Daily Checks .....................................................124

Starting the Engine ............................................127

Throttle-linked choke system .........................127

High-Altitude Injection Control Device ...........129

Cold Weather Starting (KAF1000B/E) ..............130

Jump Starting ....................................................130

Moving Off .........................................................134

Braking ..............................................................134

Stopping the Engine ..... .....................................135

Parking the Mule ...............................................135

Shifting Gears ....................................................137

2WD/4WD Shifting (KAF400H, KAF1000B/E) ..139

Shifting the Differential ......................................141

When Stuck ........................................... ............143

SAFE OPERATION .............................................144

Unfamiliar Terrain ..............................................145

Driving in Reverse ................................. ............145

Driving in “4WD” (KAF400H, KAF1000B/E) ......146

Turning the Vehicle ............................................146

Hills ....................................................................147

Climbing Hills .....................................................147

Descending Hills .................... ...........................148

Traversing Hillsides ...........................................149

Sliding and Skidding ..........................................150

Driving through Water .......................................150

Operator and Passenger Requirements ...........151

NOISE AND VIBRATION CONTROL INFORMA-

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

154

Control Information ............................................154

MAINTENANCE AND ADJUSTMENT ................155

Periodic Maintenance Chart ............................ ..156

Engine Oil ..........................................................163

Front Final Gear Case Oil (KAF400H,

KAF1000B/E) .................................................

171

Transmission Case Oil ......................................176

Cooling Fan (KAF400H/J) ......................... ........181

Cooling System (KAF1000B/E) .................... .....182

Spark Plug (KAF400H/J) ...................................185

Valve Clearance ................................................187

Engine Air Cleaner ............................................187

Spark Arrester ........ ...........................................192

Throttle Pedal ....................................................195

Choke Knob (KAF400H/J) .................................197

Idle Adjustment (K AF1000B/E) .........................199

Carburetor (KAF400H/J) ...................................200

Fuel Sys tem (KAF400H/J) ................................203

Fuel Filter ........................................................204

Fuel Hose (KAF1000B/E) ..................................205

Fuel Filter (KAF1000B/E) .......... ........................206

Water Separator (KAF1000B/E) ........................206

Fuel Tank Vent (KAF1000B/E) ..........................207

Belt Drive Torque Converter (KAF400H/J) ........208

Belt Drive Torque Converter Air Cleaner

(KAF400H/J) ................................................ ..

209

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Belt Drive Transmission (CVT) (KAF1000B/E) 211

Brakes ..............................................................213

Brake Pedal ...................................................213

Brake Disc and Brake Pad (KAF1000B/E) ....216

Brake Light Switch ............................................217

Parking Brake Lever (KAF400H/J) ...................219

Parking Brake (KAF1000B/E) ..........................220

Steering Wheel ................................................ .221

Power Steering Sys tem (KAF1000B/E) ........222

Wheels .............................................................223

Rims ..............................................................223

Wheel Nuts ....................................................223

Tires ...............................................................223

Joint Boots ........................................................225

Suspension .......................................................226

Seat Belts .........................................................229

Cargo Bed Latches (KAF1000B/E) ..................230

Headlight Beam ................................................230

Battery ..............................................................231

Fuse .............................. ....................................246

Breaker (KAF1000B/E) ....................................256

General Lubrication ..........................................256

Cleaning ...........................................................257

General Precautions .....................................257

Where to be Careful ............... .......................259

Washing Your Vehicle ...................................259

Bolt and Nut Tightening ....................................260

TRANSPORTING AND STORAGE ...................261

Transporting the Vehicle ...................................261

Storage (KAF400H/J) .......................................263

Storage (KAF1000B/E) ....................................265

Preparation for Storage .................................265

Engine Care during Long Storage .................266

Removal from Storage ..................................267

Before Starting Engine after Long Storage ...267

TROUBLESHOOTING GUIDE ...........................269

ENVIRONMENTAL PROTECTION ....................271

MAINTENANCE RECORD .................................272

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SPECIFICATIONS

PERFORMANCE

Maximum Torque

Minimum Turning Radius Differential Mode

Seating Capacity (KAF1000B/E)

DIMENSIONS

Overall Length

Overall Width

Overall Height

Wheelbase

Tread: Front

Rear

Ground Clearance

Curb Mass

Cargo Bed (L × W × H)

ENGINE

Type

Displacement

Bore × Stroke

Compression Ratio

Starting System

Cylinder Numbering Method (KAF1000B/E)

Firing Order (KAF1000B/E)

SPECIFICATIONS 15

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Carburetor (KAF400H/J)

Ignition System (KAF400H/J)

Ignition Timing (KAF400H/J)

Spark Plug (KAF400H/J)

Injection Pump (KAF1000B/E)

Lubrication System

Engine Oil: Type

Viscosity

Capacity

Coolant Capacity (KAF1000B/E)

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

16 SPECIFICATIONS

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Transmission Case Oil Capacity

FRAME

Type

Steering (KAF1000B/E)

Caster

Trail (KAF400H/J)

Tire Size: Front

Rear

Rim Size:

Front

Rear

Fuel Tank Capacity

ELECTRICAL EQUIPMENT

Battery

Headlight:

High Beam

Low Beam

Brake/Tail Light

Reverse Light

LOAD CAPACITY

Maximum Vehicle Load (Including occupants, cargo and

accessories)

Maximum Cargo Bed Load

Specifications are subject to change without notice.

SPECIFICATIONS 17

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DECLARATION OF CONFORMITY

18 DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY 19

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Kawasaki KAF400A, KAF1000B, KAF1000E, KAF400B, KAF400H, KAF400J, MULE 600 SERIES, MULE 610 4×4, MULE PRO-DX, Mule Pro-DXT, Mule SX General Owners Manual

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