Kawasaki MULE PRO-DX General Owners Manual

Category
Offroad Vehicle
Type
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, troublefree 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.
All rights reserved. No part of this publication may be reproduce d without our prior written permission.
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
© 2016 Kawasaki Heavy Industries, Ltd.
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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 MULE PRO-DX General Owners Manual

Category
Offroad Vehicle
Type
General Owners Manual

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