Kawasaki MUL PRO-DX 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

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.

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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.

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 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. Diesel 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

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 .............................................. 13

DECLARATION OF CONFORMITY ................... 17

SERIAL NUMBER LOCATIONS ........................ 19

LOCATION OF PARTS ....................................... 20

LOCATION OF LABELS .................................... 23

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

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

Multifunction Meter ........................................... 36

Speedometer ................................................. 37

Fuel Level Gauge .......................................... 38

Clock .............................................................. 38

Odometer ...................................................... 39

Trip Meters (Trip Meter A/B) .......................... 39

Hour Meter ..................................................... 40

2WD/4WD Indicator Symbol ......................... 40

Amber Glow Plug Indicator Light ................... 41

Red EPS Warning Indicator Light .................. 42

Red Parking Brake Indicator Light ................ 42

Red Reverse Indicator Light .......................... 42

Green Neutral Indicator Light ........................ 42

Red Seat-Belt Use Reminder ........................ 42

Red Coolant Temperature Warning Indicator

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

42

Red Oil Pressure Warning Indicator Light ..... 43

Lighting/Electrical Accessory Socket ........ ....... 43

Light Switches ........................................... ....... 44

Steering Wheel ................................................. 45

Brake Pedal ...................................................... 47

Cargo Bed ........................................................ 47

Tailgate .......................................................... 47

Lifting and Lowering the Cargo Bed .............. 48

Loading Cargo Bed ....................................... 50

Fuel ................................................................... 51

Diesel Fuel Requirements ............................. 51

Cold Weather Information ............................. 51

Using Biodiesel Fuel ..................................... 52

Filling the Fuel tank ....................................... 52

Glove Compartment/Tool Kit ............................ 54

Cupholders ....................................................... 55

Front Acc ess Cover .......................................... 55

Horn Switch ...................................................... 57

Main Switch ...................................................... 57

Gear Shift Lever .............................. ................. 58

Selectable 2WD/4WD Shift Switch .................. 60

Selectable DIFF-LOCK Shift Switch ................ 61

Belt Drive Transmission ................................... 62

Parking Brake Lever ......................................... 62

Doors ................................................................ 63

Seat .................................................................. 64

Seat Belts ......................................................... 65

Throttle Pedal ................................................... 67

Trailer Hitch Bracket ......................................... 68

BREAK-IN ........................................................... 69

HOW TO OPERATE ........................................... 70

Daily Checks .................................................... 70

Starting the Engine ........................................... 73

Cold Weather Starting ............... ....................... 74

Jump Starting ................................................... 75

Moving Off ........................................................ 77

Braking ............................................................. 78

Stopping the Engine ......................................... 78

Parking the Mule .............................................. 79

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Shifting Gears .................................................... 80

2WD/4WD Shifting ............................................ 81

Shifting the Differential ...................................... 82

When Stuck ....................................................... 83

SAFE OPERATION .............................. ............... 84

Unfamiliar Terrain .............................................. 84

Driving in Reverse ............................................. 85

Driving in “4WD” ................................................ 85

Turning the Vehicle ............................................ 86

Hills .................................................................... 86

Climbing Hills ..................................................... 87

Descending Hills ............................................... 88

Traversing Hillsides ........................................... 89

Sliding and Skidding .......................................... 89

Driving through Water ....................................... 90

Operator and Passenger Requirements ........... 91

NOISE AND VIBRATION CONTROL INFORMA-

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

92

Control Information ............................................ 92

MAINTENANCE AND ADJUSTMENT ................ 93

Periodic Maintenance Chart .............................. 94

Engine Oil .......................................................... 98

Front Final Gear Case Oil .................................102

Transmission Case Oil ......................................105

Cooling System .................................................108

Valve Clearance ................................................ 111

Engine Air Cleaner ............................................ 111

Spark Arrester ................................................... 114

Throttle Pedal .................................................... 116

Idle Adjustment ..................................................117

Fuel Hose .......................................................... 118

Fuel Filter ...........................................................118

Water Separator ................................................ 119

Fuel Tank Vent ...................................................120

Belt Drive Transmission (CVT) ..........................120

Brakes ...............................................................122

Brake Pedal ....................................................122

Brake Disc and Brake Pad .............................124

Brake Light Switch .............................................125

Parking Brake .................................................. ..126

Steering Wheel ..................................................127

Power Steering System ..................................127

Wheels ..............................................................128

Rims ...............................................................128

Wheel Nuts .....................................................128

Tires ................................................................128

Joint Boots .........................................................130

Suspension ........................................................131

Seat Belts ..........................................................133

Cargo Bed Latches ............................................134

Headlight Beam .................................................134

Battery ...............................................................135

Fuse .............................. .....................................143

Breaker ..............................................................149

General Lubrication ...........................................150

Cleaning ............................................................150

General Precautions ......................................150

Where to be Careful .......................................152

Washing Your Vehicle ....................................152

Bolt and Nut Tightening ................................... ..153

TRANSPORTING AND STORAGE ....................154

Transporting the Vehicle ....................................154

Storage ..............................................................155

Preparation for Storage ..................................155

Engine Care during Long Storage ..................156

Removal from Storage ...................................157

Before Starting Engine after Long Storage ....157

TROUBLESHOOTING GUIDE ............................159

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ENVIRONMENTAL PROTECTION ....................161

MAINTENANCE RECORD .................................162

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SPECIFICATIONS

PERFORMANCE

Maximum Torque 52 N·m (5.3 kgf·m, 38 ft·lb) @2 400 r/min (rpm)

Minimum Turning Radius Differential Mode 4.8 m (15.7 ft)

Seating Capacity 2 persons

DIMENSIONS

Overall Length 3 385 mm (133.3 in.)

Overall Width 1 625 mm (63.98 in.)

Overall Height 1 965 mm (77.36 in.)

Wheelbase 2 345 mm (92.32 in.)

Tread: Front 1 385 mm (54.53 in.)

Rear 1 315 mm (51.77 in.)

Ground Clearance 265 mm (10.4 in.)

Curb Mass 828 kg (1 826 lb)

Cargo Bed (L × W × H) 1 375 × 1 355 × 280 mm (54.13 × 53.35 × 11.02 in.)

ENGINE

Type Diesel, OHV, 3-cylinder, 4-stroke, liquid-c ooled

Displacement

993 cm³ (60.6 cu in.)

Bore × Stroke

74.0 × 77.0 mm (2.91 × 3.03 in.)

Compression Ratio

23.5:1

Starting System Electric starter

Cylinder Numbering Method

Left to right, 1-2-3

Firing Order

1-3-2

SPECIFICATIONS 13

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Injection Pump Bosch in-line type

Lubrication System Forced lubrication (wet sump)

Engine Oil: Type API CD, CF, CF-4, CI-4 or CJ-4*

*: When using CJ-4 oil (low ash oil) in your engine, use

fuel with less than 0.05% sulfur content to avoid en-

gine oil deterioration.

Viscosity SAE 10W-40

Capacity 2.4 L (2.5 US qt)

Coolant Capacity 6.1 L (6.4 US qt)

DRIVE TRAIN

Driving Type: Primary Belt drive torque converter (CVT)

Final 2WD/4WD system with drive shafts

Transmission Type 2-speed & reverse, automatic

Primary Reduction Ratio 3.334 ~ 0.756 (Belt drive torque converter)

Final Reduction Ratio: Front 6.382

Rear 6.245

Overall Drive Ratio: Forward

12.192 (High)

24.205 (Low)

Reverse

18.794

Transmission Gear Ratio: Forward

1.952 (High)

3.876 (Lo w)

Reverse

3.009

Front Final Gear Case Oil API GL-5 Hypoid gear oil

SAE 90 [above 5°C (41°F)]

SAE 80 [below 5°C (41°F)]

14 SPECIFICATIONS

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Front Final Gear Case Oil Capacity 0.43 L (0.45 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 2.00 L (2.1 US qt)

FRAME

Type Steel tube, ladder type

Steering Rack and pinion with Electric Power Steering (EPS) system

Caster 4.4°

Tire Size: Front 26 × 9.00-12 4PR

Rear 26 × 11.00-12 4PR

Rim Size:

Front

12 × 7.0AT

Rear

12 × 8.0AT

Fuel Tank Capacity 30 L (7.9 US gal)

ELECTRICAL EQUIPMENT

Battery 12 V 540CCA @0°F RC80

Headlight:

High Beam 12 V 60 W × 2, LED × 2

Low Beam 12 V 55 W × 2, LED × 2

Brake/Tail Light 12 V 21/5 W × 2

Reverse Light 12 V 10 W

LOAD CAPACITY

Maximum Vehicle Load (Including occupants,

cargo and accessories)

733 kg (1 616 lb)

Maximum Cargo Bed Load 453 kg (1 000 lb)

SPECIFICATIONS 15

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Specifications are subject to change without notice.

16 SPECIFICATIONS

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DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY 17

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18 DECLARATION OF CONFORMITY

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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

B. Right Front Axle

Engine No.

A. Engine Number

SERIAL NUMBER LOCATIONS 19

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