Kawasaki MULE PRO-FX Owner's manual

Quick Reference Guide

GENERAL INFORMATION j

BREAK-IN j

HOW TO OPERATE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

TRANSPORTING AND STORAGE j

TROUBLESHOOTING GUIDE j

This Quick Reference Guide will assist you in

finding the in

formation you’re looking for.

A Table of Contents is included after the

Foreword.

Whenever you see the symbols shown below,

heed their instructions! Always follow safe operat-

ing 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 avoided, 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 opera

tion or service o f 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 f or s afe oper-

ation will increase your satisfac tio n with your new

Kawasaki vehicle.

Perform the Daily

Checks

Refer to the Daily Checks section for a list of items

to check each day before use. Habitual performance

of these checks w

ill help to insure safer, more re-

liable usage. Be sure that any irregularities found

during these checks are corrected before operating

the vehicle.

Drive C arefull

y and with Good Judgement

We want you to be satisfied with your new

Kawasaki vehicle, so drive carefully, safely, and ex-

ercise good jud

gement. Practice basic maneuvers

so you can drive confide ntly and safely.

Improper use of this vehicle can be hazardous.

Never operate a

t s pe e ds too fast for your skills or

conditions. Handling characteristics of this vehicle

change depending upon cargo load and driving

modes.

Read the Ow ner

’s Manual

Read and understand this Owner’s Manual. This

is especially important for inexperienced operators.

Refer to this O

wner ’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 eq

uipped t o be a mu ltiuse 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 o n 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 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 a nd drugs im pair 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 b

elts properly. Seat belts

cannot completely protect you in every accident,

but in many cases a seat belt can reduce the risk

of seriou s injury. A

lso, 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 ar

e securely closed during oper-

ation and ne ver rem ove a door.

The doors prevent branches, gravel, and debris

from getting insid

e the passenger compartment.

Before Starting th

eEngine

Three “mu sts” 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 p ed a l for proper operation. It

should return to its rest position when released.

Use the Parking Br

ake

Always apply the parking brake before gettin g out

of your vehicle.

Obey Local Laws

Know and obey all l

aws and regulations govern-

ing the use of off-highway vehicles in your area. Re-

spect private property. Always try to preserve nature

and the environm

ent.

Refueling

Before refueling the vehicle, shut the engine off

andmakesurethearea

is we ll ventila ted and free

of any source of flame or sparks. Gaso line is very

flammable.

Tire Air Pressure

Tire inflation and ty

pe can affect the vehicle’s han-

dling characteristics. Check the tire pressure fre-

quently. Use only the recommended tires for re-

placement.

Maximum Seating Cap

acity

Do not exceed seating capacity: 3 occupants.

Occupants shall only ride in designated seating

positions and with m

aximum 3 persons in the seat.

Do not carry small children on lap.

ReduceSpeedWhenCarryingCargo,

Passenger(s), and/or Pulling a Trailer

Carrying cargo, pas

senger(s) and/o r 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

cargo, passenger(s ), and/or pulling a trailer. Re-

duce speed and all

ow greater distance for braking

when carrying cargo, passenger(s), and/or pulling

a trailer. Use extreme caution when climbing and

descending hills

, and traversin g slopes.

EMISSION CONTROL I NFORMATION

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 c ompliance with applicable regulations of the

United States Environmental Protection Agency and California Air Resources Board.

1. Crankcase Emiss

ion Control System

A sealed-type crankcase emission control system is used to eliminate blow-by gases. The b low-by gases

are led to the breather chamber through the cylinder head. Then, it is led to the combustion chamber through

the air cleaner.

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 emissi

on 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 a ir cleaner and exhaust system.

A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thor-

ough combustion p

rocess 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 conta

ins 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 o wn e r of this vehicle, you have the respon sib ility to make sur e that the recommended mainte n ance is

carried out accordi

ng to the instructions in this Owner’s Manual at your own expense.

You 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 maint

enance. You should also retain co pie s 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 tha

n 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 render

ed inoperative by any person.

Do not tamper with the original emission related parts.

•

Throttle body and

internal parts

•

Spark plugs

•

Magneto or electronic battery ignition system

•

Fuel filter/Fuel injector/Fuel pump

•

Air cleaner element

•

Electronic Control Unit (ECU)

PLEASE DO NOT TAMPER WITH N OISE CONTROL SYSTEM

To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust

silencing sy

stems. They are designed to give optimum performance while maintaining a low noise level. Please

do not remove these syst ems, or a lter them in an y wa y which res ults in an increase in n oise le vel.

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, capab ilities, a n d lim ita tions.

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.

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

differences betwee n the actual prod uct and illustra tions and text in this manual.

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

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

TABLE OF CONTENTS

SPE

CIFICATIONS.................. ..........................

11

SERIAL NUMBER LOCATIONS.. ............... ..... 15

LOCATION OF PARTS ...................... .............. 16

LOC

ATION OF LABELS................................ ..

19

LOADING INFORMATION............................... 31

GENERAL INFORMATION.............................. 33

Mu

ltifunctio n Met er ........................................

33

Speedometer............................................ .. 34

Fuel Level Gauge .... .............................. ..... 35

C

lock ................................... .......................

3

5

Odometer ...................... ............... .............. 36

Trip Meters (Trip Meter A/B)...... ................. 36

Hour Meter .............. ............... ............... ..... 37

2WD/4 WD In dicator Symbol....................... 37

Red CVT Belt Check Indicato r Light........... 38

Yellow Engine Warning Indicator Light ....... 38

Red EPS Warning Indicator Light............... 38

Red Parking Brake Indicator Light.............. 39

Red Reverse Indicator Light.................. ..... 39

Green Neutra l Indica tor Light .... ............... .. 3 9

Red Seat-Belt Use Reminder ..................... 39

Red Coolant Temperature Warning

Indicator Light....... ............... ............... ..... 39

Red Oil Pressure Warning Indicator Light .. 39

Lighting/Electrical Acce ssory Sock et............. 4 0

Light Switches .............................. ................. 40

Steering Whe el .................... .......................... 42

Brake Pedal. .............................. .................... 43

Cargo Bed .................................... ............... .. 44

Tailgate ........ ............... ............... ................. 44

Lifting and Lowering the Cargo Bed ......... .. 4 4

Loa

ding Cargo Bed ............................... .....

47

Fuel ..................................... .......................... 48

Glove Compartment ...................................... 50

Cup

holders ...................................... ..............

51

Front Access Cov er...................... ............... .. 51

Ignition Switc h .............................. ................. 53

Ke

ys .......................................... ............... .....

54

Gear Shift Le v er ...... ............... ............... ........ 55

Selectable 2WD/4WD Shift Switch................ 56

S

electable DIFF-LOCK Shift Switch ..............

5

8

Belt Drive Transmission................................. 58

Parking Brake Lever ..................... ................. 59

Doors................. ............... ............................. 60

Seat . .............................. .............................. .. 61

Seat Be lts ..................................... ................. 62

Throttle Pedal ................................................ 64

Trailer Hitch Bracket .................................... .. 6 4

BREAK-IN .................. ............... ............... ........ 66

HOW TO OPERATE......................................... 67

Daily Checks ..... .............................. .............. 67

Starting the Engine............................. ........... 70

Jump Starting ................................................ 71

Moving Off ............ .............................. ........... 73

Braking .................... ............... ............... ........ 74

Stopping the Engine ........................... ........... 74

Parking the Mule ....................... .................... 75

Shifting Gears............................ .................... 76

2WD/4W D Shifting ........................................ 77

Shifting the D ifferential ................. ............... .. 7 8

When Stuck .......... ............... .......................... 79

Catalytic Conve rter.................... .................... 80

SAFE OPERATION......................... ................. 81

Unfamiliar Terrain .......................................... 81

Driving in Re v erse ......................................... 82

Driving in “4WD” ............... ............................. 82

Turning the Vehicle........... ............... .............. 83

Hills................................................................ 83

Climbing Hills................................................. 84

Descending Hills............................................ 85

Travers ing Hills

ides .......................................

86

Sliding a nd Skidding...... .............................. .. 8 6

Driving through Water.................................. .. 87

Operator and Pas

senger Requirements........

88

MAINTENANCE AND ADJUSTMEN T............. 89

Periodic Mainten ance Chart ..................... ..... 89

Engine Oil................... .............................. ..... 94

Front Final Gear Case Oil ............................. 97

Transmission Case Oil .................................. 100

Cooling S yste

m .............................................

103

Spark Plugs ................................................... 106

Valve Clearance ............................................ 107

Engine Air Cle

aner .............. ............... ...........

107

Spark Arrester ............................................. .. 110

Throttle Pedal ................................................ 113

Idle Adjust

ment................. ............... ..............

114

Fuel Hose ...................................................... 114

Fuel Tank Vent.............................. ................. 115

Belt Drive T

ransmission (CVT) ......................

115

Brakes ................................................ ........... 117

Brake Pedal.......... .............................. ........ 117

Brake Disc

and Brake Pad .............. ...........

119

Brake Light Switch......................................... 120

Parking Brake............. .............................. ..... 121

Steering

Wheel..............................................

122

Power Steering System (KAF820F/G/H).... 122

Wheels .................. ............... ......................... 123

Rims ......................... .............................. .... 123

Wheel Nuts......... ............... ............... .......... 123

Tires ..................................... ............... ....... 123

Joint B oots............................... ............... ....... 125

Suspension...... .............................. ............... . 126

Seat Be lts ...................................... ................ 129

Cargo Bed Latches........................................ 130

Headlight Beam............................................. 1 30

Battery .......................................................... . 131

Fuse .................................................... .......... 140

Breaker............... ............... ............................ 144

General Lubric ation ....................................... 145

Cleaning ................... .............................. ....... 145

General Precau

tions...................................

145

Where to be Ca reful ............................ ....... 147

Washing Your Vehicle.............. ............... .... 148

Bolt and Nut Ti

ghtening .................................

148

TRANSPORTING AN D STORAGE ................ . 149

Trans porting the Vehicle....... ............... .......... 149

Storage.............................. ............................ 150

TROUBLESHOOTING G UIDE......................... 153

YOUR WARRANTY/OWN ER SATISFACTION

........................... .............................. ............. 155

ENVIRONMENTAL PROTECTION.............. .... 159

MAINTENANCE RE CORD ..... ......................... 160

SPECIFICAT IONS 11

SPECIFICATIONS

PERFORMANCE

Maximum Torque

65N·m(6.6kgf·m,48ft·lb)@3500r/min(rpm)

Minimum Turning Radius Differential Mode 4.8 m (15.7 ft)

Seating Capacity

3 persons

DIMENSIONS

Overall Length 3 385 mm (133.3 in.)

Overall Width 1 625 mm (63.98 in.)

Overall Height: KAF820E/F/H 1 965 mm (77.36 in.)

KAF820G 2 025 mm (79.72 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.)

Dry M ass: KAF820E

785kg(1731lb)

KAF820F

791kg(1744lb)

KAF820G 792 kg (1 746 lb)

KAF820H

793kg(1749lb)

Curb Mass:

KAF820E

818kg(1804lb)

KAF820F

824kg(1817lb)

KAF820G 825 kg (1 819 lb)

KAF820H

826kg(1821lb)

12 SPECIFICATIONS

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

ENGINE

Type

DOHC, 3-cylinder, 4-stroke, liquid-cooled

Displacement

812 cm³ (49.5 cu in.)

Bore × Stroke 72.0 × 66.5 mm (2.83 × 2.62 in.)

Compression Ratio

9.5:1

Starting System

Electric star ter

Cylinder Numbering Method Left to right, 3-2-1

Firing Order

1-2-3

Fuel System FI (Fuel Injection)

Ignition System Battery and coil (transistorized ignition)

Ignition Timing

9.5° BTDC @1 700 r/min (rpm)

Spark P lug (Standard) TORCH 7026, (Alternative) NGK IFR6B11

Lubrication System Forced lubrication (wet sum p)

Engine Oil:

Type

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

Viscosity

SAE 10W-40

Capacity 2.4 L (2.5 US qt)

Coolant Capacity 5.9 L (6.2 US qt)

DRIVE TRAIN

Driving Type: Primary

Belt d riv e torqu

econverter(CVT)

Final

2WD/4WD system w

ith drive shafts

Transmission Type

2-speed & rever

se, automatic

Primary Reduction Ratio

3.33  0.76 (Bel

t drive torque converter)

SPECIFICATIONS 13

Final Reduction Ratio

:

Front 6.382

Rear 6.245

Overall Drive Ratio:

Forward

11.261 (High)

22.356 (Low)

Reverse 17.359

Transmission Gear Ratio:

Forward

1.803 (High)

3.580 (Low)

Reverse 2.779

Front Final Gear Cas

eOil

API GL-5 Hypoid gear

oil

SAE 90 [above 5°C (41°F)]

SAE 8 0 [below 5°C (41°F)]

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

Transmission C ase Oil API GL-5 Hypoid gear oil

SAE 90 [above 5°C (41

°F)]

SAE 8 0 [below 5°C (41°F)]

Transmission Case Oil Capacity 2.0 L (2.1 US qt)

FRAME

Type

Steel tube, ladder type

Steering:

KAF820E Rack and pinion

KAF820F/G/H Rack and pinion with Electric Power Steering (EPS)

system

Caster 4.4°

Tire Size:

Front 26 × 9.00R12 4PR

Rear 26 × 11 .0 0R 12 4PR

14 SPECIFICATIONS

Rim Size:

Front 12 × 7.0AT

Rear 12 × 8.0AT

Fuel Tank Capacity 30 L (7.9 US gal)

ELECTRICAL EQUIPME

NT

Battery

12V32Ah(20HR)

Headlight:

High Beam:

KAF820E/F

12 V 60 W × 2

KAF820G/H

12V60W×2,LED×2

Low Beam:

KAF820E/F

12 V 55 W × 2

KAF820G/H

12V55W×2,LED×2

Brake/Tail Light 12 V 21/5 W × 2

LOAD CAPACITY

Maximum Vehicle Load

(Including occupa

nts,

cargo and accessories):

Except for

California Model 740 kg (1 632 lb)

California Model 582 kg (1 282 lb)

Maximum Cargo Bed

Load:

Except for

California Model 453 kg (1 000 lb)

California Model 272 kg (600 lb)

Specifications are subject to change w ithout 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 N o.

A. Frame Numbe r

B. Right Front Axle

Engine No.

A. Engine Number (Label)

B. Upper Timing Belt Cover

16 LOCATION OF PARTS

LOCATION OF PARTS

1. LED Sub Headlights (KAF820G/H)

2. Headlights

3. Front Access Cover

4. RO PS (Roll Over Protective Structure)

5. Steering Wheel

6. Seat

7. Seat Belts

8. Cargo Bed

9. Front Guard

10. Coolant Reserve Tank

11. Brake Fluid Reservoir

12. S teering Wheel Tilt Lock Lever (KAF820F/G/H)

13. D oor

14. C argo Bed L atch

15. C argo Bed Handgrip

16. M uffler (Spark Arrester)

17. Trailer Hitch Bracket

LOCATION OF PARTS 17

1. Tailgate Latch Handle

2. Tailgate

3. Sun Top (KAF820G)

4. Screen

5. Handgrip for Center Seat Passenger

6. Ha ndgrip for Right Seat Passenger

7. Tail/Brake Light

8. Rear Shock Absorber

9. Air Cleaner

10. Battery

11. Fu el Tank Cap

12. Dashboard

13. Front Shock Absorber

14. Radiator

18 LOCATION OF PARTS

1. Parking Brake Lever

2. Selectable DIFF-LOCK Shift

Switch

3. Selectable 2WD/4WD Shift

Switch

4. Headlight Switch

5. LED Sub Hea dligh t Switch

(KAF820G/H)

6. Multifunction Meter

7. Power Outlet Sockets

8. Glove Compartment

9. Cupholders

10. Ignition Switch

11. Brake Pedal

12. Throttle Pedal

13. Gear Shift Lever

LOCATION OF LABE L S 19

LOCATION OF LABELS

All warning labels which are on your vehicle are

repeated here. Read la

bels 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 op

erate your vehicle. There-

fore, it is very important that all warning labe ls be o n

your vehicle in the locations shown. If any label is

missing, damaged, o

r worn, get a replacement from

your Kawasaki dea ler and install it in the correct po-

sition.

NOTE

○

The sample warning labels in this section have

part numbers to hel

p you and your dealer obtain

the correct replacement.

○

Refer to the actual vehicle label for model specific

datagrayedoutin

the illustratio n.

1. Warning (General)

2. Certification (ANSI/OP EI)

3. Power Outlet Socket Information

4. Notice (Shifting)

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Kawasaki MULE PRO-FX Owner's manual

Kawasaki MULE PRO-FX Owner's manual

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