2019 Kawasaki Mule 4010 Trans4x4 25

WARNING
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
GENERAL INFORMATION j
Quick Reference Guide
This Quick Reference Guide will assist you in HOW TO OPERATE j
finding the information you’re looking for.
SAFE OPERATION j
MAINTENANCE AND ADJUSTMENT j
STORAGE j
TROUBLESHOOTING GUIDE j
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 operation or service of the vehicle.
EMISSION CONTROL INFORMATION
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 compliance with applicable regulations of the
United States Environmental Protections Agency and California Air Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases
are led to the breather chamber through the crankcase. Then, it is led to the intake manifold.
Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase,
and then returned back to the bottom of the crankcase.
2. Exhaust Emission Control System

The exhaust emission control system applied to this engine family is engine modifications that consist of 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 air cleaner and exhaust system.
A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thor-
ough combustion process 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 fuel tank.
Also, vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel
vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped.
Maintenance and Warranty
Proper maintenance is necessary to ensure that your vehicle will continue to have low emission levels. This
Owner’s Manual contains 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 owner of this vehicle, you have the responsibility to make sure that the recommended maintenance is
carried out according 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 maintenance. You should also retain copies of maintenance work orders, bills, etc., as verifica-
tion of this maintenance.
If there is a problem with the emission control system within the warranty period, you will need to take it and
any maintenance records to an authorized Kawasaki dealer for inspection and diagnosis. Kawasaki will work
closely with your dealer to resolve any warranty issues. If you are unable to resolve any problem after consulting
with the dealership management and need further assistance, contact Kawasaki Motors Corp., U.S.A. at the
following address:
Consumer Services
Kawasaki Motors Corp., U.S.A.
P.O. Box 25252
Santa Ana, CA 92799-5252
(866) 802-9381
[email protected]
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 than 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 rendered inoperative by any person.
Do not tamper with the original emission related parts.
• Fuel injection system and internal parts • Magneto or electronic battery ignition system
• Spark plugs • Air cleaner element
Fuel filter
•
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM
To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust
silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please
do not remove these systems, or alter them in any way which results in an increase in noise level.
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, 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
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.
All rights reserved. No part of this publication may be reproduced without our prior written permission.
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 products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company
© 2018 Kawasaki Heavy Industries, Ltd. Jan. 5, 2018. (1)

TABLE OF CONTENTS
BASIC SAFE DRIVING.................................... 11 Gear Shift Lever ......................................... 59
SPECIFICATIONS............................................ 14 2WD-4WD Shift Lever (KAF620R/S).......... 60
SERIAL NUMBER LOCATIONS...................... 18 Differential Shift Lever ................................ 60
LOCATION OF PARTS .................................... 19 Parking Brake Lever ...................................... 61
LOCATION OF LABELS.................................. 22 Seats ............................................................. 62
LOADING INFORMATION............................... 33 Seat Belts ...................................................... 63
GENERAL INFORMATION.............................. 35 Throttle Pedal ................................................ 64
Lighting/Electrical Accessory Connector ....... 35 Trailer Hitch Bracket ...................................... 65
Light Switch ................................................... 36 Winch Installation .......................................... 66
Coolant Temperature Warning Light.............. 37 HOW TO OPERATE......................................... 67
Oil Pressure Warning Light............................ 38 Daily Checks ................................................. 67
Fuel Injection Warning Light .......................... 39 Starting the Engine........................................ 69
Parking Brake Warning Light......................... 39 Jump Starting ................................................ 70
Power Steering Warning Light....................... 40 Moving Off ..................................................... 72
Steering Wheel.............................................. 40 Braking .......................................................... 72
Brake Pedal................................................... 41 Stopping the Engine ...................................... 73
Converting Rear Seat and Cargo Bed........... 41 Parking the Mule ........................................... 73
From 4-Person to 2-Person Mode.............. 41 Hi-Lo Shifting (KAF620R/S) .......................... 75
From 2-Person to 4-Person Mode.............. 44 Reversing Gears ........................................... 76
Cargo Bed ..................................................... 45 2WD-4WD Shifting (KAF620R/S) .................. 76
Tailgate ....................................................... 45 Shifting the Differential .................................. 77
Loading Cargo Bed .................................... 45 SAFE OPERATION.......................................... 79
Raising & Lowering the Cargo Bed ............ 46 Unfamiliar Terrain .......................................... 79
Fuel Tank ....................................................... 50 Driving in Reverse ......................................... 80
Glove Compartment ...................................... 53 Driving in “4WD” (KAF620R/S)...................... 80
Front Cargo Compartment ............................ 54 Turning the Vehicle........................................ 81
Horn Button ................................................... 55 Hills................................................................ 81
Ignition Switch ............................................... 56 Climbing Hills................................................. 82
Keys .............................................................. 57 Descending Hills............................................ 83
Fuel Gauge/Hour Meter................................. 58 Traversing Hillsides ....................................... 84
Shift Levers ................................................... 59 Sliding and Skidding ...................................... 84
Driving through Water.................................... 85 Fuse .............................................................. 135
MAINTENANCE AND ADJUSTMENT............. 86 Power Steering System.............................. 136
Periodic Maintenance Chart .......................... 87 Breaker.......................................................... 137
Engine Oil...................................................... 91 General Lubrication ....................................... 138
Front Final Gear Case Oil (KAF620R/S) ....... 95 Cleaning ........................................................ 138
Transmission Case Oil .................................. 98 General Precautions................................... 138
Cooling System ............................................. 101 Where to be Careful ................................... 140
Spark Plugs ................................................... 104 Washing Your Vehicle................................. 141
Valve Clearance ............................................ 105 Bolt and Nut Tightening ................................. 141
Engine Air Cleaner ........................................ 106 STORAGE........................................................ 142
Evaporative Emission Control System .......... 108 TROUBLESHOOTING GUIDE......................... 144
Spark Arrester ............................................... 108 YOUR WARRANTY/OWNER SATISFACTION
Throttle Pedal ................................................ 110 ...................................................................... 145
Idle Adjustment.............................................. 113 ENVIRONMENTAL PROTECTION.................. 149
Fuel Pump Filter ............................................ 113 MAINTENANCE RECORD .............................. 150
Fuel Tank Vent............................................... 114
Belt Drive Torque Converter .......................... 114
Belt Drive Torque Converter Air Cleaner ....... 115
Brakes ........................................................... 117
Brake Pedal................................................ 117
Brake Light Switch......................................... 120
Parking Brake Lever ...................................... 121
Steering Wheel.............................................. 122
Power Steering System.............................. 123
Wheels .......................................................... 124
Rims ........................................................... 124
Wheel Nuts................................................. 124
Tires ........................................................... 124
Joint Boots..................................................... 126
Suspension.................................................... 127
Seat Belts ...................................................... 128
Cargo Bed Latches........................................ 129
Headlight Beam............................................. 130
Battery ........................................................... 131
BASIC SAFE DRIVING 11
BASIC SAFE DRIVING

Knowing and following these rules for safe oper- Off-Highway Use Only
ation will increase your satisfaction with your new This vehicle is not an all-terrain vehicle; it is de-
Kawasaki vehicle. 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 sur-
faces.
Perform the Daily Checks
Refer to the Daily Checks section for a list of items
Occupant Capacity
to check each day before use. Habitual performance
Make sure operators are 16 years or older with a
of these checks will help to insure safer, more re-
valid driver’s license.
liable usage. Be sure that any irregularities found
Each occupant must be able to sit with back
during these checks are corrected before operating
against seat, feet flat on floor, and hands on steer-
the vehicle.
ing wheel, handgrip or handhold.
The operator should be tall enough to wear the
seat belt properly and reach all controls.
Drive Carefully and with Good Judgement
Passenger(s) should also be tall enough for the
We want you to be satisfied with your new
seat belt to fit properly and to be able to brace them-
Kawasaki vehicle, so drive carefully, safely, and ex-
selves, as necessary, by placing both feet firmly on
ercise good judgement. Practice basic maneuvers
the floor while gripping the handhold. Stay com-
so you can drive confidently and safely.
pletely inside the vehicle.
Read the Owner’s Manual

Never Drink and Drive
Read and understand this Owner’s Manual. This
Alcohol and drugs impair your judgement and slow
is especially important for inexperienced drivers.
your reactions. Even drugs prescribed by a physi-
Refer to this Owner’s Manual if you have any ques-
cian can be dangerous. Check with your doctor.
tions.
12 BASIC SAFE DRIVING
Use Proper Riding Gear Obey Local Laws
Proper protective gear can reduce the severity of Know and obey all laws and regulations govern-
injury in the event of an accident. ing the use of off-highway vehicles in your area. Re-
Choose a helmet most appropriate for your use of spect private property. Always try to preserve nature
this utility vehicle. A helmet can reduce the risk of and the environment.
head injuries. Wear appropriate eye protection and
protective clothing.
Refueling
Before refueling the vehicle, shut the engine off
Wearing Seat Belts and make sure the area is well ventilated and free
Both the operator and passenger(s) should al- of any source of flame or sparks. Gasoline is very
ways wear their seat belts properly. Seat belts flammable.
cannot completely protect you in every accident,
but in many cases a seat belt can reduce the risk
of serious injury. Also, to avoid injury, do not put Tire Air Pressure
any part of your body outside of the vehicle for any Tire inflation and type can affect the vehicle’s han-
reason. dling characteristics. Check the tire pressure fre-
quently. Use only the recommended tires for re-
placement.
Before Starting the Engine
Three “musts” before starting the engine are:
Maximum Seating Capacity
1. Apply the parking brake,
Do not exceed seating capacity: 4 occupants. Oc-
2. Put the gear shift lever in the “N” (neutral) posi-
cupants shall only ride in designated seating posi-
tion,
tions and with maximum 2 persons in each front and
3. Check the throttle pedal for proper operation. It
rear seat. Do not carry small children on lap.
should return to its rest position when released.
Use the Parking Brake

Always apply the parking brake before getting out
of your vehicle.
BASIC SAFE DRIVING 13
Reduce Speed When Carrying Cargo,

Passenger(s), and/or Pulling a Trailer
Carrying cargo, passenger(s) and/or pulling a
trailer can make the vehicle difficult to steer and
may affect vehicle handling in an unpredictable man-
ner. Braking distance is increased when carrying
cargo, 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 descending
hills, and traversing slopes.
14 SPECIFICATIONS
SPECIFICATIONS
PERFORMANCE
Maximum Torque 47.0 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm)
Minimum Turning Radius Differential Mode: 3.9 m (12.80 ft)
Seating Capacity Front 2 persons, Rear 2 persons
DIMENSIONS
Overall Length 3 265 mm (128.54 in.)
Overall Width 1 485 mm (58.46 in.)
Overall Height 1 925 mm (75.79 in.)
Wheelbase 2 165 mm (85.24 in.)
Tread: Front 1 160 mm (45.67 in.)
Rear 1 180 mm (46.46 in.)
Ground Clearance KAF620R/S 180 mm (7.09 in.)
KAF620W 195 mm (7.68 in.)
Curb Mass KAF620R/S 720 kg (1 588 lb)
KAF620W 687 kg (1 515 lb)
Cargo Bed (L × W × H) Long bed mode 1 280 × 1 210 × 285 mm (50.39 × 47.64
× 11.22 in.)
Short bed mode 770 × 1 210 × 285 mm (30.31 × 47.64
× 11.22 in.)
ENGINE
Type OHV, 2-cylinder, 4-stroke, liquid-cooled
Displacement 617 cm³ (37.6 cu in.)
SPECIFICATIONS 15
Bore × Stroke 76.0 × 68.0 mm (2.99 × 2.68 in.)

Compression Ratio 10.3 : 1
Starting System Electric starter
Cylinder Numbering Method Front to rear, 1-2
Firing Order 1-2
Carburetion System FI (Fuel Injection)
Ignition System Magneto and transistor
5° BTDC @750 r/min (rpm)  22° BTDC @4 000 r/min
Ignition Timing
(rpm)
Spark Plug NGK BPR2ES
Lubrication System Forced lubrication (wet sump)
Engine Oil: Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 1.3 L (1.4 US qt)
Coolant Capacity 4.6 L (4.9 US qt)
DRIVE TRAIN
Driving Type KAF620R/S 4WD gear
KAF620W 2WD gear
Transmission Type KAF620R/S 2-speed & reverse, automatic
KAF620W 1-speed & reverse, automatic
Primary Reduction Ratio 3.9  0.85 (Belt drive torque converter)
Final Reduction Ratio: Front 5.200
Rear 5.429
16 SPECIFICATIONS
Overall Drive Ratio: Forward: 8.404 (High)

KAF620R/S 17.303 (Low)
KAF620W –
Reverse:
KAF620R/S 19.475
KAF620W 9.459
Transmission Gear Ratio: Forward: 1.821 (High)
KAF620R/S 3.750 (Low)
Reverse:
KAF620R/S 4.220
KAF620W 2.050
Front Final Gear Case Oil KAF620R/S API GL-5 SAE140 or API GL-6 SAE90 Hypoid gear oil
for Limited Slip Differentials
Front Final Gear Case Oil KAF620R/S 0.4 L (0.4 US qt)
Capacity
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 KAF620R/S 2.5 L (2.6 US qt)
KAF620W 2.2 L (2.3 US qt)
FRAME
Type Steel tube, ladder type
Steering Assisted with Electric Power Steering (EPS) System
Caster 7.5°
SPECIFICATIONS 17
Trail 35 mm (1.4 in.)

Tire Size: Front & Rear 23 × 11.00-10 Tubeless
Rim Size: Front & Rear 10 × 8.5 AT
Fuel Tank Capacity 24 L (6.3 US gal)
ELECTRICAL EQUIPMENT
Battery 12 V 14 Ah (10 HR)
Headlight 12 V 35 W × 2
Brake/Tail Light 12 V 21/5 W × 2
LOAD CAPACITY
Maximum Vehicle Load (Including occupants,
603 kg (1 330 lb)
cargo and accessories)
Maximum Cargo Bed Load Short Bed Mode: 182 kg (400 lb)
Long Bed Mode: 363 kg (800 lb)
MODEL INFORMATION
MULE 4010 TRANS 4 × 4.......KAF620R/S
MULE 4000 TRANS ................KAF620W
NOTE
○The KAF620S is identical to the KAF620R in every aspect: controls, features, and specifications except for
the camouflage surface treatment.
Specifications are subject to change without notice.
18 SERIAL NUMBER LOCATIONS
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 No. Engine No.
A. Frame Number A. Engine Number

LOCATION OF PARTS 19
LOCATION OF PARTS
(Four-person mode)
1. Headlights 7. Rear Seat 14. Latch

2. ROPS (Roll Over Protective 8. Seat Belts 15. Air Cleaner (Belt Drive
Structure) 9. Cargo Bed Torque Converter)
3. Front Cargo Hood 10. Front Bumper 16. Belt Drive Torque Converter
4. Front Cargo Compartment 11. Radiator 17. Handgrip
5. Steering Wheel 12. Parking Brake
6. Front Seat 13. Battery
20 LOCATION OF PARTS
(Two-person mode)
1. Latch Handle 5. Brake/Tail Lights 9. Rear Seat (folded)

2. Tail Gate 6. Muffler (Spark Arrester) 10. Fuel Tank
3. Screen 7. Trailer Hitch Bracket 11. Fuel Tank Cap
4. Dashboard 8. Air Cleaner
LOCATION OF PARTS 21
1. Left Glove Compartment 8. FI Warning Light 16. Throttle Pedal

2. Light Switch 9. Power Steering Warning 17. Gear Shift Lever
3. Horn Button Light 18. 2WD-4WD Shift Lever
4. Latch Release Knob 10. Fuel Gauge/Hour Meter (KAF620R/S)
5. Oil Pressure Warning Light 11. Ignition Switch
6. Coolant Temperature 12. Right Glove Compartment
Warning Light 13. Differential Shift Lever
7. Parking Brake Warning 14. Brake Fluid Reserve Tank
Light 15. Brake Pedal
22 LOCATION OF LABELS
LOCATION OF LABELS
All warning labels which are on your vehicle are
repeated here. Read labels 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 operate your vehicle. There-
fore, it is very important that all warning labels be on
your vehicle in the locations shown. If any label is
missing, damaged, or worn, get a replacement from
your Kawasaki dealer and install it in the correct po-
sition.
NOTE
○The sample warning labels in this section have
part numbers to help you and your dealer obtain
the correct replacement.
○Refer to the actual vehicle label for model specific 1.
2.
Certification (Compliance)
Warning (Cargo Bed)
data grayed out in the illustration. 3. Notice (Shifting)
4. Information (Front Hood)
5. Specification
6. Warning (Front Cargo Hood)
7. Warning (General)
LOCATION OF LABELS 23
8. Specification
9. Warning (Rear Seat Capacity)
10. Warning (Pinching Fingers: both sides)
11. Important Information (Tires/Max. Load)
12. Warning (Refueling)
13. Warning (Cargo Bed)
14. Warning (Trailer-Towing Bracket)

15. Warning (Hot Surfaces)
16. Important Engine Information
17. Important Emission Information

18. Battery Danger/Poison (On the backside)
19. Lead-acid Battery
20. Brake Fluid
21. Radiator Cap Danger

(1) (3)
(2) (4)
(5)
(6)
(7)
(8)
(9)
(10) (12)
(11) (13)
(14) (16)
(15) (17)
(18) (20)
(19) (21)
LOADING INFORMATION 33
LOADING INFORMATION
WARNING • Carrying cargo, passengers and/or pulling a trailer
can make the vehicle difficult to steer and may af-
Incorrect loading, improper installation or
fect vehicle handling in an unpredictable manner.
use of accessories, or modification of your
Use extreme caution when climbing and descend-
vehicle may result in an unsafe operating
ing hills, and traversing slopes.
condition. Before you operate it, make sure
that the vehicle is not overloaded and that • Braking distance is increased when carrying
cargo, passengers, and/or pulling a trailer. Re-
you have followed these instructions.
duce speed and allow greater distance for braking.
With the exception of genuine Kawasaki Parts and • All cargo should be carried as low as possible to
reduce the effect on the vehicle’s center of gravity.
Accessories, Kawasaki has no control over the de-
Cargo weight should be equally distributed from
sign or application of accessories. In some cases,
side to side. This helps maintain stability by cen-
improper installation or use of accessories, or ve-
tralizing weight. Avoid carrying cargo that extends
hicle modifications, will void the utility vehicle war-
beyond the rear of the vehicle. Do not carry cargo
ranty. In selecting and using accessories, and in
on top of the ROPS.
loading the vehicle, you are personally responsible
for your own safety and the safety of other person(s) • Cargo should be securely anchored. Make sure
the cargo will not move around while the vehicle
involved.
is moving. Recheck cargo security as often as
NOTE possible (while the vehicle is stopped) and adjust
○Kawasaki Parts and Accessories have been spe- as necessary.
cially designed for use on Kawasaki utility vehi-
cles. We strongly recommend that all parts and NOTICE
accessories you add to your vehicle be genuine The front body work and fenders are not de-
Kawasaki components. signed to carry cargo or to support weight.
Because any vehicle is sensitive to increases in Do not place cargo, lean or sit on them, or
weight and changes in weight distribution, you must they may break.
take care in carrying cargo. Always follow these pre-
cautions: • This vehicle is not designed to carry passengers
in the cargo bed. Installing additional passenger
34 LOADING INFORMATION
seating or carrying passengers in the cargo bed
can cause changes in vehicle handling.
• (Maximum Vehicle Load) Weight of operator, pas-
senger(s), cargo, accessories, and trailer tongue
must not exceed following limits.
WARNING Maximum Vehicle Load: 603 kg (1 330 lb)
Passengers transported in the cargo bed can
be tossed about or even thrown out causing
serious injury or death. Do not install seating
• Do not operate this vehicle faster than 16 km/h (10
mph) when pulling a trailer. Refer to the “Trailer
or transport passengers in the cargo bed. Hitch Bracket” section in the “GENERAL INFOR-
MATION” chapter.
• (Maximum Cargo Bed Load) Do not carry more
than maximum cargo bed load as specified below.
Short Cargo Bed Mode:
182 kg (400 lb)
Long Cargo Bed Mode:
363 kg (800 lb)
GENERAL INFORMATION 35
j
GENERAL INFORMATION
NOTICE
Lighting/Electrical Accessory The accessory circuit (Power Outlet Socket)
Connector has 20 A fuse for the connector. Always in-
stall a fuse 20 A or less for the circuit. Do
The lighting/electrical accessory 12 volt connector
not connect more than 120 W of load to this
is located on the dashboard.
accessory circuit or the battery may become
An auxiliary light or an accessory may be con-
discharged, even with the engine running.
nected to this connector.
Electrical Accessory Connector

The electrical accessory connectors are located
under the dashboard.
An accessory may be connected to these connec-
tors.
A. Connector
A. Electrical Accessory Connectors

36 GENERAL INFORMATION
j
NOTICE
The accessory circuit (Electrical Accessory
Light Switch
Connectors) has 20 A fuse for the connec-
Turn on the headlights and taillights by pushing the
tors. Always install a fuse 20 A or less for
light switch in, with the ignition switch key in the “ON”
the circuit. Do not connect more than 120 W
position.
of load to this accessory circuit or the bat-
The lights go off when the switch is pushed again.
tery may become discharged, even with the
engine running.
NOTE
○The electrical accessory connection to the
connectors should be done by an authorized
Kawasaki dealer.
A. Light Switch
j
NOTICE
Coolant Temperature Warning Light Do not let the engine continue running with
a warning light on. Prolonged engine opera-
The coolant temperature warning light (TEMP)
tion can result in engine damage from over-
comes on whenever the coolant temperature rises
heating.
too high while the vehicle is in operation or when
the ignition switch key is turned to ON. If it stays on,
stop the engine and check the coolant level in the
reserve tank after the engine cools down.
Refer to the “Cooling System” section in the “Main-
tenance and Adjustment” chapter.
Also check the breaker of the radiator fan and,
if it has functioned, reset the breaker. Be sure to
check that the radiator fan is free from mud and other
obstacles. See Breaker section of MAINTENANCE
AND ADJUSTMENT chapter.
A. Coolant Temperature Warning Light

j
Oil Pressure Warning Light
The oil pressure warning light goes on whenever
the oil pressure is dangerously low or the ignition
switch key is in the ON position with the engine not
running, and goes off when the engine oil pressure
is high enough.
NOTICE
If the engine oil gets extremely low or if the
oil pump does not function properly, or oil
passages are clogged, or otherwise do not
function properly, the oil pressure warning
light will light. If this light stays on when the A. Oil Pressure Warning Light
engine speed is running slightly above the
idle speed, stop the engine immediately and
find the cause.
j
Fuel Injection Warning Light Parking Brake Warning Light
The fuel injection (DFI) warning light goes on when The parking brake warning light goes on when the
the ignition switch key is turned to “ON” and goes parking brake is applied with the ignition switch in
off soon after ensuring that its circuit functions prop- the “ON” position.
erly. The warning light also goes on whenever the
troubles occur in digital fuel injection system (DFI).
NOTE
If the warning light comes on, have the DFI system ○This light shows only that the parking brake is on.
checked by an authorized Kawasaki dealer. It does not show the degree of parking brake ap-
plication.
A. Fuel Injection Warning Light

A. Parking Brake Warning Light
j
Power Steering Warning Light Steering Wheel
The power steering warning light will momentarily This vehicle is equipped with an electric power
illuminate when the engine starts, then goes off in steering system. The system does not require reg-
one second if the system is in order. If the warning ular maintenance by users. Do not tamper with the
light illuminates any other time, it indicates the ECU electronic control unit (ECU) or loosen the fittings of
or actuator has malfunctioned, or the wiring harness steering actuator, or the neutral position setting of
has become disconnected. Stop driving immediately the steering will be adversely affected and will cause
and see an authorized Kawasaki dealer to have the serious driving problems. If such components need
system checked. service, see an authorized Kawasaki dealer.
If the steering becomes more difficult than usual
or you experience other steering problems, refer to
the “Steering Wheel” section in the “MAINTENANCE
AND ADJUSTMENT” chapter. The steering wheel
position can be adjusted to suit the operator (see
“Steering Wheel” section).
NOTE
○The power steering system functions only when
engine is running.
○If you install wireless equipment on board, contact
an authorized dealer. Installing such equipment
improperly may affect the ECU.
A. Power Steering Warning Light
NOTE
○If the warning light does not go on when the engine
starts, there may be a problem with the light itself.
See a dealer for inspection.
j
Brake Pedal Converting Rear Seat and Cargo Bed
The brake pedal is the left pedal on the foot board. This vehicle can be converted to accommodate
Depress the pedal to slow or stop the vehicle. more passengers and less cargo or fewer passen-
gers and more cargo.
The seats and the cargo bed can be converted in
the following way.
From 4-Person to 2-Person Mode
1. Pull the rear seat stopper pin on the left side.
A. Brake Pedal
A. Stopper pin
B. Rear Seat
2. Push the rear seat back forward.

3. Release the latches on both sides.
j
A. Latch A. Rear Seat (Stored position)

B. Rear Seat Back (lowered position) B. Front Seat Back
4. Push the rear seat assembly forward into the 5. Swing open the cargo bed side plates and fas-
stored position. ten the latches on the both sides.
j
A. Cargo Bed Side Plates A. Stopper Pin

B. Latch B. Screen
6. Slide the stopper pins towards inside at the bot- 7. Pull and remove the screen from the sockets,
tom of the removable screen. move forward and insert into the sockets at the
end of the side plates.
j
A. Screen A. Projections
B. Sockets B. Cargo Bed Side Plate (folded)
8. Latch the stopper pins at the bottom of the

screen.
From 2-Person to 4-Person Mode
• Reverse the procedure for 4-person to 2-person
mode conversion.
NOTE
○When folding the cargo bed end side plates, be
sure to insert the end projections into the counter-
parts on the screen.
j
Loading Cargo Bed
Cargo Bed
NOTICE
Tailgate Do not carry more than the maximum load
The tailgate can be lowered. Before lowering the stated here in the convertible cargo bed.
tailgate, park on a firm level surface and set the park- ·Short bed mode: 182 kg (400 lb)
ing brake. Raise the latch handles at each end of the ·Long bed mode: 363 kg (800 lb)
tailgate and slide both latches toward the center of
the vehicle. The tailgate can now be lowered. The
gate is held level to the cargo bed floor with cables. WARNING
Close the tailgate by sliding both latches toward
the center of the vehicle. Push the handles down to
• Overloading, failure to properly secure
cargo, or improper use of the cargo bed
make sure the latches stay securely closed. Do not can cause changes in handling which can
drive the vehicle with the tailgate lowered. lead to an accident. Follow guidelines pro-
vided in the “LOADING INFORMATION”
chapter.
• Passengers riding in the cargo bed can be
tossed about or even thrown out causing
serious injury or death. Do not install seat-
ing or carry passengers in the cargo bed.
• Driving with the cargo bed tilted may be
hazardous. Failure to lower and lock the
bed into place may cause severe injury or
death. Always lower and latch the bed after
tilting.
• Lifting and lowering the bed could be dan-
gerous. Be careful not to catch any part
of your body, such as hands or arms, be-
tween the bed and ROPS or vehicle frame
A. Tailgate
B. Latch Handle
when lifting and lowering the bed.
C. Cable
j
Raising & Lowering the Cargo Bed With the Cargo Bed Shortened Condition
The cargo bed can be tilted by releasing the 1. Pull the rear seat stopper pin on the left side.
latches on each side, and then lifting the bed with
the handgrips. Before tilting the cargo bed, park on
a firm level surface and set the parking brake.
Empty the cargo bed prior to raising the cargo bed.
Support the bed in the tilted position with the sup-
porting rod provided on the bottom of the cargo bed.
Do not drive the vehicle with the front end of the
cargo bed raised or unlatched.
To lower the bed, check to be sure the area un-
der the front of the cargo bed is clear, then carefully
lower the bed into position.
Check that the both latches have locked the bed
into place. Do not leave the cargo bed unlatched.
WARNING A. Stopper pin

Reduced clearance between cargo bed and B. Rear Seat
ROPS can cause hand injury. Do not hold
ROPS in the location of the label when rais- 2. Push the rear seat back forward.
ing or lowering the cargo bed. 3. Release the latches on both sides.
j
A. Latch A. Rear Seat (Stored position)

B. Rear Seat Back (lowered position) B. Front Seat Back
4. Push the rear seat assembly forward into the 5. Holding the hand grip and cargo bed top, raise
stored position. the cargo bed.
j
A. Handgrip A. Supporting Rod

B. Hold here. B. Cargo Bed (Raised Position )
6. Support the bed in the tilted position with the

NOTE
supporting rod. ○To lower the cargo bed, follow the reverse proce-
dure for raising. Be sure to restore the seat as be-
fore and put the latches on. Never drive the Mule
without putting the latches to the cargo bed.
With the Cargo Bed Extended Condition

1. Release the side latches.
j
WARNING
Cargo bed becomes heavier in the extended
mode. Pay attention when raising or lower-
ing the cargo bed not to injure your hand.
A. Latch
B. Rear Seat (Stored position)
2. Holding the handgrip and cargo bed on the top

edge, raise the cargo bed.
3. Support the bed in the tilted position with the
supporting rod.
NOTE
○To lower the cargo bed, follow the reverse proce-
dure for raising. Be sure to attach the latches to
the cargo bed.
j
NOTICE
Fuel Tank Always clean dirt/mud/debris/water from the
fuel tank cap and surrounding area prior to
The fuel tank is mounted under the right side
filling the tank to prevent dirt/mud/debris/wa-
of the seat. The gasoline octane rating listed is
ter from entering the fuel tank.
recommended. Use only fresh gasoline with the
Accumulation of moisture or sediment in the
recommended octane rating from an uncontam-
fuel system can restrict the flow of fuel and
inated source to insure proper running of your
cause fuel pump and/or engine damage.
vehicle. Avoid filling the tank in the rain or where
heavy dust is blowing, so that the fuel does not get
contaminated. WARNING
Gasoline is extremely flammable and can be
explosive under certain conditions, creating
the potential for serious burns. Turn the ig-
nition switch to “OFF”. Do not smoke. Make
sure the area is well-ventilated and free from
any source of flame or sparks; this includes
any appliance with a pilot light. Never fill
the tank completely to the top. If the tank is
filled completely to the top, heat may cause
the fuel to expand and overflow through the
vents in the tank cap. After refueling, make
sure the tank cap is closed securely. If gaso-
line is spilled on the fuel tank, wipe it off im-
mediately.
A. Fuel Tank
B. Filling Cap
j
Fuel Requirements: Minimum
Fuel Type Octane Rating Method
Rating
This vehicle is certified to operate on unleaded
Antiknock (RON + MON)
gasoline only. 87
Use clean, fresh unleaded gasoline with a mini- Index 2
mum Antiknock Index of 87. The Antiknock Index is
posted on service station pumps in the U.S.A. The
octane rating of a gasoline is a measure of its re- NOTICE
sistance to detonation or “knocking.” The Antiknock If engine “knocking” or “pinging” occurs,
Index is an average of the Research Octane Num- use a different brand of gasoline of a higher
ber (RON) and the Motor Octane Number (MON) as octane rating. If this condition is allowed to
shown in the table below. continue it can lead to severe engine dam-
age.
Gasoline quality is important. Fuels of low
quality or not meeting standard industry
specifications may result in unsatisfac-
tory performance. Operating problems that
result from the use of poor quality or nonrec-
ommended fuel may not be covered under
warranty.
Fuels Containing Oxygenates

Gasoline frequently contains oxygenates (alco-
hols and ethers) especially in areas of the U.S. and
Canada which are required to sell such reformu-
lated fuels as part of a strategy to reduce exhaust
emissions.
The types and volume of fuel oxygenates ap-
proved for use in unleaded gasoline by the U.S.
Environmental Protection Agency include a broad
j
range of alcohols and ethers, but only two compo- NOTICE
nents have seen any significant level of commercial
Never use gasoline with an octane rat-
use.
ing lower than the minimum specified by
Gasoline/Alcohol Blends – Gasoline containing up
Kawasaki.
to 10% ethanol (alcohol produced from agricultural
Never use “gasohol” with more than 10%
products such as corn), also known as “gasohol” is
ethanol, or more than 5% methanol. Gaso-
approved for use.
line containing methanol must also be
NOTICE blended with cosolvents and corrosion
inhibitors.
Avoid using blends of unleaded gasoline and Certain ingredients of gasoline may cause
methanol (wood alcohol) whenever possible, paint fading or damage. Be extra careful
and never use “gasohol” containing more not to spill gasoline or gasoline oxygenate
than 5% methanol. Fuel system damage and blends during refueling.
performance problems may result. When not operating your Kawasaki for 30
to 60 days, mix a fuel stabilizer (such as
Gasoline/Ether Blends — The most common ether STA-BIL) with the gasoline in the fuel tank.
is methyl tertiary butyl ether (MTBE). You may use Fuel stabilizer additives inhibit oxidation of
gasoline containing up to 15% MTBE. the fuel which minimizes gummy deposits.
NOTE Never store this product with “gasohol” in
the fuel system. Before storage it is recom-
○Other oxygenates approved for use in unleaded mended that you drain all fuel from the fuel
gasoline include TAME (up to 16.7%) and ETBE tank. See the “STORAGE” chapter in this
(up to 17.2%). Fuel containing these oxygenates manual.
can also be used in your Kawasaki.
j
Glove Compartment
A glove compartment is provided at the each end
of the dashboard. Store only light items to avoid
damage to the inside of the compartments. Release
the plug in the bottom of the left and right glove com-
partments to remove any water that may enter. Do
not put items which must not get wet or dirty in it.
A. Right Glove Compartment
A. Left Glove Compartment

j
Front Cargo Compartment
The front cargo compartment is located under the
front cargo hood. Store only light-weight items in it to
avoid damage to the inside of the compartment. Do
not put items which must not get wet or dirty inside.
A. Latch Release Knob
NOTE
○When the hood is hard to open, pull and lift up the
front hood center portion with pulling the knob to
open the hood.
A. Front Cargo Compartment Hood Closing

Close the hood until it locks.
Hood Opening
Raise the hood until it stops while pulling the latch
•After the hood is closed, push the two edges of the
hood to ensure the hood is latched.
release knob. •Pull up the front ends of the hood to make sure
latches are securely locked.
j
Horn Button
Push the horn button to sound the horn.
A. Push here
B. Latches
WARNING
An open front cargo hood can distract or im- A. Horn Button
pair visibility of the operator, causing loss of
vehicle control and potential serious injury
or death.
Latch the hood securely before operating the
vehicle.
j
OFF Engine off. All electrical circuits off.
Ignition Switch All electrical equipment can be used.
ON
Fuel gauge works.
This is a three-position, key-operated switch. The
key can be removed from the switch only when it is Electric starter is engaged by holding
in the “OFF” position. ignition switch key in this position,
only when gear shift lever is in “N”
START
(neutral) position. Upon release, key
will return to “ON” position.
Hour meter works.
NOTICE
Do not operate the starter continuously for
more than 5 seconds, or the starter will
overheat and the battery power will drop
temporarily. Wait 15 seconds between each
operation of the starter to let it cool and for
the battery to recover power.
Do not turn the ignition switch key to the
A. Ignition Switch “START” position with the engine running, or
B. “OFF” position damage to the starter can result.
C. “ON” position
D. “START” position NOTE
E. Fuel Gauge
F. Hour Meter ○The vehicle is equipped with a starter lockout
switch. This switch prevents the electric starter
from operating when the gear shift lever is in
the “H” (High), “L” (Low; KAF620R/S only) or “R”
(Reverse) position.
j
In the event you lose your keys, you will need the
Keys key number to have a duplicate made. If you cannot
locate your key number, contact the dealer where
This UV has a key, which is used for the ignition you purchased your Kawasaki UV. It’s possible the
switch, and one spare key. Included with the key is dealer may have the number in its records. If the key
a key number, which is stamped on the key itself. number is lost completely, you will need to replace
Record the key number in the space provided and the ignition switch and all other locks operated by
store the number in a safe place. that key.
Contact your Kawasaki dealer to purchase addi-
tional spare keys either using your original key as a
master or using the key code on the tag or your key.
Store one key at home and keep another spare in
your wallet or riding gear, in case the original is lost.
A. Key
B. Key Number
Write your key number here.
j
Hour Meter -
Fuel Gauge/Hour Meter The hour meter shows the total hours that the vehi-
cle has been operated. This meter cannot be reset.
Fuel Gauge (LED) - NOTE
The fuel in the fuel tank is shown by the number of
segments displayed.
○The data is maintained even if the battery is dis-
connected.
When the fuel tank is full, all the segments are
displayed. As the fuel level in the tank goes down,
○The hour meter shows the operating hours to a
maximum of 5 digits. The value is shown to the
the segments disappear one by one from F (full) to nearest 0.1 hr until the total reaches 10 000 hrs
E (empty). The lowest segment blinks in the fuel after which the meter counts in complete hours
gauge (LED) when approximately 5.0 L (1.3 US gal) only.
of usable fuel remains.
Refuel at the earliest opportunity if the most bottom
○When the figures come to 99999, they turn back
to 0.0 and start counting upward again when the
segment of the fuel gauge (LED) blinks. vehicle is operated.
A. Fuel Gauge (LED)

B. Blink A. Hour Meter
j
Shift Levers
This vehicle is equipped with three different shift
levers: the gear shift lever, the 2WD-4WD shift lever
(KAF620R/S only) and the differential shift lever.
Gear Shift Lever
The gear shift lever is located on the dashboard,
to the right of the steering shaft. The gear shift
lever has four (KAF620R/S) or three (KAF620W) po-
sitions: “H” (High), “L” (Low; KAF620R/S only), “N”
(Neutral), and “R” (Reverse).
Make certain that the vehicle is completely
stopped and the engine is idling before shifting A. Gear Shift Lever
from “H” (High) or “L” (Low; KAF620R/S only) to “R” B. “H” (High) Position
(Reverse) or vice versa. Move the gear shift lever C. “L” (Low) Position (KAF620R/S only)
up or down as indicated on the label next to the shift D. “N” (Neutral) Position
lever. E. “R” (Reverse) Position
Refer to the “Reversing Gears” section in the “How
to Operate” chapter. NOTICE
Do not shift from “H” (High) or “L” (Low;
KAF620R/S only) to “R” (Reverse) and vice
versa when the vehicle is moving or with the
engine running above idling speed, or the
transmission could be damaged.
j
This vehicle is equipped with a sub-transmission
to allow maximum transmission efficiency. Use the
low gearing for maximum torque at low speeds, for
climbing hills, pulling a trailer, or keeping constant
low speeds. The high gearing raises the speed
range for ordinary off-highway use. Stop the vehicle
before moving the Hi-Lo shift lever.
NOTICE
Use of the high range for heavy loads, climb-
ing hills, and pulling a trailer can lead to pre-
mature wear of the torque converter belt and
pulleys. Use low range for these conditions.
Refer to the “Hi-Lo Shifting” section in the “How to A. 2WD-4WD Shift Lever
Operate” chapter. B. Stopper
C. “2WD” Position
2WD-4WD Shift Lever (KAF620R/S) D. “4WD” Position
This vehicle can be operated either in “2WD” or
“4WD”. Differential Shift Lever
The 2WD-4WD shift lever is located on the dash- This vehicle is equipped with a dual-mode rear dif-
board, to the right of the steering shaft. Move the ferential. The differential shift lever is located on the
2WD-4WD shift lever up or down while pulling the dashboard, to the left of the steering shaft. Move the
stopper as indicated on the label next to the left of shift lever up or down while pulling the stopper as in-
the lever. dicated on the label next to the shift lever.
Refer to the “2WD-4WD Shifting” section in the Refer to the “Shifting the Differential” section in the
“How to Operate” chapter. “How to Operate” chapter.
j
Parking Brake Lever
The parking brake lever is located at the left side
of the seat. Pull the lever up and to the rear to apply
the parking brake.
To release, push in and hold the knob on the end of
the lever and push the lever all the way down. Spring
pressure helps return the lever to the released posi-
tion.
Be sure to release the parking brake before driving
off. Failure to do so may result in poor performance
and premature wearing of the rear brakes and belt
converter system.
A. Differential Shift Lever
B. Stopper
C. Differential (Unlocked–Axle) Mode Position
(UN–LOCK)
D. Locked-Axle Mode Position (LOCK)
A. Parking Brake Lever

j
WARNING
If the vehicle should move after it is parked,
Seats
it might be damaged or cause injury. Be sure
There are front and rear seats on this vehi-
to apply the parking brake before leaving the
cle. It can be transformed from 2-passenger to
vehicle.
4-passenger by unfolding the rear seat.
2-passenger mode
j
4-passenger mode
Seat Belts
The vehicle is equipped with retractable lap-style
seat belts for all occupants - operator and passenger
for the front seat and two passengers for the rear
seat. Always wear the seat belts when operating and
riding in the vehicle
NOTE
○Converting the rear seat must be made in combi-
nation with cargo bed conversion. See the Con-
verting Rear Seat and Cargo Bed section in the
HOW TO OPERATE chapter.
A. Seat Belt
B. Buckle
C. Red Button
D. Latch Plate
j
WARNING
Not wearing a seat belt, or wearing one im-
Throttle Pedal
properly can result in serious injury or death
The throttle pedal is the right pedal on the floor
in the event of an accident. Make certain
board. Push the pedal down to increase engine
the operator and all passengers always wear
speed. Spring pressure returns the pedal to the rest
their seat belts properly.
position when released. Always check that the throt-
tle pedal returns normally before starting the engine.
WARNING In addition, there must be adequate throttle pedal
play and correct throttle stop position adjustment.
Operator and all passengers must be able to Refer to the “Maintenance and Adjustment” chapter
place both feet flat on the floorboards while for the throttle pedal adjustment procedure.
seated upright with their backs against the
seatbacks.
To wear the seat belt properly, follow this proce-
dure:
1. Place the belt across your lap as low on your
hips as possible taking care that the belt is not
twisted.
2. Push the latch plate into the buckle until it clicks.
3. Verify the belt retracts to a SNUG FIT.
WARNING
Too much seat belt slack could reduce its
protection effectiveness in an accident. Al-
ways verify that the belt is at a SNUG FIT.
A. Throttle Pedal
To unfasten the belt, press the red button in the
buckle.
j
Trailer Hitch Bracket
This vehicle is equipped with a bracket for a trailer
hitch. Trailer towing equipment is not supplied with
this vehicle.
To avoid injury and property damage, observe the
following precautions:
WARNING
Improper towing of a loaded trailer could
cause an accident resulting in serious injury
or death.
Never carry a passenger in a trailer. Never
load more than 50 kg (110 lb) tongue weight A. Trailer Hitch Bracket
on the towing bracket. Do not operate the
vehicle faster than 16 km/h (10 mph) when
towing. Remember that towing a trailer in-
creases braking distance. Do not tow more
than 545 kg (1 200 lb) trailer weight (trailer
plus cargo weight). Attach the trailer to the
trailer hitch bracket only; do not attach a
trailer to any other location.
j
Installing procedure for a winch
Winch Installation 1. You can see the bracket attached to a cross
-member.
This vehicle is equipped with a bracket for a winch
below the radiator. The winch is not supplied with
this vehicle.
To avoid injury and property damage, observe the
following precautions:
WARNING
Improper installation or operation of a winch
could cause an accident resulting in serious
injury or death. Do not install or operate a
winch without reading and understanding
the operator’s manual supplied with the
winch.
A. Winch Bracket
B. Bolt Holes
2. Follow a manual to be supplied by the winch

maker for installing the winch and other acces-
sory as necessary.
3. After installing the winch, be sure to re-install
the bumper and bumper cover.
HOW TO OPERATE 67
HOW TO OPERATE
j
Daily Checks
Check the following items each day before operation. The time required is minimal, and habitual performance
of these checks will help ensure safe, reliable operation.
If any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter,
see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating
condition.
WARNING
Failure to perform these checks before operation may result in serious damage or an accident. Al-
ways perform daily checks before operation.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas.
Inhaling carbon monoxide can cause serious brain injury or death.
Do not run the engine in enclosed areas. Operate only in a well-ventilated area.
Fuel .................................................. Enough fuel in tank, no leaks.

Engine oil ......................................... Oil level between “F” and “L” lines on the dipstick (when engine is cold),
no leaks.
Tires ................................................. Air pressure (when cold):
Front 69 kPa (0.7 kgf/cm², 10 psi)
Rear 167 kPa (1.7 kgf/cm², 24 psi)
Check for cuts, cracks, damage, or excessive wear.
Check for any imbedded stones or other foreign particles in tread.
Front Final Gear Case ..................... No oil leaks.
68 HOW TO OPERATE
Transmission Case Oil .................... Oil level between “H” and “L” lines on the dipstick, no leaks.
Coolant ............................................ Coolant level between level lines (when engine is cold), no leaks.
Throttle ............................................ Throttle pedal free play 5  10 mm (0.2  0.4 in.). Throttle pedal operates
j smoothly and returns to rest position when released.
Steering ........................................... Steering wheel free play 0  20 mm (0  0.8 in.). Action smooth without
excessive play, rough spots, or strange noises.
Brakes ............................................. Check for braking effectiveness (while test running). Brake pedal free
play 2  10 mm (0.1  0.4 in.). Brake fluid level between level lines, no
leaks. Parking brake lever travel: 8  12 clicks.
Electrical Equipment ........................ All lights and horn work. Check for dirt on or damage to lights.
HOW TO OPERATE 69
NOTE
Starting the Engine ○The vehicle is equipped with a starter lockout
switch. This switch prevents the electric starter j
from operating when the gear shift lever is in the
DANGER “H” (High) , “L” (Low; KAF620R/S only) or “R”
Exhaust gas contains carbon monoxide, a (Reverse) position.
colorless, odorless poisonous gas.
Inhaling carbon monoxide can cause serious
brain injury or death.
Do not run the engine in enclosed areas.
Operate only in a well-ventilated area.
• Wear
ger).
the seat belts (both operator and passen-
• Apply the parking brake.

• Put the gear
Put the shift lever in the “N” (Neutral) position.
• Turn the ignitionswitch
ignition key in the switch.
• tion to activate theswitch key to the “START” posi-
electric starter. Repeat until the
engine starts.
NOTICE
Do not operate the electric starter continu-
ously for more than 5 seconds, or the starter
may overheat and the battery power will drop
temporarily. Wait 15 seconds between each
operation of the starter to let it cool and for
battery power to recover.
70 HOW TO OPERATE
Jump Starting
• Remove
seat.
the cover under the left end of the front
j If your vehicle’s battery is “run down,” it should be

removed and charged. If this is not practical, a 12
volt booster battery and jumper cables may be used
to start the engine.
DANGER
Battery acid generates hydrogen gas which
is flammable and explosive under certain
conditions. It is present within a battery at
all times, even in a discharged condition.
Keep all flames and sparks (cigarettes) away
from the battery. Wear eye protection when
working with a battery. In the event of bat-
tery acid contact with skin, eyes, or clothing, A. Cover
wash the affected areas immediately with
water for at least 5 minutes. Seek medical • Connect a jumper cable from the positive (+) ter-
minal of the booster battery to the positive (+) ter-
attention.
minal of the vehicle battery.
Connecting Jumper Cables

• Make
“OFF”.
sure the ignition switch key is turned to
HOW TO OPERATE 71
DANGER
Batteries contain sulfuric acid that can cause
burns and produce hydrogen gas which is j
highly explosive. Do not make this last con-
nection at the fuel system or battery. Take
care not to touch the positive and negative
cables together, and do not lean over the bat-
tery when making this last connection. Do
not connect to a frozen battery. It could ex-
plode. Do not reverse polarity by connecting
positive (+) to negative (–), or a battery ex-
plosion and serious damage to the electrical
system may occur.
A. Vehicle Battery Positive (+) Terminal
B. From Booster Battery Positive (+) Terminal • Follow the standard engine starting procedure.
C. Unpainted Metal Surface
D. From Booster Battery Negative (–) Terminal
NOTICE
Do not operate the starter continuously for
• Connect another jumper cable from the negative
(–) terminal of the booster battery to an unpainted more than 5 seconds, or the starter overheat
metal surface on your vehicle. Do not use the and the battery power will drop temporarily.
negative (–) terminal of the battery. Wait 15 seconds between each operation of
the starter to let it cool and for the battery to
recover power.
• After the engine starts, disconnect the jumper ca-

bles. Disconnect the negative (–) cable from the
vehicle first.
• Reinstall the battery holder and the cover.
72 HOW TO OPERATE
Moving Off Braking

j
• Depress the brake pedal.
NOTE
• Put the gear shift lever into the “H” (High) or “L”
(Low; KAF620R/S only) position. ○When the throttle pedal is released completely and
• Release the parking brake. the engine speed drops near an idle, the vehicle
• Gradually increase engine speed by pressing on
the throttle pedal.
has no engine braking. This is caused by the ve-
hicle’s automatic transmission which releases the
engine at very low speed to prevent it from stalling.
NOTE Employ the brakes to control the vehicle’s speed.
○Practice starting and stopping (using the brakes)
until you are familiar with the controls. • Release the throttle pedal completely.
• Press on the brake pedal evenly and firmly.
WARNING
Carrying cargo or towing a trailer will in-
crease braking distances. Failure to allow
for increased braking distance may result in
accident and injury. Always allow more dis-
tance to stop when carrying cargo or towing
a trailer.
HOW TO OPERATE 73
Stopping the Engine Parking the Mule

j
• Release the throttle pedal completely.
WARNING
• Put
tion.
the gear shift lever into the “N” (Neutral) posi-
Operating or parking the vehicle near
• Apply the parking brake to help prevent the vehicle
from rolling.
flammable materials can cause a fire, and
can result in property damage or severe
• Turn the ignition switch key to the “OFF” position. personal injury.
Do not idle or park your vehicle in an
area where tall or dry vegetation, or other
flammable materials could come into con-
tact with the muffler or exhaust pipe.
WARNING
The engine and exhaust system get ex-
tremely hot during normal operation and can
cause serious burns.
Never touch a hot engine, exhaust pipe, or
muffler during operation or after stopping
the engine.
• Stop the vehicle on a level surface.

NOTICE
Avoid parking on steeply inclined surfaces.
• When the engine has stopped, apply the parking

brake to help prevent the vehicle from rolling.
74 HOW TO OPERATE
WARNING
Gasoline is extremely flammable and can be
j explosive under certain conditions, creating
the potential for serious burns. Make sure
the area is well ventilated and free from any
source of flame or sparks, including the pilot
light of any appliance.
WARNING
If the vehicle should move after it is parked,
it might be damaged or cause injury. Be sure
to apply the parking brake before leaving the
vehicle.
• Remove the ignition switch key to prevent unau-

thorized use.
• When parking inside a garage or other structure,
be sure the structure is well ventilated and the ve-
hicle is not close to any source of flame or sparks.
This includes any appliance with a pilot light.
HOW TO OPERATE 75
Shifting to High Range

Hi-Lo Shifting (KAF620R/S) • Stop the vehicle completely.
• Move thegear
Put the shift lever in neutral.
j
Shifting to Low Range • shift lever to the “H” (High) position.
• Stop the vehicle completely. NOTE

• For easy Hi-Lo shifting, put the gear shift lever in
neutral.
○Before shifting make certain that the vehicle is
completely stopped. The Hi-Lo shift lever cannot
• Move the shift lever to the “L” (Low) position. be shifted when the vehicle is in motion.
A. Gear Shift Lever

B. “H” (High) Position
C. “L” (Low) Position
D. “N” (Neutral) Position
E. “R” (Reverse) Position
76 HOW TO OPERATE
Reversing Gears 2WD-4WD Shifting (KAF620R/S)

j
• Release the throttle pedal, and stop the vehicle. • Pull the stopper under the 2WD-4WD shift lever
• When you want to operate the vehicle in reverse,
stop the vehicle completely, allowing the engine to
knob and while holding it against the knob, move
the shift lever to the all way down to “4WD”.
slow to idling speed, and move the gear shift lever
to the “R” (Reverse) position.
• To shift back into “2WD” position, pull and hold the
stopper, then move the shift lever all the way up to
“2WD”.
NOTICE
NOTE
Do not shift from “H” (High) or “L” (Low;
KAF620R/S only) to “R” (Reverse) and vice
○When the shift lever is moved from “2WD” to
“4WD”, the transmission shifts immediately.
versa when the vehicle is moving or with the When the shift lever is moved from “4WD” to
engine running above idling speed, or the “2WD”, the transmission may not shift all the way
transmission could be damaged. into “2WD” until the vehicle has rolled a short
distance.
HOW TO OPERATE 77
Shifting the Differential

j
NOTE
○Do not operate the differential shift lever if the ve-
hicle is moving faster than 8 km/h (5 mph).
Shifting to Locked-Axle Mode

• Pull the stopper under the differential shift lever
knob and while holding it against the knob, move
the shift lever all the way down (LOCK).
A. 2WD-4WD Shift Lever

B. Stopper
C. “2WD” position
D. “4WD” position
A. Differential Shift Lever

B. Stopper
C. Differential (Unlocked-Axle) Mode Position
(UN-LOCK)
D. Locked-Axle Mode Position (LOCK)
78 HOW TO OPERATE
Shifting to Differential (Unlocked-Axle) Mode NOTE
• Pull and hold the stopper, then move the shift lever ○When the shift lever is moved, the differential may
all the way up (UN-LOCK). not immediately lock or unlock until the vehicle has
j
rolled a short distance.
SAFE OPERATION 79
SAFE OPERATION
Safety is an attitude. Your common sense and good judgement are your best defenses against accident
and injury in everything you do. Your safety and the safety of others depends on you and your common
sense. Use good judgement in the operation of this or any other motor vehicle.
j
This vehicle is designed for an operator and one
passenger (for 2-person mode) or an operator and Unfamiliar Terrain
three passengers (for 4-person mode). Never carry
persons in the cargo bed. Refer to the “Loading Before driving in a new area be sure to check
Information” chapter before operating this vehicle. for hidden obstacles or hazards. Keep your speed
down until you know the area well. You must know
Novice operators should practice braking and turn- the terrain you intend to drive on and be familiar with
ing in an open, off-highway area away from other your machine and its handling characteristics. Use
vehicles and persons. The terrain should be flat and existing trails and stay away from hazardous areas
free of obstacles, with either a loose or hard dirt sur- such as steep, rocky slopes or swamps. Be cautious
face, but not a mixture of both. when visibility is limited, as you may not be able to
see obstacles in your path.
WARNING
Incorrect loading, improper installation or
use of accessories, or modification of your
vehicle may result in an unsafe operating
condition. Before operation, make sure that
the vehicle is not overloaded and that you
have followed the instructions in the “Load-
ing Information” chapter.
80 SAFE OPERATION
Driving in Reverse Driving in “4WD” (KAF620R/S)

Start the engine following the procedure in the “4WD” gives greater traction when you are climb-
“Starting the Engine” section. Before shifting into re- ing steep inclines, or driving on bumpy, sandy or
verse, stop the vehicle completely. Refer to the Gear snowy surfaces. It also helps break loose, with the
j Shift Lever in the “Shift Levers” section and “Revers- differential locked under certain circumstances, for
ing Gears” section. example, when the vehicle is stuck in the mud. If
Turn around and look behind you before backing maximum torque is needed in these situations, shift
up to be sure there are no obstacles or people in your into the low position with the shift lever. Refer to
way. Gradually open the throttle and begin backing the “Shift Levers” section and “2WD-4WD Shifting
up cautiously. (KAF620R/S)” “Shifting the Differential,” and “Hi-Lo
To stop while driving in reverse, close the throttle Shifting (KAF620R/S)” sections.
and gradually apply the brake. Avoid sudden appli-
cation of the brake.
NOTE
○Do not drive in “4WD” on paved surfaces, because
NOTICE it increases tire and drive train wear and makes the
steering feel tight.
Do not operate the gear shift lever to change
gears while driving the vehicle in reverse, or
the transmission may be damaged.
Remember:
Remember:
• Use “4WD” on steep inclines or loose surfaces, or
when stuck in the mud, with the differential locked
•Look behind you before backing up. if necessary.
•Open the throttle gradually. • For maximum torque shift into low range.
•To stop, gradually apply the brake. • Do not drive in “4WD” on paved surfaces.
SAFE OPERATION 81
Turning the Vehicle Hills

The vehicle will turn in a smaller radius with As with any motor vehicle, loading of the vehicle,
the differential unlocked (in differential mode). In and the surface and steepness of the hill are among
this mode, the rear wheels can turn at different the critical considerations in climbing, descending or
speeds allowing the vehicle to turn tighter and more traversing hills. Use extreme caution on hills. Keep j
smoothly. Even in this mode, however, avoid sharp in mind that loading changes a vehicle’s center of
turns to keep the vehicle from tipping. Reduce gravity and that the higher the center of gravity, the
vehicle speed before entering the turn and use the more likely the vehicle is to tip on uneven surfaces.
throttle to maintain an even speed through the turn. Slippery, loose, or bumpy surfaces on hills are es-
pecially hazardous. Some hills are just too steep to
WARNING climb. Always use common sense and practice good
In the differential mode, if either rear wheel judgement.
leaves the ground it will spin freely, and the
wheel on the ground will transmit very little
power. When a spinning wheel touches the
ground, it may grab abruptly, causing the op-
erator to lose control. Do not make sharp
turns, even in the differential mode, in order
to avoid loss of control or tipping.
Remember:
•Slow down before entering the turn.
•Maintain an even speed through the turn.
82 SAFE OPERATION
Remember:
Climbing Hills •Some hills are too steep. Use common sense.
Do not attempt to climb hills or steep inclines until

•Never drive past your limit of visibility. If you can’t
see what is on the other side of the crest of a hill,
you have mastered the controls and basic operating slow down until you can get a clear view.
j
maneuvers of this vehicle. Always go straight uphill •Don’t turn sideways to the hill.
and, if the incline is steep and/or the surface is loose,
use “4WD” with the differential locked for greater
•If you get stuck on a hill, roll slowly straight back
down, using the brake, with the gear shift lever
traction, and in low range for maximum torque. left in the “H” (High) or “L” (Low; KAF620R/S only)
Avoid hills with slippery sides that will cause you position.
to lose traction. Do not climb hills where you cannot
see far enough ahead. If you cannot see what is on
NOTE
the other side of the crest of a hill, slow down until ○When the throttle pedal is released completely and
you can get a clear view. Don’t apply power sud- the engine speed drops near an idle, the vehicle
denly while climbing, or the front wheels might rise has no engine braking. This is caused by the ve-
off the ground. If the vehicle does not have enough hicle’s automatic transmission which releases the
power to reach the top of the hill and stalls, allow the engine at very low speed to prevent it from stalling.
vehicle to roll slowly straight back down the hill con- Use the brakes to control the vehicle’s speed.
trolling its descent with the brakes. Leave the gear
shift lever in the “H” (High) or “L” (Low; KAF620R/S
only) position until you stop at the bottom of the hill.
WARNING
Riding sideways across a hill may cause the
vehicle to overturn, causing severe injury or
death. Do not turn sideways to the hill.
SAFE OPERATION 83
NOTE
Descending Hills ○When the throttle pedal is released completely and
the engine speed drops near an idle, the vehicle
Slow down or stop at the top of a hill so you can has no engine braking. This is caused by the ve-
pick a straight, safe path for descent to avoid any ob- hicle’s automatic transmission which releases the
stacles. Normally you should descend straight down engine at very low speed to prevent it from stalling.
a hill since driving at an angle could cause the vehi- j
Use the brakes to control the vehicle’s speed.
cle to lean to one side and possibly tip over. Proceed
slowly and cautiously. Apply the brake as necessary.
Be careful if the surface is loose because the tires
are more likely to skid and braking effectiveness will
be reduced.
Turning while descending a slope must be done
very carefully and gradually to avoid tipping the ve-
hicle over.
WARNING
Riding sideways across a hill may cause the
vehicle to overturn, causing severe injury or
death. Do not turn sideways to the hill.
Remember:
•Stop and look for obstacles before descending a
hill.
•Go straight downhill.
•Go slowly.
•If you must turn, do so carefully and gradually.
84 SAFE OPERATION
Traversing Hillsides Sliding and Skidding

When driving across the side of a hill, reduce vehi- Obviously, on slippery or loose surfaces, special
cle speed and exercise extreme caution to prevent care is required. Sliding any vehicle may be haz-
tipping or loss of control. Avoid hills with slippery ardous because the wheels may suddenly regain
j sides that will cause you to lose traction. Also avoid traction and cause the vehicle to tip or overturn.
traversing hillsides covered with rocks or other ob- Therefore, never drive “over your head” or when you
stacles which may cause you to lose your balance are unsure or unprepared for the surface.
or tip over. Often you can correct a skid by turning the wheels
When driving on soft terrain, steer slightly uphill to in the direction of the skid. Do not apply heavy brak-
keep the vehicle on a straight line across the hillside. ing force or accelerate when skidding, since this may
If the vehicle begins to tip, steer downhill if possible cause further loss of control.
to regain control. Use caution and maintain low speeds to avoid un-
controlled skidding on areas covered with clay, mud,
ice, or snow. Use “4WD” (KAF620R/S) and low
(KAF620R/S) range gearing efficiently. These con-
ditions are particularly hazardous when descending
a hill or making a turn. Remember that this vehicle
is not for use on public streets, roads, or highways.
Remember:
•Be especially careful on very slippery surfaces.
•Don’t drive on public streets, roads, or highways.
SAFE OPERATION 85
WARNING
Driving through Water Operating the vehicle in rivers or streams
where water is flowing quickly can cause the
Avoid driving through water whenever it is possi-
tires to lose traction and allow the vehicle
ble. When driving across shallow water, choose a
to be swept into the current. Never operate
location to enter and exit the water where the banks
are not too steep or slippery. Check before entering
the vehicle in fast-flowing water or in water j
deeper than the bottom edge of the axle
for rocks, holes or other obstacles which may cause
caps.
you to overturn or become stuck or submerged.
Observe the following rules for operating the vehi-
After prolonged exposure to water, the wheel bear-
cle in water.
ings may require lubrication or replacement.
Wash the vehicle in fresh water if it has been ex-
posed to salt water or operated in muddy conditions.
WARNING
Wet brakes provide greatly reduced effi-
ciency and could lead to an accident and
injury. After operation in water, always apply
the brakes long enough for friction to dry the
linings. Also, the brake that gets wet may
wear out faster. Check for brake wear more
frequently if the vehicle is used in water.
Remember:
A. Axle Cap •Avoid driving through water whenever possible.
•Don’t drive in deep and fast moving water.
•Dry out the brakes.
86 MAINTENANCE AND ADJUSTMENT
MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor-
dance with the Periodic Maintenance Chart to keep the Mule in good running condition. The initial mainte-
nance is vitally important and must not be neglected.
If you are in doubt as to any adjustment or vehicle operation, please ask your authorized Kawasaki dealer to
check the Mule.
Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect mainte-
j nance or improper adjustment done by the owner.
MAINTENANCE AND ADJUSTMENT 87
Periodic Maintenance Chart

In addition to the following items, always perform the Daily Checks listed in the HOW TO OPERATE chapter.
•
D
= Clean, adjust, lubricate, replace parts as necessary.
= Service to be performed by an authorized Kawasaki Dealer or someone equally competent.
* = Service more frequently when operated in mud, dust, or other harsh riding conditions.
= Emission Related
j
FREQUENCY
First Service Regular Service
Every 500
After 50 hrs. Every 250
hrs. or
or 1,000 km hrs. or 5,000
OPERATION 10,000 km
(600 miles) km (3,000
(6,000 miles)
of use miles) of use
of use
ENGINE
Converter drive belt-inspect* D
Converter drive belt deflection-inspect* D
Converter driven pulley shoe-inspect* D
Converter air cleaner element-clean* • •
Converter dust or water-drain* •
Fuel hoses or pipe and connections
D D
-inspect*
○ Air cleaner element-clean* • •
○ Air cleaner housing dust or water-drain* • •
FREQUENCY
Every 500
hrs. or
or 1,000 km hrs. or 5,000
OPERATION 10,000 km
(600 miles) km (3,000
(6,000 miles)
of use
j ○ Spark plug-clean and gap •
○ Valve clearance-inspect D D
Engine oil-change* 1 year • •
Oil filter-replace* • •
○ Throttle pedal play-inspect • •
○ Idle speed-adjust D D
Throttle link lever-inspect D D
Spark arrester-clean •
Radiator-clean* • •
Water hoses and connections-inspect* 1 year D D
Fuel hose-replace 5 years (D)
Coolant-change 2 years (D)
Evaporative emission control
○ system-inspect* • •
FREQUENCY
Every 500
hrs. or
or 1,000 km hrs. or 5,000
OPERATION 10,000 km
(600 miles) km (3,000
(6,000 miles)
of use
CHASSIS j
Steering-inspect • •
Steering and axle shaft joint dust
D D
boots-inspect
Brake pedal play-inspect* • •
Parking brake lever-inspect • •
Brake hose and pipe-inspect D D
Brake fluid level-inspect • •
Brake wear-inspect* D
Tire wear-inspect* • •
Brake light switch-inspect • •
Seat belt-inspect •
General lubrication-perform* D
Bolts, nuts, and fasteners tightness-inspect D D
Wheel nuts tightness-inspect • •
Front final gear case oil and transmission
case oil-change*
1 year • •
FREQUENCY
Every 500
hrs. or
or 1,000 km hrs. or 5,000
OPERATION 10,000 km
(600 miles) km (3,000
(6,000 miles)
of use
j Brake fluid-change 2 years (D)
Brake master cylinder cup and dust seal
2 years (D)
-replace
Brake wheel cylinder assembly -replace 2 years (D)
Brake hose-replace 4 years (D)
NOTICE
Engine Oil Racing the engine before the oil reaches ev-
ery part can cause engine damage.
In order for the engine to function properly, main-
tain the engine oil at the proper level, and change the
oil and oil filter in accordance with the Periodic Main- • Ifutes
the vehicle has just been used, wait several min-
for all the oil to drain down.
tenance Chart. Not only do dirt and metal particles
collect in the oil, but the oil itself loses its lubricative • Pull upthethevehicle
Park on level ground.
quality if used too long. • it dry, and insert the out
dipstick of the dipstick tube, wipe
dipstick till it bottoms into the j
tube securely.
WARNING
Vehicle operation with insufficient, deterio-
rated, or contaminated engine oil will cause
accelerated wear and may result in engine
seizure, accident, and injury. Check the oil
level before each use and change the oil and
filter according to the periodic maintenance
chart in the owner’s manual.
Oil Level Inspection

• Ifandtherunoil ithas just been changed, start the engine
for several minutes at idle speed. This
fills the oil filter with oil. Stop the engine, then wait
several minutes until the oil settles.
A. Dipstick
• Pull out the dipstick and check the oil level. The Oil and/or Oil Filter Change
oil level should be between the “F” (Full) and “L”
(Low) lines on the dipstick.
• Warm up the engine thoroughly and then stop the
engine.
NOTE
○In 4-person mode, first fold the rear seat and push
its assembly into the stored position, and then
raise the cargo bed and support it with the rod.
○In 2-person mode, raise the cargo bed and support
j it with the rod.
• Remove the oil filler cap.
A. Dipstick
B. “F” (Full) Line
C. “L” (Low) Line
• Reinsert
securely.
the dipstick until it bottoms into the tube
• Ifusing
the oil level is too high, remove the excess oil,
a syringe or other suitable device.
• and add level
If the oil is too low, unscrew the oil filler cap
the correct amount of oil. Use the same A. Oil Filler Cap
type and brand of oil that is already in the engine.
• Install the filler cap. • Place an oil pan beneath the engine.
• Remove the drain plug.
• Ifcartridge
the oil filter is to be changed, remove the oil filter
and replace it with a new one.
A. Drain Plug
• With the vehicle held level, let the oil drain com-
pletely. A. Oil Filter Cartridge
WARNING • Apply a thin film of oil to the gasket and screw the
cartridge in until the gasket touches the engine,
Engine oil is a toxic substance. Dispose of then turn it 3/4 turn.
used oil properly. Contact your local author-
ities for approved disposal methods or pos-
sible recycling.
Engine Oil
Grade: Kawasaki Performance 4-Stroke
ATV/UTV Oil*
Kawasaki Performance 4-Stroke
Semi-Synthetic Oil*
Kawasaki Performance 4-Stroke Full
Synthetic Oil*
j or other 4-stroke oils with API SG,
SH, SJ, SL, SM and JASO MA, MA1,
MA2 rating
Viscosity: SAE 10W-40
Capacity: 1.0 L (1.1 US qt)
A. Gasket
[when filter is not removed]
• Install the drain plug with its gasket. Tighten it to
the specified torque. 1.2 L (1.3 US qt)
Tightening Torque [when filter is removed]
Drain Plug: 32 N·m (3.3 kgf·m, 24 ft·lb) *Kawasaki Performance Oils and Lubricants have
been specifically engineered for your vehicle. Con-
NOTE sistent use of these products meets or exceeds war-
○Replace any damaged gaskets with new ones. ranty and service requirements and can help to ex-
tend the life of your Kawasaki.
• Fill the engine up to the “F” (Full) line on the dip-
stick with high quality engine oil as specified in the NOTE
table. ○Do not add any chemical additive to the oil. Oils
• Start the engine and check for oil leakage. fulfilling the above requirements are fully formu-
lated and provide adequate lubrication for the en-
gine.
Although 10W-40 engine oil is the recommended

oil for most conditions, the oil viscosity may need Front Final Gear Case Oil (KAF620R/S)
to be changed to accommodate atmospheric condi-
tions in your riding area. In order for the differential, pinion, and ring gears
to function properly, check the oil level and change
the oil in accordance with the Periodic Maintenance
Chart.
WARNING
j
Vehicle operation with insufficient, deterio-
rated, or contaminated oil causes acceler-
ated wear of the differential, pinion, and ring
gears and may result in seizure. Seizure can
lock the front and rear wheels and skid the
front and rear tires, with consequent loss
of control, accident, and injury. Check the
oil level and change the oil according to the
owner’s manual.

• Remove the front final gear case guard by remov-
ing the mounting bolts and nuts.
• With the vehicle level front-to-rear and side-to

-side, remove the filler cap from the front final
gear case.
A. Guard
B. Nuts (Front Side)
A. Front Final Gear Case

B. Filler Cap
NOTICE
Be careful not to allow any dirt or foreign ma-
terials to enter the gear case.
• Check the oil level. The oil level should come to

the bottom thread of the filler opening. If it is low,
add oil through the oil filler opening as necessary.
A. Bolts (Rear Side)

Oil Change
NOTE
○Before draining the oil, warm it up by running the
vehicle. Warm oil drains easily and picks up any
sediment.
• Remove the front final gear case guard.

• With the vehicle level, place an oil pan beneath the
gear case. j
• Remove the filler cap and drain plug.
WARNING
Gear case oil is a toxic substance. Dispose
A. Front Final Gear Case of used oil properly. Contact your local au-
B. Filler Opening thorities for approved disposal methods or
C. Bottom Thread possible recycling.
D. Drain Plug
WARNING
• Install
torque.
the filler cap and tighten it to the specified
Oil on tires can make them slippery which
can cause an accident and injury. When
Tightening Torque draining or filling the gear case, be careful
Filler Cap: 29 N·m (3.0 kgf·m, 21 ft·lb) that no oil gets on the tires or rims. Clean off
any oil that inadvertently gets on them with
soap and water.
NOTE
○Use the same type and brand of oil that is already • After the oil has completely drained out, install the
in the gear case. drain plug and gasket. If the gasket is damaged,
replace it with a new one.
Tightening Torque
Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)
• Fill the gear case up to the bottom thread of the

filler opening with a high quality oil as specified in
Transmission Case Oil
the table. In order for the transmission, differential, pinion,
Front Final Gear Case Oil and ring gears to function properly, check the oil level
and change the oil in accordance with the Periodic
0.4 L Maintenance Chart.
Oil Capacity
(0.4 US qt)
API GL-5 SAE140 or API GL-6 WARNING
j SAE90
Oil Type Vehicle operation with insufficient, deterio-
Hypoid gear oil for Limited Slip rated, or contaminated oil causes acceler-
Differentials ated wear of the transmission, differential,
pinion, and ring gears and may result in
• Install the filler cap and gear case guard. seizure. Seizure can lock the rear wheels
and skid the rear tires, with consequent loss
of control, accident, and injury. Check the
oil level and change the oil according to the
owner’s manual.

• Park the vehicle on level ground.
• Lift the cargo bed and support it with the rod.
• Unscrew the oil filler plug, wipe the dipstick dry,
and insert it into the filler hole but DO NOT
SCREW IT IN.
A. Transmission Case A. Oil Filler Plug and Dipstick

B. Oil Filler Plug B. Insert the dipstick into the filler hole but do not
screw it in.
C. “H” (High) Line
NOTICE D. “L” (Low) Line
Be careful not to allow any dirt or foreign ma-
terials to enter the transmission case. • Ifusing
the oil level is too high, remove the excess oil,
a syringe or other suitable device, through
the oil filler opening.
• Pull out the dipstick and check the oil level. The
oil level should be between the “H” (High) and “L” • Ifoil.the oil level is too low, add the correct amount of
(Low) lines on the dipstick.
• Install the filler plug.
NOTE
○Use the same type and brand of oil that is already
in the transmission case.
Oil Change WARNING
NOTE The exhaust system can get extremely hot
○Before draining the oil, warm it up by running the during normal operation and cause serious
burns. To avoid a serious burn, never touch
vehicle. Warm oil drains easily and picks up any
sediment. a hot muffler or exhaust pipe during oil drain-
ing.
• With the vehicle level, place an oil pan beneath the
transmission case.
• Remove the drain plug. • Lift the cargo bed and support it with the rod.
j • Remove the filler plug.
WARNING
Oil on tires can make them slippery which
can cause an accident and injury. When
draining or filling the transmission case, be
careful that no oil gets on the tires or rims.
Clean off any oil that inadvertently gets on
them with soap and water. Transmission
case oil is a toxic substance. Dispose of
used oil properly.
Contact your local authorities for approved
disposal methods or possible recycling.
A. Transmission Case
• After the oil has completely drained out, install the
drain plug with its gasket. Tighten it to the spec-
B. Drain Plug ified torque. If the gasket is damaged, replace it
with a new one.
• Fill the transmission case up to the “H” (High) line
on the dipstick with a high quality oil as specified
in the table.
Tightening Torque
Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb)
Transmission Case Oil

Oil Capacity KAF620R/S: 2.5 L (2.6 US qt) Cooling System
KAF620W: 2.2 L (2.3 US qt)
Oil Type API “GL-5” Hypoid gear oil WARNING
above 5°C (41°F) SAE 90 The cooling system can get extremely hot
below 5°C (41°F) SAE 80 during normal operation and cause serious
burns. Do not touch the radiator when it is
• Install the filler plug. hot, nor open the radiator cap. Hot coolant
inside will cause severe burns.
j
Radiator and Cooling Fan

Check and clean the radiator fins for obstruction by
insects or mud in accordance with the Periodic Main-
tenance Chart. In dusty areas, the radiator should
be cleaned more frequently than the recommended
interval.
WARNING
To avoid injury, keep your hands and cloth-
ing away from the fan blades at all times.
Coolant
Coolant absorbs excessive heat from the engine
and transfers it to the air at the radiator. If the coolant
level becomes low, the engine overheats and may
suffer damage. Check the coolant level each day
before operating the vehicle, and replenish coolant
if the level is low. Change the coolant in accordance
with the Periodic Maintenance Chart.
j NOTE
○A permanent type of antifreeze is installed in the
cooling system when shipped. It is colored green
and contains ethylene glycol. It is mixed at 50%
with water and has a freezing point of –35°C
A. Radiator (–31°F).
• Clean the radiator fins of any obstructions with a Coolant Level Inspection
stream of low-pressure water.
• Ifit insects or mud can not be completely removed, • Situate the vehicle on level ground.
should be cleaned by an authorized Kawasaki • Lift the front cargo hood up. Refer to the “Front
Cargo Compartment” section in the “General In-
dealer. formation” chapter.
NOTICE • Check the coolant level through the coolant level
gauge on the reserve tank. The coolant level
Using high-pressure water, as from a car should be between the “F” (Full) and “L” (Low)
wash facility, could damage the radiator fins marks.
and impair the radiator’s effectiveness.
NOTE
Do not obstruct or deflect airflow through
the radiator by installing unauthorized ac- ○Check the level when the engine is cold (room or
cessories in front of the radiator or behind atmospheric temperature).
the cooling fan. Interference with the ra-
diator airflow can lead to overheating and Coolant Capacity
consequent engine damage. 4.6 L (4.9 US qt)
NOTE
○In an emergency you can add water alone to the
coolant reserve tank, however it must be returned
to the correct mixture ratio by the addition of an-
tifreeze concentrate as soon as possible.
NOTICE
If coolant must be added often, or the reserve
tank completely runs dry, there is probably
j
leakage in the system. Have the cooling sys-
tem inspected by your authorized Kawasaki
dealer.
A. Reserve Tank Coolant Change

B. “F” (Full) Mark
C. “L” (Low) Mark
Have the coolant changed by an authorized
D. Cap Kawasaki dealer.
• Ifcapthefrom
amount of coolant is insufficient, unscrew the
the reserve tank and add coolant through
the filler opening to the “F” (Full) mark. Install the
cap.
Recommended Coolant Solution
Coolant Mixture Ratio:
Water 50%: Antifreeze 50% (1 : 1)
Recommended Antifreeze:
Permanent type antifreeze (ethylene glycol
plus corrosion and rust inhibitor chemicals for
aluminum engines and radiator).
Spark Plugs
The standard spark plug is shown in the table. The
spark plug should be taken out periodically in ac-
cordance with the Periodic Maintenance Chart for
cleaning, inspection, and resetting of the plug gap.
Maintenance
j If the plugs are oily or have carbon built up on
them, clean them. The plugs may also be cleaned
using a high flash-point solvent and a nonmetal
brush (nylon etc.). Measure the gap with a wire-type
thickness gauge, and adjust the gap if incorrect
by bending the outer electrode. If the insulator is
cracked, replace the plug. Use the standard plug.
Spark Plug
Standard Plug NGK BPR2ES
0.7  0.8 mm
Plug Gap
(0.028  0.032 in.)
Tightening Torque 25 N·m (2.5 kgf·m, 18 ft·lb)
Spark Plug Removal

• Lift the cargo bed to support it with the rod. Valve Clearance
• plugs. pull the spark plug caps from the spark
Carefully
Valve and valve seat wear decrease valve clear-
ance, upsetting valve timing.
NOTICE
If valve clearance is left unadjusted, wear will
eventually cause the valves to remain partly j
open; which lowers performance, burns the
valves and valve seats, and may cause seri-
ous engine damage.
Valve clearance for each valve should be checked

and adjusted in accordance with the Periodic Main-
tenance Chart.
Inspection and adjustment should be done by an
authorized Kawasaki dealer.
A. Spark Plug Caps Valve Clearance (EX & IN) : 0.25 mm (0.010 in.)
• Unscrew the spark plugs.
NOTE
○After installing the plugs, fit the plug caps securely
onto the spark plugs, and pull the caps tightly to
make sure that they are properly installed.
Engine Air Cleaner

A clogged engine air cleaner restricts the engine’s
air intake, increasing fuel consumption, reducing en-
gine power, and causing spark plug fouling.
WARNING
j A clogged air cleaner may allow dirt and
dust to enter the fuel injection system and
the throttle may stick resulting in a haz-
ardous operating condition. Clean the air
filter according to the periodic maintenance
chart; more often if the vehicle is used in
extremely dusty conditions. A. Air Cleaner Housing
B. Cap
C. Snaps
NOTICE • Pull the air cleaner element out of the housing.
A clogged air cleaner may allow dirt and dust • housinga clean,
Push lint-free towel into the air cleaner
to keep dirt or other foreign material from
to enter the engine causing excessive wear
and possible engine damage. entering.
The air filter element should be cleaned in accor- WARNING

dance with the Periodic Maintenance Chart. In dusty If dirt or dust is allowed to pass through into
areas, the elements should be cleaned more fre- the fuel injection system, the throttle may
quently than the recommended interval. stick or become inoperable resulting in a
Element Removal hazardous operating condition.
• Pull up the snaps and remove the air cleaner hous-
ing cap from the housing.
NOTICE • Clean the paper element by tapping it lightly to

loosen dust.
If dirt gets into the engine, excessive engine
wear and possible engine damage may oc- • Blow away the remaining dust by applying com-
pressed air from the inside to the outside (from the
cur.
clean side to the dirty side).
• Inspect the element material for damage. If any
part of the element is damaged, the element must
be replaced.
Dust and/or Water Inspection j
• Push open the drain hose on the bottom of the air
cleaner housing to expel dust and/or water accu-
mulated inside.
A. Paper Element
NOTE
○Element installation is performed in the reverse
order of removal.
○Install the cap with its drain facing downward.
Element Cleaning A. Drain Hose
• Remove the element (see Element Removal).
Evaporative Emission Control System Spark Arrester

This system routes fuel vapors from the fuel sys- This vehicle is equipped with a spark arrester ap-
tem into the running engine or stores the vapors in proved for off-highway use by the U.S. Forest Ser-
a canister when the engine is stopped. Although no vice. It must be properly maintained to ensure its
adjustments are required, a thorough visual inspec- efficiency. Clean the spark arrester in accordance
tion must be made at the intervals specified by the with the Periodic Maintenance Chart.
“Periodic Maintenance Chart”.
j NOTICE
Inspection
• Check that the hoses are securely connected. The spark arrester must be functioning prop-
• hoses. any kinked, deteriorated, or damaged
Replace erly to provide adequate fire protection.
Spark Arrester Cleaning
WARNING
The muffler can become extremely hot dur-
ing normal operation and cause severe
burns.
Since the engine must be running during this
procedure, wear heat-resistant gloves while
cleaning the spark arrester.
• Remove the drain plug from the muffler.

DANGER
Exhaust gas contains carbon monoxide, a
Inhaling carbon monoxide can cause serious
brain injury or death.
Do not run the engine in enclosed areas. Op-
erate only in a well-ventilated area.
• Stop the engine. j

• Install the drain plug.
A. Spark Arrester (inside the muffler)

B. Drain Plug

• Instartanthe
open area away from combustible materials,
engine with the gear shift lever in the "N"
(Neutral) position.
• Raise and lower engine speed while tapping on
the muffler with a rubber mallet until carbon parti-
cles are purged from the muffler.
Throttle Pedal
If the throttle pedal has excessive play due to ei-
ther cable stretch or misadjustment, it will cause a
delay in throttle response, especially at low engine
speed. Also, the throttle may not open fully. If the
throttle pedal has no play, the throttle may be hard
to control, and the idle speed may be erratic. Check
j the throttle pedal play periodically in accordance with
the Periodic Maintenance Chart, and adjust the play
if necessary.
Throttle Pedal Play Inspection
A. Throttle Pedal
• Put the gear shift lever in the “N” (Neutral) position. B. 5  10 mm (0.2  0.4 in.)
• Start the engine, and warm it up thoroughly.
• fore the engine
Measure the distance the throttle pedal moves be-
begins to pick up speed. Free play
Throttle Pedal Play Adjustment
should be 5  10 mm (0.2  0.4 in.). • Lift the cargo bed and support it with the rod.
• Stop the engine and check that the throttle pedal • at the endandofturn
Loosen the throttle cable mounting nuts
the throttle cable.
moves smoothly from full open to close, and the
throttle closes quickly and completely. • Slide the adjuster until the proper amount of throt-
tle pedal play is obtained.
• If the throttle pedal does not return properly, check
the throttle cable routing, pedal free play, and ca-
ble damage. Then lubricate the throttle cable.
A. Throttle Cable A. Cover

B. Mounting Nuts B. Bolt
• Loosen the locknut.

• Tighten the mounting nuts securely. • Screw in the throttle pedal stop bolt.
Throttle Pedal Stop Position Adjustment • Depress the throttle pedal until the pulley on the
main throttle valve touches to the stopper at the
The full throttle pedal stop position can be adjusted
fully opened position and hold it there.
to prevent pulling the throttle cable more than re-
quired.
• Remove the cover by unscrewing the bolt.
A. Pully (Fully Opened Position) A. Throttle Pedal

B. Stopper B. Locknut
C. Throttle Pedal Stop Bolt
• Turn the throttle pedal stop bolt until the bolt head
lightly touches the bottom of the throttle pedal.
• Tighten the locknut securely.
• smoothly. to check the throttle cable moves
Be sure
Idle Adjustment Fuel Pump Filter

Idle adjustment is controlled by the ECU and can- The fuel pump filter can become blocked caus-
not be adjusted. If the idle speed is unstable, have ing fuel pump damage if dirt/mud/debris or contam-
your dealer inspect the throttle body. inated fuel enters the fuel tank. The engine may
Specified Idle Speed: 950 ±50 rpm hesitate or lose power if the fuel pump filter be-
comes blocked. If you suspect that the fuel filter has
become blocked, have your authorized Kawasaki
High Altitude Use dealer inspect the fuel pump and fuel tank. j
High altitude adjustment is not required as the
ECU (electronic control unit) controls the air/fuel
mixture automatically.
Fuel Tank Vent Belt Drive Torque Converter

The fuel tank vent hoses must be routed as spec- The vehicle is equipped with a belt drive torque
ified. converter type automatic transmission. The belt,
The engine may stall or lose power if the fuel tank driven pulley shoes and drain cap should be
vent is plugged or if the vent hoses are pinched. checked in accordance with the Periodic Main-
Inspect the vent hoses before riding and whenever tenance Chart.
the engine seems to lose power. If the fuel tank is The belt and driven pulley shoes inspection should
j full but the engine feels as if it is running out of fuel, be done by an authorized Kawasaki dealer.
check the vent and vent hoses.
A. Belt Drive Torque Converter (inside)

A. Fuel Tank Vent Hoses B. Drain Cap
B. Check Valve
C. Fuel Tank Dust and/or Water Inspection
• Unscrew the clamp screw and remove the drain
cap on the bottom of the converter housing to ex-
pel dust and/or water accumulated inside.
Belt Drive Torque Converter Air Cleaner

A clogged belt drive torque converter air cleaner
may cause the torque converter to malfunction.
NOTICE
A clogged air cleaner may allow dirt and dust
to enter the belt drive torque converter caus- j
ing excessive wear of the inner parts and
loss of driving power.
The air cleaner elements must be cleaned in ac-

cordance with the Periodic Maintenance Chart. In
dusty areas, the elements should be cleaned more A. Air Cleaner Housing Cover
frequently than the recommended interval. The ele- B. Snaps
ments should be replaced if they are damaged.
Element Removal
• For the belt drive torque converter air cleaner, re-
lease the snaps and remove the air cleaner hous-
ing cover from the housing.
• Pull the air cleaner element out of the housing.
• housinga clean,
Push lint-free towel into the air cleaner
to keep dirt or other foreign material from
entering.
A. Urethane Foam Element

B. Holder
NOTICE • Inspect the element material for damage. If any
part of the element is damaged, the element must
If dirt gets into the belt drive torque con-
be replaced.
verter, excessive wear and loss of driving
power may result.
NOTE
○Element installation is performed in the reverse
j order of removal.
Element Cleaning
• Remove the element (see Element Removal).
• holder. the urethane foam element from the
Remove
• Clean the foam element in a bath of high flash

-point solvent using a soft bristle brush.
• Squeeze it dry in a clean towel. Do not wring the
element or blow it dry; the element can be dam-
aged.
• Inspect the foam element for damage. If it is torn,
punctured, or hardened, replace it.
NOTE
○Replace the foam element after cleaning it five
times or if it is damaged.
• Clean the holder by tapping it lightly to loosen dust.

• Blow away the remaining dust by applying com-
pressed air from the inside to the outside (from the
clean side to the dirty side).
Brakes • Ifthanthespecified
brake pedal has more or less free play
or the pedal action feels rough or
The vehicle is equipped with hydraulically acti- "catchy," have the brake system inspected imme-
vated drum brakes on all four wheels. diately by an authorized Kawasaki dealer.
Brake Pedal Brake Shoe Linings
Brake Pedal Free Play Inspection Brake Shoe Lining Wear Inspection
In accordance with the Periodic Maintenance In accordance with the Periodic Maintenance
Chart have the brake shoe linings checked for wear j
Chart, check the brake pedal free play.
by an authorized Kawasaki dealer.
•Depress the brake pedal lightly by hand.
There should be 2  10 mm (0.1  0.4 in.) of free
•play.
Brake Fluid
In accordance with the Periodic Maintenance
Chart, inspect the brake fluid level in the reservoir
and change the brake fluid. The brake fluid should
also be changed if it becomes contaminated with
dirt or water.
Fluid Requirement
Use heavy-duty brake fluid only from a fresh, un-
opened container marked DOT3.
A. Brake Pedal
B. 2  10 mm (0.1  0.4 in.)
WARNING
Over time, brake fluid can absorb moisture,
lowering its boiling point and reducing brake
effectiveness. Do not use fluid from a con-
tainer that has been left unsealed or that
has been open for a long time. Do not mix
two types and brands of fluid for use in the
brakes. Don’t leave the reservoir cap off for
j any length of time to avoid moisture con-
tamination of the fluid. Don’t add or change
brake fluid in the rain or during conditions
of blowing dust or debris.
NOTICE A. Inspection Hole
Brake fluid quickly ruins painted surfaces. • Ifcheck

the fluid level is lower than the lower level line,
for fluid leaks in the brake lines, and open
Wipe up any spilled fluid immediately.
the front cargo hood (see “Front Cargo Compart-
ment” section in the “General Information” chap-
Fluid Level Inspection ter) and fill the reservoir to the upper level line.
• With the vehicle on level ground, check through
the inspection hole in the dashboard that the fluid • Remove the rubber cover.
level in the reservoir is between the upper (marked
MAX) and lower (marked MIN) level lines.
WARNING
Mixing two types and brands of fluid for use
in the brake lowers the brake fluid boiling
point and could reduce brake effectiveness.
Change the fluid in the brake system com-
pletely if the fluid level is low but the type and
brand of the fluid already in the reservoir are
unknown.
j
• Apply the brake forcefully for a few seconds and
check for fluid leakage around the fittings.
WARNING
A. Cap Air in brake line can make the brake feel
mushy or soft. This may cause reduced
braking performance or brake failure and
result in an accident. If brake lever travel
is excessive or the brake feels mushy, have
an authorized Kawasaki dealer inspect it
immediately.
Fluid Change
Have the brake fluid changed by an authorized
Kawasaki dealer.
A. Brake Fluid Reservoir

B. Upper Level Line (MAX)
C. Lower Level Line (MIN)
Adjustment
Brake Light Switch • Adjustment is best performed by an authorized
Kawasaki dealer since the brake light switch is
When the brake pedal is depressed, the brake light hard to adjust.
goes on. The brake light switch should be inspected
in accordance with the Periodic Maintenance Chart. NOTICE
Inspection To avoid damaging the electrical connec-
• Turn the ignition switch to the “ON” position. tions inside the switch, be sure that the
j • Depress the brake pedal. The brake light should
go on after about 10 mm (0.4 in.) of pedal travel.
switch body does not turn during adjust-
ment.
A. Brake Pedal
B. 10 mm (0.4 in.)
• Ifadjust
it does not, check the bulb and, if necessary,
the brake light switch.
Parking Brake Lever

• After 8 to 12 clicks of lever travel, the vehicle
should not roll while parked.
The parking brake helps hold the vehicle from

rolling while parked.
Chart, check that the parking brake lever functions
properly.
Inspection j
• Pull the rubber boot up on the bottom.
A. 8  12 clicks
• If it does, adjust the parking brake lever.

Adjustment
• Loosen the locknut (upper nut) on the middle of
the parking brake lever, and turn the nut next to
the locknut until the brake lever will only move 8 
12 clicks upward.
B. Rubber Boot
• Pull the parking brake lever up and to the rear.

Steering Wheel
Chart, check the steering wheel for the specified
free play and smooth operation.
Free Play Inspection

j • Park the vehicle on level ground.
• Lightly turn the steering wheel left and right.
• There
play.
should be 0  20 mm (0  0.8 in.) of free
• Iforthere is excessive free play or strange noises,

the steering feels rough or "catchy," have
A. Locknut
B. Nut
the steering system checked by an authorized
Kawasaki dealer.
• Tighten the locknut securely.
• Reinstall the rubber boot making sure that the pro-
jections on its lower edge are completely pushed
into the holes in the bracket.
NOTE
○Be sure to hold the cable end with a wrench to
prevent the cable from twisting.
○If the brake lever can not be adjusted with the
nuts shown here, or if there is any doubt as to
the condition or braking effectiveness, have the
parking brake system inspected by an authorized
Kawasaki dealer.
A. 0  20 mm (0  0.8 in.)
Steering Position Adjustment

The steering wheel position can be adjusted to suit
• The steering wheel was continuously turned or
held to the full turn stops with torque applied by
the operator. driver. In this case the ECU works to protect the
• Loosen the upper and lower nuts on the steering
column bracket and move the steering wheel up
system from overheating by stopping the power
assisting. Stop turning the steering wheel and wait
or down. until the system temperature drops, and the power
steering recovers.
• Fuses in the harness may have blown. There are
several reasons that the fuses may blow. Refer to
the Fuse section in this chapter for details. j
• Battery voltage has dropped. Voltage drop can
happen when the engine starts; inspect the battery
voltage.
• Cable harness or connectors may have been dis-
connected. See an authorized dealer for service.
NOTE
○If the steering becomes irregular or unusual for
any reason other than above, have an authorized
dealer check the steering and relevant compo-
nents immediately. In some cases the power
A. Steering Column Bracket
steering’s neutral position can be affected by an
B. Nuts
accident or bump.
• Tighten the bolts and nuts.
Power Steering System
Steering may become more difficult than usual for
the following reasons:
NOTE
Wheels ○Tires are an important part of the suspension of
the vehicle. Tire construction characteristics and
Rims tire inflation pressure can greatly influence vehicle
handling. Kawasaki recommends that you always
The rims are a drop-center, tubeless tire design.
replace tires with standard replacement tires as
Take care not to damage the sealing surfaces of the
shown above. It is also very important to have
tire or rim when removing or installing tires. Note that
tires of the same type and size on all axles, and
the rims, like automotive rims, are not symmetrical.
j at the same inflation pressure, on each axle.
All wheels must be installed so that the valve stems
are on the outside of the vehicle. ○Installation of non-standard tires, or use of differ-
ent tires on one axle, can change or impair the
Wheel Nuts handling of the vehicle.
Check for wheel nut tightness in accordance with ○Installation of tubeless tires on rims requires com-
the Periodic Maintenance Chart. pressed air and is normally recommended as a
dealer service operation. Nevertheless, a tube
Tightening Torque: 110 N·m (11.2 kgf·m, 81.1 ft·lb) can be inserted into the tire by the operator as an
emergency repair.
Tires
The front and rear tires are knobby tubeless tires. Maximum Tire Air Pressure for Seating Beads
When replacing tires, check the valve stems and 250 kPa
Front and Rear
cores for damage. Take care not to damage the tire (2.5 kgf/cm², 36 psi)
sealing surfaces of the rims.
Standard Tires (front and rear): Payload and Tire Pressure
23 × 11.00-10 DURO DI-K968 Failure to maintain proper inflation pressures or
observe payload limits for your tires can change or
impair handling and performance of the vehicle. The
Tire Air Pressure (when cold)
maximum recommended load carrying capacity is
69 kPa 603 kg (1 330 lb).
Front
(0.7 kgf/cm², 10 psi) Use a tire pressure gauge to accurately set tire
167 kPa pressure.
Rear
(1.7 kgf/cm², 24 psi)
WARNING Minimum Tread Depth: 3 mm (0.12 in.)

Operating with unequally or improperly pres-
surized tires can adversely affect steering or • Visually inspect the tire for cracks and cuts, replac-
ing the tire in case of bad damage. Swelling or
handling. Inflate both front tires to the same
high spots indicate internal damage, requiring tire
pressure and both rear tires to the same
replacement.
pressure.
• Remove any imbedded stones or other foreign
particles from the tread.
Tire Wear, Damage
As tire tread wears down, tires become more sus- j
ceptible to puncture and failure.
• In accordance with the Periodic Maintenance
Chart, measure the depth of the tread with a
depth gauge, and replace any tire that has worn
down to the minimum allowable tread depth.
A. Tire Depth Gauge

Joint Boots
Chart, inspect the joint boots on the front axles, tie
rod ends, steering knuckles, and rear axle shafts for
cracks, holes, damage or deterioration. If there is
any one of them, have the joint boot replaced by an
authorized Kawasaki dealer.
j
A. Rear Axle
B. Joint Boot
A. Steering Knuckle
B. Tie Rod
C. Front Axle
D. Joint Boots
Suspension
Rear Shock Absorber Spring Force Adjustment

The spring adjusting sleeves on the rear shock ab-
sorbers have 5 positions so that the springs can be
adjusted for different riding and loading conditions.
A. Adjusting Sleeve (Turn here with a hook wrench)

If the spring action feels too soft or too stiff, have
the sleeves adjusted by an authorized Kawasaki
dealer in accordance with the following table.
• Turn the adjusting sleeves on the shock absorbers
to the desired position.
A. Shock Absorber
B. Adjusting Sleeve
Spring Action
Posi- Spring Sur- Seat Belts
Setting Load Speed
tion Force face
1 Weak Soft Light Good Low Chart, check that each seat belt functions properly.
2 ↑ ↑ ↑ ↑ ↑ Push the latch plate into the buckle until it clicks.
The latch plate must slide smoothly into the buckle.
3 | | | | |
The click sound indicates it is securely latched. Pull
4 ↓ ↓ ↓ ↓ ↓ the belt vigorously to make sure the retractor locks
j the seat belt.
5 Strong Hard Heavy Bad High
WARNING
Improper shock absorber adjustment can
cause poor handling and loss of stability,
which could lead to an accident.
Always adjust the shock absorbers on the
left and right side to the same setting.
A. Seat Belt
B. Buckle
C. Red Button
Push the red button in the buckle to make sure the

latch plate is released freely and the belt is wound Cargo Bed Latches
into the retractor freely. Also check the belt web-
bing for wear, cuts or damage. If any irregularities Depending on the cargo loading and/or passenger
are found, have the seat belt system checked or re- riding conditions, latch lever compression needs to
placed by an authorized Kawasaki dealer. be adjusted.
Release the fitting bolts and adjust the position of
the latch assembly so that the latch lever will be se-
cured without rattling and tighten the bolts.
j
A. Retractor
B. Seat Belt
C. Latch Plate
A. Latch Assembly
B. Latch Lever
C. Fitting Bolts
NOTE
○Adjustment should be made for both sides.
Headlight Beam
The headlight beams can be adjusted vertically.
• Remove the holder.
A. Adjusting Screws
A. Holder
• Turn the adjusting screw on each headlight rim in

or out to adjust the headlight vertically.
Battery
The battery is located under the left end of the front
seat.
DANGER
Battery contains sulfuric acid and produces
hydrogen gas. Sulfuric acid can cause burns
j
and hydrogen gas can cause an explosion.
Read and heed the battery safety label.
Battery Removal
• Remove the cover under the front seat left end. A. Holder
B. (+) Terminal
C. (–) Terminal
• Disconnect the cables from the battery, first from

the (–) terminal and then the (+) terminal.
NOTE
○There is no need to separate the smaller cables
clamped with the main battery cables.
• Take the battery out.

• and water.
Clean the battery using a solution of baking soda
Be sure that the lead connections are
clean.
• Perform a visual inspection. Inspect for defective
or cracked case and cover, and loose or damaged
A. Cover
terminal posts or cables. Replace battery and/or
• Remove the battery holder. cables immediately if any damage is found.
Battery Installation
• Check that the rubber dampers on the battery
holder and the floor board are properly in place.
• Put the battery in place on the rubber damper.
• Connect the three positive cables to the (+) termi-
nal, and then connect the negative cable to the (–)
terminal.
NOTE
j ○Be sure to reconnect any other cables.
• Put a light coat of grease on the terminals to pre-
vent corrosion.
• Run the breather hoses into the holes of the floor-
board until the white painted mark position.
• Be sure that the breather hose ends are approx.
25 mm (0.98 in.) from bottom surface of the floor-
A. Breather Hoses
B. White Painted Mark
C. Slits
board.
• Be sure that the slit of each breather hose faces
up.
• Reinstall the battery cover and holder.
WARNING
Loose battery cables can create sparks
which can cause a fire or explosion resulting
in injury or death.
Make sure the battery terminal screws are
tightened securely and the covers are in-
stalled over the terminals.
Battery Characteristics
The battery installed in this vehicle is a sealed
type, and the sealing strip should not be removed
at any time after the specified electrolyte has been
installed in the battery for initial service. It is not nec- Current Drain
essary to check the battery electrolyte level or add
Days from 100% Days from 100%
distilled water. Discharg-
Charged to 50% Charged to 100%
However, in order to maximize battery life and en- ing Ampere
Discharged Discharged
sure that it will provide the power needed to start
your vehicle you must properly maintain the battery’s 7 mA 60 Days 119 Days
charge. When used regularly, the charging system 10 mA 42 Days 83 Days
in your vehicle helps keep the battery fully charged.
If your vehicle is only used occasionally or for short 15 mA 28 Days 56 Days
periods of time, the battery is more likely to dis- 20 mA 21 Days 42 Days
j
charge.
Due to their internal composition, batteries contin- 30 mA 14 Days 28 Days
ually self discharge. The discharge rate depends
In extremely cold weather the fluid in an inade-
on the type of battery and ambient temperature. As
quately charged battery can easily freeze, which
temperatures rise, so does the discharge rate. Ev-
can crack the case and buckle the plates. A fully
ery 15°C (59°F) doubles the rate.
charged battery can withstand sub-freezing temper-
Electrical accessories, such as digital clocks and
atures with no damage.
computer memory, also draw current from the bat-
tery even when the key is switched off. Combine Battery Sulfation
such “key-off” draws with hot temperature, and a A common cause of battery failure is sulfation.
battery can go from fully charged to completely dis- Sulfation occurs when the battery is left in a dis-
charged in a matter of days. charged condition for an extended time. Sulfate is a
Self-discharge normal by product of the chemical reactions within a
battery. But when continuous discharge allows the
Approx. Number of Days From sulfate to crystallize in the cells, the battery plates
100% Charged to 100% discharged become permanently damaged and will not hold a
Temperature
Lead-Antimony Lead-Calcium charge. Battery failure due to sulfation is not war-
Battery Battery rantable.
40°C (104°F) 100 Days 300 Days
25°C (77°F) 200 Days 600 Days
0°C (32°F) 550 Days 950 Days
Battery Maintenance For more details, ask your Kawasaki dealer.
It is the owner’s responsibility to keep the battery
Battery Charging
fully charged. Failure to do so can lead to battery
failure and leave you stranded. •Remove the battery from the vehicle (see Battery
Removal).
If you are riding your vehicle infrequently, inspect
the battery voltage weekly using a voltmeter. If •Attach the leads from the charger and charge the
battery at a rate (amperage × hours) that is indi-
it drops below 12.6 volts, the battery should be
cated on the battery. If it is not possible to read
charged using an appropriate charger (check with
the rate, charge the battery at an amperage that
your kawasaki dealer or visit by kawasaki.com). If
j is about 1/10th of the battery capacity.
you will not be using your vehicle for longer than
two weeks, the battery should be charged using an •The charger will keep the battery fully charged un-
til you are ready to reinstall the battery in the vehi-
appropriate charger. Do not use an automotive-type
cle (see Battery Installation).
quick charger that may overcharge the battery and
damage it. NOTICE
NOTE Never remove the sealing strip, or the battery
○Leaving the battery connected causes the electri- can be damaged.
cal components to make the battery discharged, Do not install a conventional battery in this
resulting the over discharge of the battery. In this vehicle, or the electrical system cannot work
case, the repair or replacement of the battery is properly.
not included in the warranty. If you do not drive for
four weeks or more, disconnect the battery from
Make East Penn Manufacturing
the vehicle.
Type 8U1L
Kawasaki-recommended chargers are:
Battery Mate 150-9 NOTE
OptiMate 4
Yuasa MB-2040/2060 ○If you charge the sealed battery, never fail to ob-
serve the instructions shown on the label on the
Christie C10122S
battery and charger.
If the above chargers are not available, use equiv-
alent one.
WARNING
Battery posts, terminals and related acces-
Fuse
sories contain lead and lead compounds,
There are eight fuses in the fuse box under the
chemicals known to the State of California to
seat. If the electrical systems do not function, in-
cause cancer and reproductive harm. Wash
spect the fuse. Before replacing a fuse, check the
hands after handling.
wiring harness and electrical equipment for bare
wires or other possible causes.
NOTICE j
Do not use a fuse of a higher capacity than
the specified fuse rating, or damage to the
electrical system could result. Refer to the
Fuse Location label on the other side fuse
case lid.
A. Fuse Box
B. Front Seat
Power Steering System
There are 40 A and 7.5 A fuses for the power steer-
ing system under the front seat.
A. 40 A Fuse
B. Bolted Lead
C. Spare Fuse
A. 40 A Fuse (Cover removed.)

B. 7.5 A Fuse WARNING
The electrical system can produce painful
If the fuse is blown, steering becomes heavy. Re-
electrical shocks. When replacing the 40 A
place the blown fuse with a fuse of the same specific
fuse, first remove the cables from the battery
amperage and type. If a replaced fuse blows again,
terminals to avoid electric shock.
there can be trouble with the ECU or harness/con-
nectors. See an authorized dealer for inspection.
• You can check the 40 A fuse if it is blown at the
top of the fuse.
When replacing the fuse, release the bolted leads
first.
NOTE
Breaker ○When you touch the cooling fan, be sure to discon-
nect the (–) cable of the battery, since the cooling
The breaker for the radiator fan is located under fan can turn automatically even with the ignition
the seat near the fuse box. If the fan does not switch off.
function, inspect the breaker. In order to reset the
breaker, push the button at the side of the breaker
case. Before resetting, however, check that the radi-
ator fan is free from mud or other obstacle as well as
the wiring harness and electrical equipment for bare j
wires or other possible causes.
A. Breaker
B. Reset Button
C. Fuse Box
General Lubrication Cleaning

General Precautions
Chart, have the general lubrication performed by an
authorized Kawasaki dealer or perform it referring Frequent and proper care of your vehicle will
to the Service Manual for this vehicle. enhance its appearance, optimize overall perfor-
mance, and extend its useful life. Covering your
vehicle with a high quality, breathable vehicle cover
j will help protect its finish from harmful UV rays,
pollutants, and reduce the amount of dust reaching
its surfaces.
WARNING
Build-up of debris or flammable material in
and around the vehicle chassis, engine, and
exhaust can cause mechanical problems
and increase the risk of fire. When operating
the vehicle in conditions that allow debris or
flammable material to collect in and around
the vehicle, inspect the engine, electrical
component and exhaust areas frequently.
If debris or flammable materials have col-
lected, park the vehicle outside and stop
the engine. Allow the engine to cool, then
remove any collected debris. Do not park
or store the vehicle in an enclosed space
prior to inspecting for build-up of debris or
flammable materials.
• Be sure the engine and exhaust are cool before

washing.
• When washing the vehicle, always use a mild neu-

tral detergent and water.
Radiator
Clean off any obstructions with a stream of low
• Avoid applying all harsh chemicals, solvents,
degreaser, oil remover, electrical contact cleaner,
-pressure water.
and household cleaning products such as ammo- NOTICE

nia-based window cleaners. They will damage Using high-pressure water, as from a car
or deteriorate painted parts, plastic parts, rubber wash facility, could damage the radiator fins
parts and other synthetic parts including covers and impair the radiator’s effectiveness. Do
and LED headlight lens. not obstruct or deflect airflow through the j
• Avoid applying degreaser to seals, brake pads,
and tires.
radiator by installing unauthorized acces-
sories in front of the radiator or behind the
• Gasoline, brake fluid, and coolant will damage the
finish of painted and plastic surfaces: wash them
cooling fan. Interference with the radiator
airflow can lead to overheating and conse-
off immediately. quent engine damage.
• Avoid wire brushes, steel wool, and all other abra-
sive pads or brushes.
• Take care when washing the headlight lens and
other plastic parts as they can easily be scratched.
Matte Paint Parts
• When washing the vehicle, always use a mild neu-
tral detergent and water, or cleaners for matte
NOTE paint.
○After driving in an area where the roads are salted • The matte paint effect may be lost when the paint
or near the ocean, immediately wash your vehicle is excessively rubbed.
with cold water. Do not use warm water as it ac-
celerates the chemical reaction of the salt. After
• If any doubt, consult an authorized Kawasaki
dealer.
drying, apply a corrosion protection spray on all
metal and chrome surfaces to prevent corrosion. Plastic Parts
○Condensation may form on the inside of the head- After washing, use a soft cloth to gently dry plastic
parts. When dry, treat the headlight lens and other
light lens after riding in the rain, washing the ve-
hicle or humid weather. To remove the moisture, nonpainted plastic parts with an approved plastic
start the engine and turn on the headlight. Gradu- cleaner/polisher product.
ally the condensation on the inside of the lens will
clear off.
NOTICE The sidewalls of tires and other rubber compo-
nents should be treated with a rubber protectant to
Plastic parts may deteriorate and break if
help prolong their useful life.
they come in contact with chemical sub-
stances or household cleaning products Where to be Careful
such as gasoline, brake fluid, window clean- Avoid spraying water with any great force near the
ers, thread-locking agents, or other harsh following places.
chemicals. If a plastic part comes in contact
with any harsh chemical substance, wash it • Front and rear brakes - if water gets into the brake
drums, they will not work effectively until they have
j off immediately with water and a mild neu- dried out.
tral detergent, and then inspect for damage.
Avoid using abrasive pads or brushes to • Under the rear seat - if water gets into the ignition
coils or into the spark plug caps, it can ground out
clean plastic parts, as they will damage the the spark. When this happens the vehicle will not
part’s finish. operate properly and the affected parts must be
wiped dry.
Chrome and Aluminum • Power Steering System - if water gets into the ac-
tuator or is sprayed over the ECU, they may cause
Chrome and uncoated aluminum parts can be
treated with a chrome/aluminum polish. Coated malfunction.
aluminum should be washed with a mild neutral de-
tergent and finished with a spray polish. Aluminum NOTICE
wheels, both painted and unpainted can be cleaned Coin operated, high pressure spray wash-
with special non-acid based wheel spray cleaners. ers are not recommended. Water may be
Leather, Vinyl, and Rubber forced into bearings and other components
If your vehicle has leather accessories, special causing eventual failure from rust and cor-
care must be taken. Use a leather cleaner/treatment rosion. Some soaps are highly alkaline and
to clean and care for leather accessories. Washing may leave a residue or cause spotting.
leather parts with detergent and water will damage
them, shortening their life. NOTE
Vinyl parts should be washed with the rest of the
vehicle, then treated with a vinyl treatment.
○Abrasive cleanser or high pressure washer will
damage the surface finish on the bodywork.
Washing Your Vehicle

Bolt and Nut Tightening
•Before washing, precautions must be taken to
keep water off the following parts.
Muffler rear opening - cover with a plastic bag. In accordance with the Periodic Maintenance
Ignition switch - cover the keyhole with tape. Chart, have the tightness of the bolts, nuts, and fas-
teners checked by an authorized Kawasaki dealer.
•Rinse your vehicle with cold water from a garden
hose to remove any loose dirt.
•Mix a mild neutral detergent (designed for motor-
cycles or automobiles) and water in a bucket. Use j
a soft cloth or sponge to wash your vehicle.
•After washing, rinse your vehicle thoroughly with
clean water to remove any residue (residue from
the detergent can damage parts of your vehicle).
•Remove the plastic bag and tape.
•Use a soft cloth to dry your vehicle. As you dry,
inspect your vehicle for chips and scratches. Do
not let the water air dry as this can damage the
painted surfaces.
•Carefully ride your vehicle at a slow speed and
apply the brakes several times. This helps dry
the brakes and restores them to normal operating
performance.
142 STORAGE
STORAGE
Preparation for Storage: NOTE
• Clean the entire vehicle thoroughly. ○As an alternative to draining the fuel system, a fuel
• Run the engine for about five minutes to warm the
oil, shut it off and drain the engine oil.
stabilizer, such as STA-BIL, may be used. Follow
the manufacturer’s instructions for use.
WARNING
WARNING
Engine oil is a toxic substance. Dispose of
used oil properly. Contact your local author- Fuel stabilizers may contain poisonous sub-
ities for approved disposal methods or pos- stances. Heed the manufacturer’s warnings
j for use.
sible recycling.
• Put in fresh engine oil. • Remove the spark plugs and spray fogging oil,
such as Kawasaki K-Kare Fogging Oil (part num-
• Empty the fuel from the fuel tank. ber K61030-002), directly into each cylinder. Turn
the engine over several times with the ignition
WARNING switch key to coat the cylinder walls. Install the
Gasoline is extremely flammable and can be spark plugs.
explosive under certain conditions. Do not
smoke. Turn the ignition switch “OFF”. Make WARNING
sure the area is well ventilated and free from An air/oil mist may be forcibly ejected from
any source of flame or sparks; this includes the spark plug holes and could get into your
any appliance with a pilot light. eyes. Do not lean over the engine when per-
forming this procedure. If you do get oil in
your eyes, wash them immediately with lib-
WARNING eral amounts of clean, fresh water and con-
Gasoline is a toxic substance. Dispose of sult a physician as soon as possible.
fuel properly. Contact your local authorities
for approved disposal methods.
• Put boards under the front and rear wheels to keep
dampness away from the tire rubber.
STORAGE 143
• Spray oil on all unpainted metal surfaces to pre-

vent rusting. Avoid getting oil on rubber parts or in
Removal from Storage:
the brakes.
• Lubricate all the cables as indicated in the General
Lubrication section. DANGER
• Remove the battery, and store it where it will not
be exposed to direct sunlight, moisture, or freezing
Exhaust gas contains carbon monoxide, a
temperatures. During storage it should be given a Inhaling carbon monoxide can cause serious
slow charge (one ampere or less) about once a brain injury or death.
month. Do not run the engine in enclosed areas. Op-
erate only in a well-ventilated area.
NOTICE
• Remove the plastic bags from the exhaust pipe j
Keep the battery well charged during cold
weather so that the electrolyte does not and air cleaner intake.
freeze and crack open the battery. The more • Clean the terminals of the battery, charge the bat-
tery if necessary, and install it in the vehicle.
discharged a battery becomes, the more
easily it freezes. • Make sure the spark plugs are tight.
Never remove the sealing strip, or the battery • Check all
Fill the fuel tank with fuel.
can be damaged. • section. the points listed in the “Daily Checks”
• Tie a plastic bag over the exhaust pipe and air • Lubricate
section.
as indicated in the “General Lubrication”
cleaner intake (rear ROPS top) to prevent mois-
ture or small animals from entering.
• Put a cover over the vehicle to keep dust and dirt
from collecting on it.
144 TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Starter Motor Won’t Turn • Coolant deteriorated
• Fuse failed (be sure to check for cause of failure) • Engine oil lowbreaker functioned
Cooling fan
• Battery cables do not make good electrical contact
with battery terminals
•
No Power
• Battery discharged
•Engine overheated
Engine Cranks, But Won’t Start •Too much idling or low speed running (not
• No fuel in tank enough air flow)
• Air filterinclogged
Water fuel •Overloaded
• Engine flooded or intake blocked •Wrong spark plug
• Fuel tank vent clogged •Radiator clogged
• Spark plug wire not on spark plug •Coolant level too low
j • Spark plug dirty •Coolant deteriorated
• •Cooling fan breaker functioned
Engine Stops •Engine oil low
• No fuel in tank •Compression leakage
• Air filterinclogged
Water fuel •Valve clearance insufficient
• Fuel tank vent clogged

or intake blocked •Air filter clogged or intake blocked
• Engine overheated •Spark plug dirty or worm
• Too much idling or low speed •Engine oil incorrect
• enough air flow) running (not •Water in fuel

Power Steering Won’t Work
• Overloaded • ECU functioned to prevent overheating.
• Wrong spark plug • Batteryfailed
Fuse
• Coolant level
Radiator clogged • Cable harness/connectors
discharged
• too low • disconnected
YOUR WARRANTY/OWNER SATISFACTION 145
YOUR WARRANTY/OWNER SATISFACTION

Welcome to the Kawasaki family!
Congratulations on buying your Kawasaki vehicle. You’ve chosen a great, high-quality product with state-of-the
-art features and built to Kawasaki’s high standards. Your satisfaction is important to your authorized Kawasaki
dealer and to Kawasaki Motors Corp., U.S.A. Here is some important information regarding your vehicle’s lim-
ited warranty.
Frequently Asked Questions
What is a Limited Warranty?
The most important thing to know about your warranty is that it protects you from manufacturing defects in
material or workmanship during the warranty period. You can find the warranty period in the Kawasaki Limited
Warranty Certificate your Kawasaki dealer provided to you at the time of sale. The warranty does not cover the
cost of regularly-scheduled maintenance. The warranty also does not apply to the normal wear of items such
as tires, brake pads, transmission drive belts, chains, sprockets, etc.
What is the Kawasaki Protection Plus?
Much of the warranty coverage offered by the limited warranty can be extended by purchasing the Kawasaki
Protection Plus (KPP). See your Kawasaki dealer or go to Kawasaki.com for more information if you don’t
already have the KPP.
What Am I Responsible For?
You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner’s
manual.
You are responsible for notifying your dealer immediately if there is a problem, and you, as the owner, will need
to authorize the dealer to inspect the unit.
146 YOUR WARRANTY/OWNER SATISFACTION
You will be responsible for paying for routine maintenance, including the first scheduled service. You can have
the required servicing done by your Kawasaki dealer (recommended) or an equally-qualified service facility.
You can also do your own maintenance work if you have the proper tools, service references, and mechanical
skills. However, if a failure is found to be caused by improper servicing, it would not be covered by the limited
warranty.
You may purchase a Kawasaki Service Manual and any necessary special tools directly from your Kawasaki
dealer.
You will be responsible for paying for repairs needed because of an accident, to replace worn parts such as
tires, chains, brakes, and for repairs needed because of a lack of maintenance, misuse or racing.
Whether you do it yourself or take your vehicle to a Kawasaki dealer, be sure to record your service in the
Maintenance Record section of this Owner’s Manual. Keep all receipts for the service and/or items necessary
to perform the maintenance so that in the event of a failure you can document the service history.
What Are The Dealership’s Responsibilities?
Your Kawasaki dealer offers a wide range of services, parts, accessories, and information on your product and
on Kawasaki.
Each dealer is independently owned and operated and is responsible for the dealership’s operations, its repair,
warranty, and service work, and its personnel.
Your dealer is responsible for completing the set up and pre-delivery service of your new Kawasaki vehicle. The
dealership should also explain its operation, maintenance, and warranty provisions so you understand them at
the time of purchase or at any other time you have questions.
The dealership is responsible for inspecting your Kawasaki vehicle if there is a failure, investigating the cause
of the problem, and getting any needed authorization from Kawasaki if the repair is one that will be covered by
the limited warranty. The dealership will also file all necessary paperwork. The dealership is responsible for
correctly completing any necessary repairs, whether they are covered by the limited warranty or not.
YOUR WARRANTY/OWNER SATISFACTION 147
How Do I Get Warranty Service?
If there is a problem with your vehicle within the limited warranty period, you will need to schedule a service
appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and diag-
nosis. You can go to any Kawasaki dealer for warranty repairs. Your Kawasaki dealer will inspect your vehicle
and give you the results of the inspection. The dealer will perform the repairs at no cost to you if it is determined
that the problem is covered by the warranty.
Kawasaki will work with your dealer to resolve any warranty issues. No authorization for warranty work can be
given until your vehicle has been inspected by a Kawasaki dealer.
What if I am not Satisfied With My Warranty Service?
If you aren’t satisfied with your dealership’s repair work or operations, it is best to discuss the situation with the
appropriate dealership manager. If you have already done this, then contact the dealership’s owner or general
manager to request a review of the issue.
If you are unable to resolve a problem after consulting with the dealership management and need further as-
sistance, contact Kawasaki Motors Corp., U.S.A. at the address below. Please be certain to provide the model,
vehicle identification number (VIN), mileage or hours of use, accessories, dates that events occurred and what
action has been taken by both you and your dealer. Include the name and address of the dealership. To
assist us in resolving your inquiry, please include copies of related receipts and any other pertinent informa-
tion including the name of the dealership personnel with whom you have been working. Upon receipt of your
correspondence, Kawasaki Motors Corp., U.S.A. will contact the dealership and work with it in resolving your
problem.
148 YOUR WARRANTY/OWNER SATISFACTION
Want to Contact Kawasaki?
This owner’s manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should
either be able to answer any other questions you might have immediately or be able to find the answer for you.
Please send your correspondence to:.

Consumer Services
Kawasaki Motors Corp., U.S.A.
P.O. Box 25252
Santa Ana, CA 92799-5252
(949) 460-5688
ENVIRONMENTAL PROTECTION 149
ENVIRONMENTAL PROTECTION
Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors
through education and fostering responsible enjoyment of public lands. When using your Kawasaki Utility Ve-
hicle (UV), please follow these Tread Lightly! guidelines:
Tread Lightly!
Travel responsibly on designated roads and trails or in permitted areas.
Respect the rights of others including private property owners and all recreational trail users, campers and
others to allow them to enjoy their recreational activities undisturbed.
Educate yourself by obtaining travel maps and regulations from public agencies, planning for your trip, taking
recreation skills classes, and knowing how to use and operate your equipment safely.
Avoid sensitive areas such as meadows, lakeshores, wetlands and streams, unless on designated routes.
This protects wildlife habitat and sensitive soils from damage.
D o your part by leaving the area better than you found it, properly disposing of waste, minimizing the use of
fire, avoiding the spread of invasive species, restoring degraded areas, and joining a local enthusiast organi-
zation.
Properly discard used batteries, tires, engine oil, other vehicle components, or the entire vehicle that you
might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency
for their proper disposal procedure.
150 MAINTENANCE RECORD
MAINTENANCE RECORD
Owner Name...................................................................................................................................
Address ..........................................................................................................................................
Phone Number ...............................................................................................................................
Engine Number ..............................................................................................................................
Vehicle Number..............................................................................................................................
Key Code ........................................................................................................................................
Selling Dealer Name ......................................................................................................................
Address ..........................................................................................................................................
Phone Number ...............................................................................................................................
Warranty Start Date .......................................................................................................................
Note: Keep this information and a spare key in a secure location.
Date Traveled Distance Maintenance Performed Dealer Name Dealer Address

MAINTENANCE RECORD 151





2019 Kawasaki Mule 4010 Trans4x4 25

Uploaded by

Copyright:

Available Formats

2019 Kawasaki Mule 4010 Trans4x4 25

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2019 Kawasaki Mule 4010 Trans4x4 25

Uploaded by

Copyright:

Available Formats

WARNING

MAINTENANCE AND ADJUSTMENT j

A Table of Contents is included after the

2. Exhaust Emission Control System

3. Evaporative Emission Control System

Tampering with Emission Control System Prohibited

KAWASAKI HEAVY INDUSTRIES, LTD.

© 2018 Kawasaki Heavy Industries, Ltd. Jan. 5, 2018. (1)

BASIC SAFE DRIVING

Read the Owner’s Manual

Use the Parking Brake

Reduce Speed When Carrying Cargo,

Bore × Stroke 76.0 × 68.0 mm (2.99 × 2.68 in.)

Overall Drive Ratio: Forward: 8.404 (High)

Trail 35 mm (1.4 in.)

SERIAL NUMBER LOCATIONS

Frame No. Engine No.

A. Frame Number A. Engine Number

1. Headlights 7. Rear Seat 14. Latch

1. Latch Handle 5. Brake/Tail Lights 9. Rear Seat (folded)

1. Left Glove Compartment 8. FI Warning Light 16. Throttle Pedal

14. Warning (Trailer-Towing Bracket)

17. Important Emission Information

21. Radiator Cap Danger

Electrical Accessory Connector

A. Electrical Accessory Connectors

A. Coolant Temperature Warning Light

A. Fuel Injection Warning Light

A. Power Steering Warning Light

2. Push the rear seat back forward.

A. Latch A. Rear Seat (Stored position)

A. Cargo Bed Side Plates A. Stopper Pin

8. Latch the stopper pins at the bottom of the

WARNING A. Stopper pin

A. Latch A. Rear Seat (Stored position)

A. Handgrip A. Supporting Rod

6. Support the bed in the tilted position with the

With the Cargo Bed Extended Condition

2. Holding the handgrip and cargo bed on the top

Fuels Containing Oxygenates

A. Right Glove Compartment

A. Left Glove Compartment

A. Latch Release Knob

A. Front Cargo Compartment Hood Closing

A. Fuel Gauge (LED)

A. Parking Brake Lever

2. Follow a manual to be supplied by the winch

Fuel .................................................. Enough fuel in tank, no leaks.

• Apply the parking brake.

j If your vehicle’s battery is “run down,” it should be

Connecting Jumper Cables

• After the engine starts, disconnect the jumper ca-

Moving Off Braking

Stopping the Engine Parking the Mule

• Stop the vehicle on a level surface.

• When the engine has stopped, apply the parking

A. Parking Brake Lever

• Remove the ignition switch key to prevent unau-

Shifting to High Range

• Stop the vehicle completely. NOTE