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ENGLISH

Utility VehicleOwner's Manual

Original instructions

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Quick Reference Guide

This Quick Reference Guide will assist you infinding the information you're looking for.

A Table of Contents is included after the Foreword.

GENERAL INFORMATION

BREAK-IN

HOW TO OPERATE

SAFE OPERATION

MAINTENANCE AND ADJUSTMENT

TRANSPORTING AND STORAGE

TROUBLESHOOTING GUIDE

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Whenever you see the symbols shown below,heed their instructions! Always follow safe operatingand maintenance practices.

DANGERDANGER indicates a hazardous situationwhich, if not avoided, will result in death orserious injury.

WARNINGWARNING indicates a hazardous situationwhich, if not avoided, could result in death orserious injury.

NOTICENOTICE is used to address practices not re-lated to personal injury.

NOTE○NOTE indicates information that may help orguide you in the operation or service of the ve-hicle.

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BASIC SAFE DRIVINGKnowing and following these rules for safe opera-

tion will increase your satisfaction with your new Ka-wasaki vehicle.

Perform the Daily ChecksRefer to the Daily Checks section for a list of items

to check each day before use. Habitual perform-ance of these checks will help to insure safer, morereliable usage. Be sure that any irregularities foundduring these checks are corrected before operatingthe vehicle.

Drive Carefully and with Good JudgementWe want you to be satisfied with your new Kawa-

saki vehicle, so drive carefully, safely, and exercisegood judgement. Practice basic maneuvers so youcan drive confidently and safely.Improper use of this vehicle can be hazardous.

Never operate at speeds too fast for your skills orconditions. Handling characteristics of this vehiclechange depending upon cargo load and drivingmodes.

Read the Owner's ManualRead and understand this Owner's Manual. This

is especially important for inexperienced operators.Refer to this Owner's Manual if you have any ques-tions.

Off-Highway Use OnlyThis vehicle is not an all-terrain vehicle; it is de-

signed and equipped to be a multiuse utility vehicle

for off-highway use only. Use of this vehicle on pub-lic roads and paved surfaces is hazardous. Do notoperate this vehicle on public roads or paved surfa-ces.

Occupant CapacityMake sure operators are 16 years or older with a

valid driver's license.Each occupant must be able to sit with back

against seat, feet flat on floor, and hands on steeringwheel, handgrip or handhold.The operator should be tall enough to wear the

seat belt properly and reach all controls.Passenger(s) should also be tall enough for the

seat belt to fit properly and to be able to brace them-selves, as necessary, by placing both feet firmly onthe floor while gripping the handgrip or handhold.Stay completely inside the vehicle.

Never Drink and DriveAlcohol and drugs impair your judgement and

slow your reactions. Even drugs prescribed by aphysician can be dangerous. Check with your doc-tor.

Use Proper Riding GearProper protective gear can reduce the severity of

injury in the event of an accident.Choose a helmet most appropriate for your use of

this utility vehicle. A helmet can reduce the risk of

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head injuries. Wear appropriate eye protection andprotective clothing.

Wearing Seat BeltsBoth the operator and passenger(s) should al-

ways wear their seat belts properly. Seat belts can-not completely protect you in every accident, but inmany cases a seat belt can reduce the risk of seri-ous injury. Also, to avoid injury, do not put any partof your body outside of the vehicle for any reason.

Close the DoorsBe sure all doors are securely closed during oper-

ation and never remove a door.The doors prevent branches, gravel, and debris

from getting inside the passenger compartment.

Before Starting the EngineThree “musts” before starting the engine are:

1. Apply the parking brake,2. Put the gear shift lever in the “N” (neutral) posi-

tion,3. Check the throttle pedal for proper operation. It

should return to its rest position when released.

Use the Parking BrakeAlways apply the parking brake before getting out

of your vehicle.

Obey Local LawsKnow and obey all laws and regulations governing

the use of off-highway vehicles in your area. Re-spect private property. Always try to preserve natureand the environment.

RefuelingBefore refueling the vehicle, shut the engine off

and make sure the area is well ventilated and free ofany source of flame or sparks. Diesel fuel is veryflammable.

Tire Air PressureTire inflation and type can affect the vehicle's han-

dling characteristics. Check the tire pressure fre-quently. Use only the recommended tires forreplacement.

Maximum Seating CapacityDo not exceed seating capacity: 4 occupants.Occupants shall only ride in designated seating

positions and with maximum 2 persons in each frontand rear seat.Do not carry small children on lap.

Reduce Speed When Carrying Cargo, Passen-ger(s), and/or Pulling a TrailerCarrying cargo, passenger(s) and/or pulling a

trailer can make the vehicle difficult to steer andmay affect vehicle handling in an unpredictablemanner.Braking distance is increased when carrying car-

go, passenger(s), and/or pulling a trailer. Reducespeed and allow greater distance for braking whencarrying cargo, passenger(s), and/or pulling a trailer.Use extreme caution when climbing and descend-ing hills, and traversing slopes.

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FOREWORDCongratulations 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 thoroughlyfamiliar 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 thismanual.

For those who would like more detailed information on their Mule, a Service Manual is available for purchasefrom any authorized Kawasaki Mule dealer. The Service Manual contains detailed disassembly and mainte-nance information. Those who plan to do their own work should, of course, be competent mechanics and pos-sess the special tools described in the Service Manual.

Keep this Owner's Manual aboard your Mule at all times so that you can refer to it whenever you need infor-mation.This manual should be considered a permanent part of the Mule and should remain with the Mule when it is

sold.

All rights reserved. No part of this publication may be reproduced without our prior written permission.

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

© 2015 Kawasaki Heavy Industries, Ltd. Oct. 9, 2015. (1)

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TABLE OF CONTENTS

SPECIFICATIONS .............................................. 13DECLARATION OF CONFORMITY ................... 17SERIAL NUMBER LOCATIONS ........................ 19LOCATION OF PARTS ....................................... 20LOCATION OF LABELS .................................... 23LOADING INFORMATION ................................. 34GENERAL INFORMATION ................................ 36Multifunction Meter ........................................... 36Speedometer ................................................. 37Fuel Level Gauge .......................................... 38Clock .............................................................. 38Odometer ...................................................... 39Trip Meters (Trip Meter A/B) .......................... 39Hour Meter ..................................................... 402WD/4WD Indicator Symbol ......................... 40Amber Glow Plug Indicator Light ................... 41Red EPS Warning Indicator Light .................. 42Red Parking Brake Indicator Light ................ 42Red Reverse Indicator Light .......................... 42Green Neutral Indicator Light ........................ 42Red Seat-Belt Use Reminder ........................ 42Red Coolant Temperature Warning IndicatorLight ............................................................ 42

Red Oil Pressure Warning Indicator Light ..... 43Lighting/Electrical Accessory Socket ............... 43Light Switches .................................................. 44Steering Wheel ................................................. 45Brake Pedal ...................................................... 47Converting Rear Seat and Cargo Bed ............. 47From 4-Persons to 2-Persons Mode ............. 47From 2-Persons to 4-Persons Mode ............. 50

Cargo Bed ........................................................ 51Tailgate .......................................................... 51Loading Cargo Bed ....................................... 52Lifting and Lowering the Cargo Bed .............. 53

Fuel ................................................................... 58Diesel Fuel Requirements ............................. 58Cold Weather Information ............................. 58Using Biodiesel Fuel ..................................... 58Filling the Fuel tank ....................................... 59

Glove Compartment/Tool Kit ............................ 61Cupholders ....................................................... 61Front Access Cover .......................................... 62Horn Switch ...................................................... 63Main Switch ...................................................... 64Gear Shift Lever ............................................... 65Selectable 2WD/4WD Shift Switch .................. 66Selectable DIFF-LOCK Shift Switch ................ 68Belt Drive Transmission ................................... 68Parking Brake Lever ......................................... 69Doors ................................................................ 70Seats ................................................................ 71Seat Belts ......................................................... 73Throttle Pedal ................................................... 75Trailer Hitch Bracket ......................................... 75

BREAK-IN ........................................................... 77HOW TO OPERATE ........................................... 78Daily Checks .................................................... 78Starting the Engine ........................................... 81High-Altitude Injection Control Device .......... 81

Cold Weather Starting ...................................... 82Jump Starting ................................................... 83

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Moving Off ......................................................... 85Braking .............................................................. 86Stopping the Engine .......................................... 86Parking the Mule ............................................... 87Shifting Gears .................................................... 882WD/4WD Shifting ............................................ 89Shifting the Differential ...................................... 90When Stuck ....................................................... 91

SAFE OPERATION ............................................. 92Unfamiliar Terrain .............................................. 92Driving in Reverse ............................................. 93Driving in “4WD” ................................................ 93Turning the Vehicle ............................................ 94Hills .................................................................... 94Climbing Hills ..................................................... 95Descending Hills ............................................... 96Traversing Hillsides ........................................... 97Sliding and Skidding .......................................... 97Driving through Water ....................................... 98Operator and Passenger Requirements ........... 99

NOISE AND VIBRATION CONTROL INFORMA-TION ..................................................................101Control Information ............................................101

MAINTENANCE AND ADJUSTMENT ................102Periodic Maintenance Chart ..............................103Engine Oil ..........................................................107Front Final Gear Case Oil ................................. 111Transmission Case Oil ......................................114Cooling System ................................................. 117Valve Clearance ................................................120Engine Air Cleaner ............................................120Spark Arrester ...................................................123Throttle Pedal ....................................................125Idle Adjustment ..................................................126

Fuel Hose ..........................................................127Fuel Filter ...........................................................127Water Separator ................................................128Fuel Tank Vent ...................................................129Belt Drive Transmission (CVT) ..........................129Brakes ...............................................................131Brake Pedal ....................................................131Brake Disc and Brake Pad .............................133

Brake Light Switch .............................................134Parking Brake ....................................................135Steering Wheel ..................................................136Power Steering System ..................................136

Wheels ..............................................................137Rims ...............................................................137Wheel Nuts .....................................................137Tires ................................................................137

Joint Boots .........................................................139Suspension ........................................................140Seat Belts ..........................................................142Cargo Bed Latches ............................................143Headlight Beam .................................................143Battery ...............................................................144Fuse ...................................................................152Breaker ..............................................................159General Lubrication ...........................................159Cleaning ............................................................160General Precautions ......................................160Where to be Careful .......................................162Washing Your Vehicle ....................................162

Bolt and Nut Tightening .....................................163TRANSPORTING AND STORAGE ....................164Transporting the Vehicle ....................................164Storage ..............................................................165Preparation for Storage ..................................165

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Engine Care during Long Storage .................166Removal from Storage ..................................167Before Starting Engine after Long Storage ...167

TROUBLESHOOTING GUIDE ...........................169ENVIRONMENTAL PROTECTION ....................171MAINTENANCE RECORD .................................172

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SPECIFICATIONS

PERFORMANCE

Maximum Torque 52.1 N·m (5.3 kgf·m, 38 ft·lb) @2 400 r/min (rpm)

Minimum Turning Radius Differential Mode 4.8 m (15.7 ft)

Seating Capacity Front 2 persons, Rear 2 persons

DIMENSIONS

Overall Length 3 385 mm (133.3 in.)

Overall Width 1 625 mm (63.98 in.)

Overall Height 1 970 mm (77.56 in.)

Wheelbase 2 345 mm (92.32 in.)

Tread: Front 1 389 mm (54.68 in.)

Rear 1 321 mm (52.01 in.)

Ground Clearance 260 mm (10.2 in.)

Curb Mass 865 kg (1 907 lb)

Cargo Bed (L × W × H) (Short Bed Mode) 560 × 1 363 × 279 mm (22.05 × 53.66 ×10.98 in.)

(Long Bed Mode) 1 085 × 1 363 × 279 mm (42.72 × 53.66 ×10.98 in.)

ENGINE

Type Diesel, OHV, 3-cylinder, 4-stroke, liquid-cooled

Displacement 993 cm³ (60.6 cu in.)

Bore × Stroke 74.0 × 77.0 mm (2.91 × 3.03 in.)

Compression Ratio 23.5:1

Starting System Electric starter

SPECIFICATIONS 13

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

Firing Order 1-3-2

Injection Pump Bosch in-line type

Lubrication System Forced lubrication (wet sump)

Engine Oil: Type API CD, CF, CF-4, CI-4 or CJ-4**: When using CJ-4 oil (low ash oil) in your engine, use

fuel with less than 0.05% sulfur content to avoid en-gine oil deterioration.

Viscosity SAE 10W-40

Capacity 2.4 L (2.5 US qt)

Coolant Capacity 6.1 L (6.4 US qt)

DRIVE TRAIN

Driving Type: Primary Belt drive torque converter (CVT)

Final 2WD/4WD system with drive shafts

Transmission Type 2-speed & reverse, automaticPrimary Reduction Ratio 3.334 ~ 0.756 (Belt drive torque converter)

Final Reduction Ratio: Front 6.382

Rear 6.245

Overall Drive Ratio: Forward 12.192 (High)

24.205 (Low)

Reverse 18.794

14 SPECIFICATIONS

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Transmission Gear Ratio: Forward 1.952 (High)

3.876 (Low)

Reverse 3.009

Front Final Gear Case Oil API GL-5 Hypoid gear oilSAE 90 [above 5°C (41°F)]SAE 80 [below 5°C (41°F)]

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

Transmission Case Oil API GL-5 Hypoid gear oilSAE 90 [above 5°C (41°F)]SAE 80 [below 5°C (41°F)]

Transmission Case Oil Capacity 2.00 L (2.1 US qt)

FRAME

Type Steel tube, ladder type

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

Caster 4.4°

Tire Size: Front 26 × 9.00-12 4PR

Rear 26 × 11.00-12 4PR

Rim Size: Front 12 × 7.0AT

Rear 12 × 8.0AT

Fuel Tank Capacity 30 L (7.9 US gal)

ELECTRICAL EQUIPMENT

Battery 12 V 540CCA @0°F RC80

SPECIFICATIONS 15

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Headlight:

High Beam 12 V 60 W × 2, LED × 2

Low Beam 12 V 55 W × 2, LED × 2

Brake/Tail Light 12 V 21/5 W × 2

Reverse Light 12 V 10 W

LOAD CAPACITY

Maximum Vehicle Load (Including occupants,cargo and accessories)

733 kg (1 616 lb)

Maximum Cargo Bed Load (Short Bed Mode) 158 kg (350 lb)(Long Bed Mode) 453 kg (1 000 lb)

Specifications are subject to change without notice.

16 SPECIFICATIONS

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DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY 17

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18 DECLARATION OF CONFORMITY

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SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the vehicle. They are the only means of identifyingyour particular machine from others of the same model type. These serial numbers may be needed by yourdealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as wellas the model type and any peculiar features of your machine that can help them identify it.

Frame No.

A. Frame NumberB. Right Front Axle

Engine No.

A. Engine Number

SERIAL NUMBER LOCATIONS 19

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LOCATION OF PARTS

(4-Persons Mode)

1. LED Sub Headlights2. Headlights3. Front Access Cover4. ROPS (Roll Over Protective

Structure)5. Steering Wheel6. Front Seat7. Front Seat Belts8. Rear Seat

9. Rear Seat Belts10. Screen Lock Arm11. Cargo Bed12. Front Guard13. Coolant Reserve Tank14. Brake Fluid Reservoir15. Steering Wheel Tilt Lock Lever16. Front Door

17. Handhold for Rear Seat Pas-sengers

18. Rear Door19. Cargo Bed Handgrip20. Cargo Bed Latch21. Muffler (Spark Arrester)22. Trailer Hitch Bracket

20 LOCATION OF PARTS

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(2-Persons Mode)

1. Tailgate Latch Handle2. Tailgate3. Screen4. Handgrip for Front Right Seat

Passenger5. Tail/Brake Light

6. Rear Shock Absorber7. Cargo Bed Side Plate8. Air Cleaner9. Battery

10. Rear Seat (Folded Position)11. Fuel Tank Cap

12. Dashboard13. Front Shock Absorber14. Radiator

LOCATION OF PARTS 21

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1. Parking Brake Lever2. Horn Switch3. Selectable DIFF-LOCK Shift

Switch4. Selectable 2WD/4WD Shift

Switch

5. Headlight Switch6. LED Sub Headlight Switch7. Multifunction Meter8. Power Outlet Sockets9. Glove Compartment

10. Cupholders

11. Main Switch12. Brake Pedal13. Throttle Pedal14. Gear Shift Lever15. Tool Kit

22 LOCATION OF PARTS

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LOCATION OF LABELS

All warning labels which are on your vehicle arerepeated here. Read labels on your vehicle andunderstand them thoroughly. They contain informa-tion which is important for your safety and the safetyof anyone else who may operate your vehicle.Therefore, it is very important that all warning labelsbe on your vehicle in the locations shown. If any la-bel is missing, damaged, or worn, get a replacementfrom your Kawasaki dealer and install it in the cor-rect position.

NOTE○The sample warning labels in this section havepart numbers to help you and your dealer obtainthe correct replacement.

○Refer to the actual vehicle label for model specificdata grayed out in the illustration.

1. Warning (General)2. CE Mark

LOCATION OF LABELS 23

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3. Specification (ROPS)4. Specification (Model)5. Danger (Radiator Cap)6. Danger (Radiator Cap)7. Warning (Brake Fluid)

24 LOCATION OF LABELS

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8. Danger/Poison (Battery)9. Warning (Refueling)

10. Warning (Cargo Bed Lifting: both sides)


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11. Warning (Trailer Towing)12. Warning (Cargo Bed Loading)13. Important Information (Tires/Max. Load)


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1. Read Owner’s Manual2. Safety alert symbol3. Maximum seating capacity: 2 persons in each

seat, see “BASIC SAFE DRIVING” section4. Fasten seat belts. Wear an approved helmet and

protective gear, see “BASIC SAFE DRIVING”section

5. Never use on public roads, see “BASIC SAFEDRIVING” section

6. Never use with drugs or alcohol, see “BASICSAFE DRIVING” section

7. Make sure operators are 16 years or older with avalid driver’s license, see “BASIC SAFE DRIV-ING” section


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1. Safety alert symbol2. Read Owner’s Manual3. Hot liquid. Never open when engine is hot, see

page 117


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1. Read Owner’s Manual2. Use diesel fuel only, see page 58


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1. Safety alert symbol2. Read Owner’s Manual3. Hand crush, see page 53


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(11) 1. Safety alert symbol2. Read Owner’s Manual3. Maximum arm length4. Vertical force limitation, see page 755. Horizontal force limitation, see page 75


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1. Safety alert symbol2. Read Owner’s Manual3. Maximum cargo bed load, see page 354. Never carry passengers in cargo bed, see page

57


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1. Read Owner’s Manual2. Tire pressure, see page 1373. Safety alert symbol4. Load condition (including occupants and cargo),

see page 1375. Front tire size, see page 1376. Rear tire size, see page 137


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LOADING INFORMATION

WARNINGIncorrect loading, improper installation or useof accessories, or modification of your ve-hicle may result in an unsafe operating condi-tion. Before you operate it, make sure that thevehicle is not overloaded and that you havefollowed these instructions.

With the exception of genuine Kawasaki Partsand Accessories, Kawasaki has no control over thedesign or application of accessories. In some cases,improper installation or use of accessories, or ve-hicle modifications, will void the utility vehicle war-ranty. In selecting and using accessories, and inloading the vehicle, you are personally responsiblefor your own safety and the safety of other person(s)involved.

NOTE○Kawasaki Parts and Accessories have been spe-cially designed for use on Kawasaki utility ve-hicles. We strongly recommend that all parts andaccessories you add to your vehicle be genuineKawasaki components.

Because any vehicle is sensitive to increases inweight and changes in weight distribution, you musttake care in carrying cargo. Always follow these pre-cautions:

• Carrying cargo, passengers and/or pulling a trailercan make the vehicle difficult to steer and may af-fect vehicle handling in an unpredictable manner.Use extreme caution when climbing and descend-ing hills, and traversing slopes.

• Braking distance is increased when carrying car-go, passengers, and/or pulling a trailer. Reducespeed and allow greater distance for braking.

• All cargo should be carried as low as possible toreduce the effect on the vehicle’s center of gravity.Cargo weight should be equally distributed fromside to side. This helps maintain stability by cen-tralizing weight. Avoid carrying cargo that extendsbeyond the rear of the vehicle. Do not carry cargoon top of the ROPS.

• Cargo should be securely anchored. Make surethe cargo will not move around while the vehicle ismoving. Recheck cargo security as often as pos-sible (while the vehicle is stopped) and adjust asnecessary.

NOTICEThe front body work and fenders are not de-signed to carry cargo or to support weight.Do not place cargo, lean or sit on them, orthey may break.

• This vehicle is not designed to carry passengersin the cargo bed. Installing additional passenger

34 LOADING INFORMATION

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seating or carrying passengers in the cargo bedcan cause changes in vehicle handling.

WARNINGPassengers transported in the cargo bed canbe tossed about or even thrown out causingserious injury or death. Do not install seatingor transport passengers in the cargo bed.

• (Maximum Cargo Bed Load) Do not carry morethan maximum cargo bed load as specified below.

Short Cargo Bed Mode: 158 kg (350 lb)

Long Cargo Bed Mode: 453 kg (1 000 lb)

• (Maximum Vehicle Load) Weight of operator, pas-senger(s), cargo, accessories, and trailer tonguemust not exceed following limits.

Maximum Vehicle Load: 733 kg (1 616 lb)

• Do not operate this vehicle faster than 16 km/h(10 mph) when pulling a trailer. Refer to the“Trailer Hitch Bracket” section in the “GENERALINFORMATION” chapter.

LOADING INFORMATION 35

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GENERAL INFORMATION

Multifunction Meter 1. Amber Glow Plug Indicator Light2. Red EPS Warning Indicator Light3. Speedometer4. Fuel Level Gauge5. Red Parking Brake Indicator Light6. Red Reverse Indicator Light7. Green Neutral Indicator Light8. Right Button9. Odometer/Trip Meters (Trip Meter A and B)/Hour

Meter10.Clock11.Left Button12.“2WD” Indicator Symbol13.Red Seat-Belt Use Reminder14.Red Coolant Temperature Warning Indicator

Light15.Red Oil Pressure Warning Indicator Light16.“4WD” Indicator Symbol

Pushing the left button shifts the display in theodometer/trip meters/hour meter through the 4modes; odometer, trip meter A and B, and hour me-ter.When the main switch is turned on, all the “LCD”

segments and “LED” lights are displayed for a sec-ond, then the clock and meters operate normally de-pending on the mode selected.

36 GENERAL INFORMATION

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Speedometer

The speedometer shows the speed of the vehicle.

A. Speedometer

mph·km/h Display:mph·km/h display can alternate between English

and metric modes (mph and km/h) in the digital me-ter. Make sure that mph or km/h is correctly dis-played according to local regulations before driving.Shift the mph·km/h display in the digital meter as fol-lows.

NOTE○Do not operate the vehicle with the digital meterdisplaying in the wrong unit (mph or km/h).

• Display the odometer in the digital meter.

• The mph·km/h display shifts by pushing and hold-ing the left button and pushing the right buttonwithin two seconds.

A. mph·km/h DisplayB. Left ButtonC. Right Button

• The mph·km/h display shifts as follows.

NOTE○The data is maintained even if the battery is dis-connected.

GENERAL INFORMATION 37

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Fuel Level Gauge

The fuel in the fuel tank is shown in segments. All6 segments are displayed when the fuel tank is full.As fuel is consumed the segments go out accord-ingly. When the bottom segment is reached, it willbegin blinking to warn of a low fuel level.When it begins blinking, 6.6 liters (1.7 US gal) of

fuel remains. Fill the fuel tank as soon as possiblebecause there is no reserve tank in this vehicle (seeFuel section).

A. Blinking to warn of a low fuel level

Clock

To adjust hours and minutes:

• Turn the main switch on.

• The odometer is displayed.

• Push the right button for more than two seconds.Both the hour and minute displays start blinking.

A. Hour DisplayB. Minute Display

• Push the right button. The hour display onlyblinks. Push the left button to advance the hours.

A. Hour Display

• Push the right button. The hour display stopsblinking and the minute display starts blinking.Push the left button to advance the minutes.


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A. Minute Display

• Push the right button. Both the hour and minutedisplays start blinking again.

• Push the left button. The displays stop blinkingand the clock starts working.

NOTE○Pushing the left button momentarily advances thehour or minute step by step. Pushing and holdingthe button advances the hour or minute continu-ously.

○The clock works normally from the back-up powerwhile the main switch is turned off.

○When the battery is disconnected, the clock re-sets to 1:00, and starts working again when thebattery is connected.

Odometer

The odometer shows the total distance in kilo-meters or miles that the vehicle has been driven.The meter cannot be reset.

NOTE○When the figures come to 999999, they arestopped and locked.

A. Odometer

Trip Meters (Trip Meter A/B)

The trip meter shows the distance in kilometers ormiles traveled since it was last reset to zero.To reset the trip meter:

• Push the left button to display the trip meter A orB.

• Push the right button and hold it in.

• After two seconds, the figure display turns to 0.0,and then starts counting when the vehicle is oper-ated. The meter counts until it is next reset.

NOTE○When the trip meter reaches 9999.9 when the ve-hicle is running, it turns back to 0.0 and startscounting again.


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A. Trip Meter A

Hour Meter

The hour meter shows the total hours that the ve-hicle has been operated. This meter cannot be re-set.

NOTE○When the figures come to 99999.9, they arestopped and locked.

A. Hour Meter

2WD/4WD Indicator Symbol

This vehicle can be driven in either “2WD” or“4WD.”When the selectable 2WD/4WD shift switch is in

“4WD,” the “4WD” indicator symbol will appear.After shifting there is a momentary delay before

the indicator symbols change.


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A. “2WD” Indicator SymbolB. “4WD” Indicator Symbol

A. Amber Glow Plug Indicator LightB. Red EPS Warning Indicator LightC. Red Parking Brake Indicator LightD. Red Reverse Indicator LightE. Green Neutral Indicator LightF. Red Seat-Belt Use ReminderG. Red Coolant Temperature Warning Indicator

LightH. Red Oil Pressure Warning Indicator Light

Amber Glow Plug Indicator Light

The glow plug indicator light goes on for 4 sec-onds when the main switch key is turned to the “ON”position. The indicator light also goes on wheneverthe key is in the “START” position. The indicator lightgoes off after the plug is fully heated. If it does notgo on or go off, have the glow plug and related sys-tem checked by an authorized Kawasaki dealer.


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Refer to the “Starting the Engine” section in the“HOW TO OPERATE” chapter for detailed informa-tion.

Red EPS Warning Indicator Light

The EPS warning indicator light will momentarilyilluminate when the engine starts, then go off in asecond if the system is in order. If this warning indi-cator light illuminates any other time, it indicates theECU or actuator has malfunctioned, or the wiringharness has become disconnected. Stop driving im-mediately and contact an authorized Kawasakidealer to have the system checked.

NOTE○If this warning indicator light does not go on whenthe main switch is turned on, there may be a prob-lem with the light itself. Contact an authorized Ka-wasaki dealer for inspection.

Red Parking Brake Indicator Light

When the parking brake is applied with the mainswitch in the “ON” position, the parking brake indica-tor light illuminates.

Red Reverse Indicator Light

When the transmission is in reverse gear, the re-verse indicator light illuminates.

Green Neutral Indicator Light

When the transmission is in neutral, the neutral in-dicator light illuminates.

Red Seat-Belt Use Reminder

When the main switch is turned on, the seat-beltuse reminder will illuminate and stay on for approxi-mately 8 seconds, even if the operator's belt isbuckled. The light is a reminder to the operator tomake sure that passengers have buckled their seatbelts.

Red Coolant Temperature Warning IndicatorLight

The coolant temperature warning indicator light il-luminates whenever the coolant temperature risestoo high while the vehicle is in operation. If it stayson, stop the engine and check the coolant level inthe coolant reserve tank after the engine coolsdown.Be sure to check that the radiator fan is free from

mud and other obstacles. Refer to the “Breaker”section in the “MAINTENANCE AND ADJUST-MENT” chapter.

NOTICEDo not continue running the engine with thetemperature warning indicator light continu-ously illuminated. Prolonged engine opera-tion can result in engine damage fromoverheating.

NOTE○When you touch the fan, be sure to disconnectthe negative (–) battery cable, since the fan can


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operate automatically even with the main switchoff.

Red Oil Pressure Warning Indicator Light

The oil pressure warning indicator light blinks towarn the operator whenever the oil pressure is dan-gerously low or the main switch is in the “ON” posi-tion with the engine not running, and goes off whenthe proper engine oil pressure is reached. Refer tothe “MAINTENANCE AND ADJUSTMENT” chapterfor more detailed engine oil information.

Lighting/Electrical Accessory Socket

The lighting/electrical accessory 12 volt socketsare located on the dashboard.An auxiliary light or an accessory may be con-

nected to these connectors.

A. Power Outlet Sockets

NOTICEDo not connect a light or load of more than120 watts on one or both sockets, or the bat-tery may rapidly discharge.


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Light Switches

The light switches are 3-position type with an indi-cator.The headlights can be turned on by pushing the

headlight switch to the “ ” or “ ” positionwhen the main switch is in the “ON” position.

: Low Beam: High Beam

When the headlights are on high beam, the highbeam indicator light in the switch goes on as a re-minder. The headlights go off when the headlightswitch is pushed in “OFF” position.

A. High Beam PositionB. Low Beam PositionC. OFF PositionD. High Beam IndicatorsE. Headlight SwitchF. LED Sub Headlight Switch

This vehicle is equipped with LED sub headlights.The operation of the LED sub headlight switch issimilar with the headlight switch.


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A. HeadlightsB. LED Sub Headlights

Steering Wheel

This vehicle is equipped with an electric powersteering system. The system does not require regu-lar maintenance by users. Do not tamper with theelectronic control unit (ECU) or loosen the fittings ofsteering actuator, or the neutral position setting ofthe steering will be adversely affected and willcause serious driving problems. If such componentsneed service, contact an authorized Kawasaki deal-er.If the steering becomes more difficult than usual

or you feel a steering problem, refer to the “SteeringWheel” section in the “MAINTENANCE AND AD-JUSTMENT” chapter.

A. Steering Wheel


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NOTE○The power steering system functions only whenengine is running.

○If you install wireless equipment on board, contactan authorized Kawasaki dealer. Installing suchequipment improperly may affect the ECU.

Steering Position AdjustmentThe steering wheel position can be adjusted to

suit the operator.Make any steering wheel adjustment before start-

ing the vehicle.

WARNINGAdjusting the steering wheel position whiledriving could cause loss of control and an ac-cident resulting in serious injury or death. Toprevent loss of control, do not adjust thesteering wheel position unless the vehicle isstopped.

• Move the steering wheel up or down while pullingup the tilt lock lever under the steering wheel.

• Release the tilt lock lever to lock the steeringwheel in position.

A. Tilt Lock LeverB. Pull up.C. Steering WheelD. Adjusting Direction

NOTE○Make sure you have securely locked the steeringwheel in place by moving it up and down.


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Brake Pedal

The brake pedal is the left pedal on the floorboard.Depress the pedal to slow or stop the vehicle.

A. Brake PedalB. Floorboard

Converting Rear Seat and Cargo Bed

This vehicle can be converted to accommodatemore passengers and less cargo or fewer passen-gers and more cargo.The seats and the cargo bed can be converted in

the following way.

WARNINGThe latches must be unlocked during the con-verting operation, allowing the possibility forthe cargo bed to suddenly lift and cause seri-ous injury. To prevent the cargo bed fromsuddenly lifting, do not convert the rear seatwith the cargo bed loaded.

From 4-Persons to 2-Persons Mode

WARNINGFingers or hands could be pinched duringcargo bed conversion. When converting thecargo bed, be careful not to catch fingers,hands, or any other body parts between thefolding bed side walls.

1. Open the rear doors and release the cargo bedlatches on both sides.

2. Lift the rear seat by holding the handgrip on ei-ther side, and turn the rear seat forward.


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A. Cargo Bed Latch (Both Sides)B. HandgripsC. Rear Seat CushionD. Plastic Seat Base

NOTICEDo not lift the rear seat using the plastic seatbase as it will break the plastic seat base.

3. Push the rear seat frame forward into the storedposition.

A. Rear Seat Frame (Stored Position)

4. On both sides, pull the lower end of the screenlock arms to release it from the cargo bed frame.

5. Turn the screen lock arms upward until lowerlocking arm is released from the lock pin in thecargo bed base.


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A. Screen Lock Arm (Both Sides)B. Lower Locking Arm (Both Sides)C. Lock Pin (Both Sides)

6. Slide the cargo bed screen forward in conjunc-tion with pushing the hinge between the cargobed side plates on both sides.

NOTE○To move the screen smoothly, push both cargobed side plates evenly as much as possible.

A. Cargo Bed ScreenB. Cargo Bed Side Plates

7. After fully extending the cargo bed side plates,lower both screen lock arms, aligning their lowerlocking arms with the lock pins in the cargo bedbase.

8. Push the screen lock arms into the brackets onthe side plates on both sides until you hear aclick.

NOTE○Pull the screen lock arms lightly to check if theyare locked securely.

9. Secure the cargo bed side plates with the cargobed latches on both sides.


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A. Cargo Bed Side PlatesB. Screen Lock ArmC. BracketD. Lower Locking ArmE. HandgripF. Cargo Bed Latch

10.Close the rear doors.

WARNINGFailure to properly lock the cargo bed orscreen may allow them to move suddenlywhile driving, causing loss of control and anaccident resulting in serious injury or death.To prevent the cargo bed from suddenly mov-ing, make sure that the cargo bed and screenhas been locked properly after handlingthem.

From 2-Persons to 4-Persons Mode

WARNINGFingers or hands could be pinched duringcargo bed conversion. When converting thecargo bed, be careful not to catch fingers,hands, or any other body parts between thefolding bed side walls.

• Reverse the procedure for 4-persons to 2-personsmode conversion.

NOTE○After folding the cargo bed side plates, push bothscreen lock arms to the lock pin until you hear aclick.


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A. Screen Lock ArmB. Lock Pin

WARNINGFailure to properly lock the cargo bed orscreen may allow them to move suddenlywhile driving, causing loss of control and anaccident resulting in serious injury or death.To prevent the cargo bed from suddenly mov-ing, make sure that the cargo bed and screenhas been locked properly after handlingthem.

Cargo Bed

Tailgate

The tailgate of the cargo bed can be lowered. Be-fore lowering the tailgate, park on a firm level sur-face and set the parking brake.To open the tailgate, release the latches and lower

the tailgate. Cables hold the tailgate level with thecargo bed.

A. TailgateB. Latch Handle (Both Sides)

To close the tailgate, lift to the upright position andsecure firmly with the latches.Push the tailgate latch handles forward to make

sure the latches stay securely closed. Do not drivethe vehicle with the tailgate lowered.


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A. TailgateB. Cable

Loading Cargo Bed

WARNINGLoading the cargo bed before the conversionoperation is completed and the cargo bed isunlocked may cause the bed to suddenly tilt,resulting in serious injury. To prevent the bedfrom suddenly lifting, be sure the conversionis complete and the cargo bed latches arefirmly locked.

NOTICEDo not carry more than the maximum loadstated here in the convertible cargo bed.

• Short bed mode: 158 kg (350 lb)

• Long bed mode: 453 kg (1 000 lb)

WARNING

• Overloading, failure to properly secure car-go, or improper use of the cargo bed cancause changes in handling which can leadto an accident. Follow guidelines providedin the “LOADING INFORMATION” chapter.

• Passengers transported in the cargo bedcan be tossed about or even thrown outcausing serious injury or death. Do not in-stall seating or transport passengers in thecargo bed.

• Driving with the cargo bed tilted may behazardous. Failure to lower and lock thebed into place may cause serious injury ordeath. Always lower and latch the bed aftertilting.

• Lifting and lowering the bed could be dan-gerous. Be careful not to catch any part ofyour body, such as hands or arms, betweenthe bed and ROPS or vehicle frame whenlifting and lowering the bed.


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Lifting and Lowering the Cargo Bed

The cargo bed can be tilted by releasing thelatches on each side, and then lifting the bed withthe handgrips. Before tilting the cargo bed, park ona 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 damper and supporting rod provided on thebottom of the cargo bed. Do not drive the vehiclewith the front end of the cargo bed raised or un-latched.To lower the bed, check to be sure the area under

the front of the cargo bed is clear, then carefully low-er the bed into position.Check that both latches have locked the bed into

place. Do not leave the cargo bed unlatched.

Lifting the Cargo Bed while in Short Configura-tion

1. Open the rear doors and release the cargo bedlatches on both sides.

2. Lift the rear seat by holding the handgrip on ei-ther side, and turn the rear seat forward.

A. Cargo Bed Latch (Both Sides)B. HandgripsC. Rear Seat CushionD. Plastic Seat Base

NOTICEDo not lift the rear seat using the plastic seatbase as it will break the plastic seat base.

3. Push the rear seat frame forward into the storedposition.


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A. Rear Seat Frame (Stored Position)

4. Hold the handgrip as shown. Holding the hand-grip, lift the cargo bed carefully.

A. HandgripB. Cargo Bed

WARNINGReduced clearance between the cargo bedand the ROPS can cause arm injury when lift-ing or lowering the cargo bed. To avoid injury,grasp cargo bed at the handle and do not holdthe ROPS when lifting or lowering the cargobed.

5. Pull the supporting rod out of its clip and securelyhook the curved end of the supporting rod ontothe bar of the ROPS to support the cargo bed.


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A. Supporting DamperB. Cargo Bed (Raised Position)C. Supporting Rod

WARNINGUsing only the bed supporting damper forcargo bed support may allow the cargo bed tosuddenly lower. To prevent injury caused bysudden lowering of the cargo bed, supportthe cargo bed with the support rod wheneverlifting the cargo bed.

Lifting the Cargo Bed in Extended Configura-tion

1. Open the rear doors. Make sure the screen lockarms are locked properly then release the cargobed latches on both sides.

A. Cargo Bed Latch (Both Sides)B. Screen Lock Arm (Both Sides)

WARNINGFailure to properly lock the screen lock armscould cause the cargo bed side plates to foldand allow the screen to slide down while lift-ing the cargo bed, resulting in serious injury.To prevent the cargo screen from slidingdown, make sure that the screen lock armsare locked properly before lifting the cargobed.


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WARNINGThe front of the cargo bed becomes heavierin the extended mode and may raise and low-er more quickly, increasing the risk of arm in-jury. To prevent injury, use extra care whenraising or lowering the bed in extended mode.

2. Hold the handgrip as shown. Holding the hand-grip, lift the cargo bed carefully.

A. HandgripB. Cargo Bed

WARNINGReduced clearance between the cargo bedand the ROPS can cause arm injury when lift-ing or lowering the cargo bed. To avoid injury,grasp cargo bed at the handle and do not holdthe ROPS when lifting or lowering the cargobed.

3. Pull the supporting rod out of its clip and securelyhook the curved end of the supporting rod ontothe bar of the ROPS to support the cargo bed.

A. Supporting DamperB. Cargo Bed (Raised Position)C. Supporting Rod


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WARNINGUsing only the bed supporting damper forcargo bed support may allow the cargo bed tosuddenly lower. To prevent injury caused bysudden lowering of the cargo bed, supportthe cargo bed with the support rod wheneverlifting the cargo bed.

Lowering the Cargo BedBefore lowering the bed, check to be sure the

area under the front of the cargo bed is clear. Returnthe supporting rod to the original position and se-cure it with the clip. Hold the handgrip and carefullylower the bed into position. Check that both latcheshave locked the bed into place. Do not leave thecargo bed unlatched.

WARNINGThe front of the cargo bed becomes heavieras it lowers into position and can suddenlylower, trapping arms between the bed andframe causing serious injury. To prevent thebed from suddenly lowering, use the handlesto properly support the bed when lowering orlifting the bed.

NOTE○To lower the cargo bed, follow the reverse proce-dure for lifting. Be sure to restore the seat as

before and put the latches on. Never drive theMule without locking the latches to the cargo bed.

WARNING

• Overloading, failure to properly secure car-go, or improper use of the cargo bed cancause changes in handling which can leadto an accident. Follow guidelines providedin the “LOADING INFORMATION” chapter.

• Passengers transported in the cargo bedcan be tossed about or even thrown outcausing serious injury or death. Do not in-stall seating or transport passengers in thecargo bed.

• Driving with the cargo bed tilted may behazardous. Failure to lower and lock thebed into place may cause serious injury ordeath. Always lower and latch the bed aftertilting.

• Lifting and lowering the bed could be dan-gerous. Be careful not to catch any part ofyour body, such as hands or arms, betweenthe bed and ROPS or vehicle frame whenlifting and lowering the bed.


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Fuel

Diesel Fuel Requirements

Kawasaki recommends diesel fuels that meet thefollowing requirements for use in this vehicle. Useclean, fresh diesel fuel to maintain performance andlife from the engine.

Fuel Specification and Cetane Number(1) The diesel fuel must meet the European EN590

specification.(2) Use diesel fuel with a cetane number equal to

or higher than that shown below. If available inyour area, a high cetane “premium” diesel fuelmay offer improved cold-starting and warm-upperformance.

Fuel type: Diesel fuel for vehicle

Minimum cetane number: 45

Lower SulfurA sulfur content less than 0.05% by volume is rec-

ommended. To avoid engine corrosion, and engineoil contamination, do not use fuel with more than0.5% sulfur content.When using CJ-4 oil (low ash oil) in your engine,

use fuel with less than 0.05% sulfur content to avoidengine oil deterioration.

Cold Weather Information

In cold weather, diesel fuel may thicken enough toclog the fuel filter. This is usually caused by natu-rally-occurring paraffin in diesel fuel turning to wax

as it gets colder. If the engine starts but stalls after ashort time and will not restart, the fuel filter may beclogged. For best results in cold weather use winterdiesel fuel.

WARNINGStarting fluids such as ether are explosiveand may cause severe injury. Do not usestarting fluids containing ether in the air in-take system.

NOTICEDo not add gasoline, gasohol, alcohol oraftermarket cetane improver additives to die-sel fuel. Damage to the fuel injection systemmay result.

NOTICEWax flakes in the fuel tank could damage thefuel level sensor. At temperatures below –10°C (14°F), use winter diesel fuel to prevent thediesel fuel from turning to wax.

Using Biodiesel Fuel

Biodiesel fuels blended with diesel fuel may beused in this vehicle only if the blended fuel meetsthe following conditions:


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(1) Biodiesel fuel concentration must not exceed7% by volume (B7).

(2) The petroleum diesel fuel base must meet theEuropean EN590 specification. The pure bio-diesel base must meet the European StandardEN14214. Raw pressed vegetable oils are NOTacceptable for use in any concentration.

Precautions when Using Biodiesel Fuels(1) Cranking time when engine starting in cold

weather will be prolonged.(2) Biodiesel blended fuel attracts moisture and

may contain higher water content than conven-tional diesel fuels. Keep storage and vehicletanks as full as possible and ensure all capsand covers are installed properly to preventwater from entering and collecting in the fuelsystem.

(3) Clean up any spilled fuel immediately to preventdamage to painted surfaces.

(4) To avoid damage caused by fuel degradation,biodiesel blended fuel should not be used if ithas been stored for more than 3 months. If anengine is going to be placed in storage, the bio-diesel blended fuel should be flushed out by op-erating the engine for at least 30 minutes onconventional diesel fuel after replacing biodieselfuel in the vehicle fuel tank with petroleum-based diesel fuel.

Filling the Fuel tank

The fuel tank is mounted under the right side ofthe seat. Use only fresh diesel fuel with the

recommended cetane number from an uncontami-nated source to ensure proper running of your ve-hicle.Avoid filling the tank in the rain or where heavy

dust is blowing so that the fuel does not get contami-nated.

A. Fuel Tank Cap

Never fill the tank completely to the top. After refu-eling, make sure the fuel tank cap is closed se-curely.


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A. Filler NeckB. Fuel Top Level (Bottom of Filler Neck)C. Fuel Tank

NOTICEAlways clean dirt/mud/debris/water from thefuel tank cap and surrounding area prior tofilling the tank to prevent dirt/mud/debris/-water from entering the fuel tank. Accumula-tion of moisture or sediment in the fuelsystem can restrict the flow of fuel and causefuel system and/or engine damage.

WARNINGDiesel fuel is extremely flammable and canignite under certain conditions. To avoid thepotential for burns or other injuries when re-fueling, turn the main switch key off. Do notsmoke. Make sure the area is well ventilatedand free from any source of flame or sparks;this includes any appliance with a pilot light.Never fill the tank completely to the top. Afterrefueling, make sure the fuel tank cap isclosed securely. If diesel fuel is spilled on thefuel tank, wipe it off immediately.


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Glove Compartment/Tool Kit

A glove compartment is provided at the right sideof the dashboard. Store only light items to avoiddamage to the inside of the compartment. Do notstore items which must not get wet or dirty.The tool kit is located at the inside of the glove

compartment.

A. Glove CompartmentB. Tool Kit

Cupholders

Cupholders are provided at the left and right sidesof the dashboard.

A. Cupholder (Both Sides)


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Front Access Cover

The front access cover can be removed for main-tenance such as a coolant level inspection.

NOTICEDo not store items under the front accesscover. This area is not designed for storage.

Cover Opening

• Turn the knobs counterclockwise 90° to releasethe locks.

• Pull the front of the front access cover up andopen the cover.

A. Front Access CoverB. Knobs

• Pull the front access cover forward to disengagethe tabs from the slits of the front hood.

A. Front Access CoverB. TabsC. Slits

Cover Closing

• Insert the tabs on the front access cover to theslits of the front hood.

• Lower the front access cover and turn the knobsclockwise until they stop to lock the front accesscover.


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A. Front Access CoverB. Knob (Both Sides)

• Pull up the front ends of the front access cover tomake sure the cover is locked securely.

WARNINGAn open front access cover can distract orimpair visibility of the operator, causing lossof vehicle control and potential serious injuryor death.Lock the front access cover securely beforeoperating the vehicle.

Horn Switch

Push the horn switch to sound the horn.

A. Horn Switch


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Main Switch

This is a three-position, key-operated switch. Thekey can be removed from the switch only when it isin the “OFF” position.

A. Main SwitchB. “OFF” PositionC. “ON” PositionD. “START” Position

OFF Engine off. All electrical circuits off.

ONAll electrical equipment can be used.Hour meter works.

START

Electric starter is engaged by holdingmain switch key in this position, onlywhen gear shift lever is in “N” (neutral)position or applying brake pedal. Uponrelease, key will return to “ON” position.

NOTICEDo not operate the starter continuously formore than 5 seconds, or the starter will over-heat and the battery power will drop tempora-rily. Wait 15 seconds between each operationof the starter to let it cool and for the batteryto recover power.Do not turn the main switch key to the“START” position with the engine running, ordamage to the starter can result.

NOTE○The vehicle is equipped with a starter lockout sys-tem. This system prevents the electric starter fromoperating when the gear shift lever is in the “H”(High), “L” (Low) or “R” (Reverse) position, unlessthe brake is applied.

Blank keys are available at your Kawasaki dealer.Ask your dealer to make any additional spare keysyou need, using your original key as a master.


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Gear Shift Lever

The gear shift lever is located on the dashboard,to the right side of the steering wheel. The gear shiftlever has four positions: “L” (Low), “H” (High), “N”(Neutral), and “R” (Reverse).Make certain that the vehicle is completely

stopped and the engine is idling before shifting from“H” (High) or “L” (Low) to “R” (Reverse) or vice ver-sa. Move the gear shift lever up or down as indi-cated on the embossed mark next to the gear shiftlever.Refer to the “Shifting Gears” section in the “HOW

TO OPERATE” chapter.A. Gear Shift LeverB. “L” (Low) PositionC. “H” (High) PositionD. “N” (Neutral) PositionE. “R” (Reverse) Position

NOTICEDo not shift from “H” (High) or “L” (Low) to“R” (Reverse) and vice versa when the ve-hicle is moving or with the engine runningabove idling speed, or the transmission couldbe damaged.

This vehicle is equipped with a sub-transmissionto allow maximum transmission efficiency. Use thelow gearing for maximum torque at low speeds, forclimbing hills, pulling a trailer, or keeping constantlow speeds. The high gearing raises the speed


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range for ordinary off-highway use. Stop the vehiclebefore moving the gear shift lever.

NOTICEUse 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 andpulleys. Use low range for these conditions.

Refer to the “Shifting Gears” section in the “HOWTO OPERATE” chapter.

Selectable 2WD/4WD Shift Switch

You can select “2WD” or “4WD” to suit variousdriving conditions. The selectable 2WD/4WD shiftswitch is located on the dashboard.

A. Selectable 2WD/4WD Shift SwitchB. “2WD” PositionC. “4WD” Position

The current operating condition is indicated withthe 2WD/4WD indicator symbols in the multifunctionmeter.


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A. “2WD” Indicator SymbolB. “4WD” Indicator Symbol

Refer to the “Multifunction Meter” section in thischapter, together with the “2WD/4WD Shifting” sec-tion in the “HOW TO OPERATE” chapter.

WARNINGThe handling characteristics of this vehiclediffers between “2WD” and “4WD” accordingto terrain. Changing the operating mode whilemoving can cause sudden changes in han-dling performance which can cause the oper-ator to lose control and have an accident.Always stop the vehicle before changing from“2WD” to “4WD” and vice versa.

NOTICEShifting from “2WD” to “4WD” (or “4WD” to“2WD”) when the vehicle is in motion couldcause drive train damage.


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Selectable DIFF-LOCK Shift Switch

You can select differential “LOCK” (locked-rearaxle) or “UNLOCK” (unlocked-rear axle) modes tosuit various driving conditions. The selectable DIFF-LOCK shift switch is located on the dashboard.

A. Selectable DIFF-LOCK Shift SwitchB. “LOCK” Position (Locked-Rear Axle Mode)C. “UNLOCK” Position (Unlocked-Rear Axle Mode)D. DIFF-LOCK Indicator Light

The “LOCK” (locked-rear axle) condition is indi-cated by a light in the switch as a reminder. Refer tothe “Shifting the Differential” section in the “HOWTO OPERATE” chapter.

Belt Drive Transmission

This vehicle is equipped with a belt-driven Contin-uously Variable Transmission (CVT). This automaticdrive system, although simple to operate, does re-quire periodic inspection. Refer to the “MAINTE-NANCE AND ADJUSTMENT” chapter.


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Parking Brake Lever

The parking brake lever is located at the left sideof the steering wheel. Pull the lever rearward to ap-ply the parking brake.To release, push in and hold the knob on the end

of the lever and push the lever all the way forward.Spring pressure helps return the lever to the re-leased position.Be sure to release the parking brake before driv-

ing off. Failure to do so may result in poor perform-ance and premature wearing of the rear brakes andbelt converter system.The alarm buzzer will sound if the vehicle is run-

ning with the parking brake applied. Stop the vehicleand release the parking brake.

A. Parking Brake LeverB. Knob

WARNINGIf the vehicle should move after it is parked, itmight be damaged or cause injury. Be sure toapply the parking brake before leaving the ve-hicle.


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Doors

Pull the door handle outward to open the door.Push or pull the door inward until the latch clicks

to close the door. After closing the door, be sure tocheck that the latch is securely locked. If a door isdamaged or does not close securely, contact an au-thorized Kawasaki dealer for repair or replacement.

A. Door HandleB. DoorC. Latch

NOTE○Make sure that the all doors are properly closedbefore starting the vehicle.

NOTICEThe doors are not designed to bear weight.Never lean on or place excessive weight onthe doors or they will be damaged.


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Seats

There are front and rear seats on this vehicle. Itcan be transformed from 2-persons to 4-persons byunfolding the rear seat.2-Persons Mode

A. Rear Seat (Folded Position)

4-Persons Mode

A. Rear Seat

NOTE○Converting the rear seat must be made in combi-nation with cargo bed conversion. Refer to the“Converting Rear Seat and Cargo Bed” section inthis chapter.

The front seat can be removed for vehicle mainte-nance and adjustment.

Front Seat Removal• Pull up the right and left ends of the front seat toclear the projections.

• Remove the front seat.


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A. Front SeatB. ProjectionsC. Pull up.

Front Seat Installation• Make sure that grommets are in position.

• Insert the projections of the front seat into thegrommets.

A. Front SeatB. Projection (Both Sides)C. Grommet (Both Sides)


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Seat Belts

The vehicle is equipped with retractable three-point seat belts for all occupants - operator and pas-senger for the front seat and two passengers for therear seat. Always wear the seat belts when operat-ing and riding in the vehicle.

A. Seat BeltB. Latch PlateC. Buckle

WARNINGNot wearing a seat belt, or wearing one im-properly can result in serious injury or deathin the event of an accident. Make certain theoperator and all passengers always wear theirseat belts properly.

WARNINGOperator and all passengers must be able toplace both feet flat on the floorboards whileseated upright with their backs against theseatbacks.

To wear the seat belt properly, follow this proce-dure:1. Place the belt across your lap and chest taking

care that the belt is not twisted.2. Push the latch plate into the buckle until it clicks.

Pull up on the latch plate to make sure it is se-cure.

A. Seat BeltB. Latch PlateC. BuckleD. Red Button


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3. Put the lap portion of the belt low on your hips.Push down on the buckle end of the belt as youpull up on the shoulder part so the belt is snugacross your hips.

4. Place the shoulder belt over your shoulder andacross your chest. The shoulder belt should fitagainst your chest. If it is loose, pull the belt outall the way and then let it retract.

A. Lap Portion of BeltB. Shoulder Belt

5. To unfasten the belt, press the red button in thebuckle.

WARNINGToo much seat belt slack could reduce its pro-tection effectiveness in an accident. Alwaysverify that the belt is at a SNUG FIT.

The seat belt is equipped with a dual mode latchplate. Under normal driving conditions the belt willself adjust to the seat occupant so that it is snugaround both the occupant's waist and shoulder.Under rough driving situations the dual mode latchplate will lock the seat belt in place.To release the lock:

• Move the slider in the direction of the arrow mark.

A. SliderB. Arrow Marks


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Throttle Pedal

The throttle pedal is the right pedal on the floor-board. Push the pedal down to increase enginespeed. Spring pressure returns the pedal to the restposition when released. Always check that the throt-tle pedal returns normally before starting the engine.In addition, there must be adequate throttle pedalplay and correct throttle stop position adjustment.Refer to the “MAINTENANCE AND ADJUSTMENT”chapter for the throttle pedal adjustment procedure.

A. Throttle PedalB. Floorboard

Trailer Hitch Bracket

This vehicle is equipped with a bracket for a trailerhitch. Trailer towing equipment is not supplied withthis vehicle.To avoid injury and property damage, observe the

following precautions:

WARNINGImproper towing of a loaded trailer couldcause an accident resulting in serious injuryor death.

• Never carry a passenger in a trailer.

• Never load more than 68.1 kg (150 lb)tongue weight on the towing bracket.

• Do not operate the vehicle faster than 16km/h (10 mph) when towing. Remember thattowing a trailer increases braking distance.

• Do not tow more than 907 kg (2 000 lb)trailer weight (trailer plus cargo weight).

• Attach a trailer to the trailer hitch bracketonly. Do not attach a trailer to any other lo-cation or you may lose control of the ve-hicle and have an accident.


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A. Trailer Hitch Bracket


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BREAK-IN

The first 20 hours or 200 km (120 mile) of vehicleoperation is designated as the break-in period. Donot exceed 1/2 throttle during the break-in period. Ifthe vehicle is not used carefully during this period,you may end up with a “broken down” instead of“broken in” vehicle.

Break-in period Maximum throttle position

First 20 hours or200 km (120 mile)

1/2 throttle

NOTE○Do not start moving or race the engine immedi-ately after starting it, even if the engine is alreadywarm.

○Do not race the engine while the transmission isin neutral.

○It is important to perform the initial service afterthe first 20 hours or 200 km (120 mile) of opera-tion as described in this manual and the servicemanual for this vehicle. See the “Periodic Mainte-nance Chart” in the “MAINTENANCE AND AD-JUSTMENT” chapter.

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HOW TO OPERATE

Daily Checks

Check the following items each day before operation. The time required is minimal, and habitual performanceof these checks will help ensure safe, reliable operation.If any irregularities are found during these checks, refer to the “MAINTENANCE AND ADJUSTMENT” chap-

ter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operat-ing condition.

WARNINGFailure to perform these checks before operation may result in serious damage or an accident. Al-ways perform daily checks before operation.

DANGERExhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon mon-oxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas. Operate on-ly in a well-ventilated area.

Fuel ................................................... Enough fuel in tank, no leaks.Fuel Filter .......................................... Check filter element for contamination.Water Separator ............................... Check for water accumulation and filter element contamination.Engine Oil ......................................... Oil level between Full and Low holes on the dipstick (when engine is

cold), no leaks.Tires .................................................. Air pressure (when cold):

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Tire Load Cold Tire Pressure

Front Up to 733 kg (1 616 lb) 78.4 kPa (0.80 kgf/cm², 11.4 psi)

RearUp to 590 kg (1 300 lb) 110 kPa (1.12 kgf/cm², 16.0 psi)

590 ~ 733 kg (1 300 ~ 1 616 lb) 130 kPa (1.33 kgf/cm², 18.9 psi)

Check for cuts, cracks, damage, or excessive wear. Check for any im-bedded stones or other foreign particles in tread.

Front Final Gear Case Oil ................. Oil level come to the bottom of the filler opening, no leaks.Transmission Case Oil ...................... Oil level between high and low levels on the rib in the oil filler opening,

no leaks.Coolant ............................................. Coolant level between level lines (when engine is cold), no leaks.Air Cleaner Element .......................... Check for dirt; clean or replace as required.Screen at Belt Drive Transmission(CVT) Air Duct .............................. Check and clean the screen for obstruction by insects, mud or foreign

object.Throttle .............................................. Throttle pedal free play 2 ~ 10 mm (0.08 ~ 0.39 in.). Throttle pedal op-

erates smoothly and returns to rest position when released.Steering ............................................ Steering wheel free play 0 ~ 20 mm (0 ~ 0.79 in.). Action smooth with-

out excessive play, rough spots, or strange noises.Brakes ............................................... Check for braking effectiveness (while test running). Brake pedal free

play 2 ~ 10 mm (0.08 ~ 0.39 in.). Brake fluid level between level lines,no leaks. Parking brake: Stops vehicle completely. Visually check thereturn springs for damage.

Parking Brake Indicator .................... Make sure the parking brake indicator light illuminates when the park-ing brake is applied with the main switch in the “ON” position.

Electrical Equipment ......................... All lights work. Check for dirt on or damage to lights.ROPS ................................................ Make sure there is no damage to the structure or loose bolts.Seat Belts ......................................... Make sure that all seat belts are in good condition and operate prop-

erly. The belt should pull smoothly and retract when released. The latchplate should click securely with the buckle and release when the re-lease button is pushed firmly.

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Doors ................................................ Make sure there is no damage to the structure or loose bolts and alldoors are latched securely they are closed.

80 HOW TO OPERATE

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Starting the Engine

DANGERExhaust gas contains carbon monoxide, acolorless, odorless poisonous gas. Inhalingcarbon monoxide can cause serious brain in-jury or death. DO NOT run the engine in en-closed areas. Operate only in a well-ventilated area.

• Close all doors.

• Wear the seat belts (for an operator and passen-ger (s)).

• Make sure the parking brake is applied.

• Put the gear shift lever in the “N” (neutral) posi-tion.

• Put the main switch key in the main switch.

• Turn the main switch key to the “ON” position. Theglow plug system is designed so that the glowplug indicator light goes on at that time, and turnoff after 4 seconds.

• After the glow plug indicator light turns off, turn themain switch key to the “START” position to acti-vate the electric starter. Repeat until the enginestarts.

NOTICEDo not operate the electric starter continu-ously for more than 5 seconds, or the startermay overheat and the battery power will droptemporarily. Wait 15 seconds between eachoperation of the starter to let it cool and forbattery power to recover.

NOTE○The vehicle is equipped with a starter lockout sys-tem. This system prevents the electric starter fromoperating when the gear shift lever is in the “H”(High) , “L” (Low) or “R” (Reverse) position, unlessthe brake is applied.

High-Altitude Injection Control Device

This vehicle has a high-altitude injection controldevice installed. It suppresses black smoke whenoperating at high altitudes and at the same timeaims to control particulate matter.The control device measures the atmospheric

pressure just after the engine has started. If at thistime the control device determines that the altitudeis 800 m (2 600 ft) or more, it reduces the fuel injec-tion amount and thus controls the occurrence ofblack smoke.Because of this reduction in the injection amount,

the engine output decreases.

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NOTE○The high-altitude injection control device does notactuate during engine operation. Therefore, whenthe machine is moved to a high altitude or to a lowaltitude during operation, turn the main switch keyto the “OFF” position. This resets the control de-vice. After re-starting the engine, the necessity forinjection control is again determined.

Cold Weather Starting

Idling speed may not be stable and/or the enginecould stall when it is started in cold weather. How-ever this is not engine failure.If the ambient temperature is 0°C (32°F) or lower,

use the following starting procedure to make idlingspeed steady.

• Close all doors.

• Wear the seat belts (for an operator and passen-ger (s)).

• Make sure the parking brake is applied.


• Put the main switch key in the main switch.

• Turn the main switch key to the “ON” position.

• The glow plug indicator goes on for 4 seconds.

• When the glow plug indicator goes off, push downthe throttle pedal partially, and turn the mainswitch key to the “START” position. The glow plugindicator goes on again, and the engine starts run-ning.

• Return the main switch key to the “ON” position.The glow plug indicator goes off.

• After the engine is started, keep the throttle pedalpartially pushed down for one minute maximumuntil idling speed becomes steady.

• After idling speed is steady, release the throttlepedal.

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Jump Starting

If your vehicle's battery is “run down,” it should beremoved and charged. If this is not practical, a 12volt booster battery and jumper cables may be usedto start the engine.

DANGERBattery acid generates hydrogen gas which isflammable and explosive under certain condi-tions. It is present within a battery at all times,even in a discharged condition. Keep allflames and sparks (cigarettes) away from thebattery. Wear eye protection when workingwith a battery. In the event of battery acid con-tact with skin, eyes, or clothing, wash the af-fected areas immediately with water for atleast 5 minutes. Seek medical attention.

Connecting Jumper Cables• Make sure the main switch is turned off.

• Remove the battery cover located at the right sideof the rear seat. Refer to the “Battery” section inthe “MAINTENANCE AND ADJUSTMENT” chap-ter.

A. Battery Cover

• Lift the cargo bed and support it with the support-ing rod. Refer to the “Cargo Bed” section in the“GENERAL INFORMATION” chapter.

• Connect a jumper cable from the positive (+) ter-minal of the booster battery to the positive (+) ter-minal of the vehicle battery.

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A. Vehicle Battery Positive (+) TerminalB. From Booster Battery Positive (+) TerminalC. From Booster Battery Negative (–) TerminalD. Bracket

• Connect another jumper cable from the negative(–) terminal of the booster battery to the bracket.

NOTICEDo not connect the booster battery to the fol-lowing portions as a ground.

• Battery negative (–) terminal

• Electrical components or leads

• Fuel line or fuel relative components

DANGERBatteries contain sulfuric acid that can causeburns and produce hydrogen gas which ishighly explosive.

• Do not make this last connection at the fuelsystem or battery.

• Take care not to touch the positive and neg-ative cables together, and do not lean overthe battery when making this last connec-tion.

• Do not connect to a frozen battery. It couldexplode.

• Do not reverse polarity by connecting posi-tive (+) to negative (–), or a battery explo-sion and serious damage to the electricalsystem may occur.

• Follow the standard engine starting procedure.

NOTICEDo not operate the starter continuously formore than 5 seconds, or the starter overheatand the battery power will drop temporarily.Wait 15 seconds between each operation ofthe starter to let it cool and for the battery torecover power.

• After the engine starts, disconnect the jumper ca-bles. Disconnect the negative (–) cable from thevehicle first.

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• Reinstall the battery cover. Refer to the “Battery”section in the “MAINTENANCE AND ADJUST-MENT” chapter.

• Lower the cargo bed and secure it with thelatches. Refer to the “Cargo Bed” section in the“GENERAL INFORMATION” chapter.

Moving Off

• Make sure that all doors are properly closed.

• Depress the brake pedal.

• Put the gear shift lever into the “H” (High) or “L”(Low) position.

• Release the parking brake.

• Gradually increase engine speed by pressing onthe throttle pedal.

NOTE○Practice starting and stopping (using the brakes)until you are familiar with the controls.

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Braking

NOTE○When the throttle pedal is released completelyand the engine speed drops near an idle, the ve-hicle has no engine braking. This is caused by thevehicle's automatic transmission which releasesthe engine at very low speed to prevent it fromstalling. Employ the brakes to control the vehicle'sspeed.

• Release the throttle pedal completely.

• Press on the brake pedal evenly and firmly.

WARNINGCarrying cargo or towing a trailer will in-crease braking distances. Failure to allow forincreased braking distance may result in acci-dent and injury. Always allow more distanceto stop when carrying cargo or towing atrailer.

Stopping the Engine

• Release the throttle pedal completely.

• Put the gear shift lever into the “N” (neutral) posi-tion.

• Apply the parking brake to help prevent the ve-hicle from rolling.

• Turn the main switch key to the “OFF” position.

86 HOW TO OPERATE

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Parking the Mule

WARNINGOperating or parking the vehicle near flamma-ble materials can cause a fire, and can resultin property damage or severe personal injury.Do not idle or park your vehicle in an areawhere tall or dry vegetation, or other flamma-ble materials could come into contact withthe muffler or exhaust pipe.

WARNINGThe engine and exhaust system get extremelyhot during normal operation and can causeserious burns.Never touch a hot engine, exhaust pipe, ormuffler during operation or after stopping theengine.

• Stop the vehicle on a level surface.

NOTICEAvoid parking on steeply inclined surfaces.

• When the engine has stopped, apply the parkingbrake to help prevent the vehicle from rolling.

A. Parking Brake Lever

WARNINGIf the vehicle should move after it is parked, itmight be damaged or cause injury. Be sure toapply the parking brake before leaving the ve-hicle.

• Remove the main switch key to prevent unauthor-ized 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.

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WARNINGDiesel fuel is extremely flammable and can beexplosive under certain conditions, creatingthe potential for serious burns. Do not smoke.Make sure the area is well ventilated and freefrom any source of flame or sparks; this in-cludes any appliance with a pilot light.

Shifting Gears

• Stop the vehicle completely.

• Move the gear shift lever into the “H” (High) or “L”(Low) position.

• If you intend to operate the vehicle in reverse,move the gear shift lever into the “R” (Reverse)position. Refer to the “Driving in Reverse” sectionin the “SAFE OPERATION” chapter.

• Gradually increase engine speed by depressingthe throttle pedal.

A. Gear Shift LeverB. “L” (Low) PositionC. “H” (High) PositionD. “N” (Neutral) PositionE. “R” (Reverse) Position

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WARNINGShifting the transmission while the vehicle ismoving can cause abrupt changes in speedand direction resulting in loss of control andaccident with severe personal injury or death.Do not shift the transmission while the ve-hicle is moving. Stop the vehicle to shift thetransmission.

NOTICEShifting to high or low range when the vehicleis in motion could cause engine damage.Do not shift from “H” (High) or “L” (Low) to“R” (Reverse) and vice versa when the ve-hicle is moving or with the engine runningabove idling speed, or the transmission couldbe damaged.

NOTICEUse of the high range for heavy loads, climb-ing hills, pulling a trailer, and sustained low-speed riding can lead to premature wear ofthe torque converter belt and pulleys. Use thelow range for these condition.

2WD/4WD Shifting


• Push the selectable 2WD/4WD shift switch to se-lect the drive modes.

A. Selectable 2WD/4WD Shift SwitchB. “2WD” PositionC. “4WD” Position

NOTE○The “4WD” operating mode is indicated with the“4WD” indicator symbol. Refer to the “Multifunc-tion Meter” section in the “GENERAL INFORMA-TION” chapter.

○When the shift switch is changed from “4WD” to“2WD” and vice versa, the transmission shiftswhen the vehicle has rolled a short distance.Drive off slowly to allow “4WD” to engage or

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disengage. As it engages, the “4WD” indicatorsymbol will appear.

○It is normal to hear a small clanking noise when“4WD” engages or disengages while rolling onhard surfaces, such as hard-packed dirt.

WARNINGThe handling characteristics of this vehiclediffers between “2WD” and “4WD” accordingto terrain. Changing the operating mode whilemoving can cause sudden changes in han-dling performance which can cause the oper-ator to lose control and have an accident.Always stop the vehicle before changing from“2WD” to “4WD” and vice versa.

NOTICEShifting from “2WD” to “4WD” (or “4WD” to“2WD”) when the vehicle is in motion couldcause drive train damage.

Shifting the Differential


• Push the selectable DIFF-LOCK shift switch to“LOCK” position.

A. Selectable DIFF-LOCK Shift SwitchB. “LOCK” Position (Locked-Rear Axle Mode)C. “UNLOCK” Position (Unlocked-Rear Axle Mode)D. DIFF-LOCK Indicator Light

• After crossing the obstacle, push the shift switchto “UNLOCK” (Unlocked-Rear Axle) position.

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WARNINGShifting to Locked-Axle Mode while turning orbefore entering a turn can reduce steering re-sponse, increasing the effort to turn. An unex-pected change in direction can cause theoperator to lose control, resulting in an acci-dent and injury. Do not shift to Locked-AxleMode while turning or before entering a turn.

NOTE○By pushing the shift switch to “LOCK” position, ro-tational speed of both wheels is equalized therebyincreasing traction.

Shifting to Differential (Unlocked-Rear Axle)Mode• Stop the vehicle completely.

• Turn the selectable DIFF-LOCK shift switch to“UNLOCK” position.

NOTICEShifting from “UNLOCK” to “LOCK” (or“LOCK” to “UNLOCK”) when the vehicle is inmotion could cause drive train damage.

When Stuck

Release the throttle pedal immediately to protectthe drive belt and take the following actions to es-cape from the stuck condition.

• Change the gear shift lever to the “L” (Low) posi-tion, push the selectable DIFF-LOCK shift switchto “LOCK” position, push the selectable2WD/4WD shift switch to “4WD” position, and tryto escape by slowly revving up the engine. Referto the “Shifting the Differential” section in thischapter.

• If the above method is not successful, you canuse a winch installed at the front of the vehicle(Winch is an optional part.) or seek help from an-other vehicle for towing.

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SAFE OPERATION

Safety is an attitude. Your common sense andgood judgement are your best defenses against ac-cident and injury in everything you do. Your safetyand the safety of others depends on you and yourcommon sense. Use good judgement in the opera-tion of this or any other motor vehicle.

This vehicle is designed for an operator and pas-senger (for 2-persons mode) or an operator andthree passengers (for 4-persons mode). Never carrypersons in the cargo bed. Refer to the “LOADINGINFORMATION” chapter before operating this ve-hicle.

Novice operators should practice braking andturning in an open, off-highway area away from oth-er vehicles and persons. The terrain should be flatand free of obstacles, with either a loose or hard dirtsurface, but not a mixture of both.

WARNINGIncorrect loading, improper installation or useof accessories, or modification of your ve-hicle may result in an unsafe operating condi-tion. Before operation, make sure that thevehicle is not overloaded and that you havefollowed the instructions in the “LOADING IN-FORMATION” chapter.

Unfamiliar Terrain

Before driving in a new area be sure to check forhidden obstacles or hazards. Keep your speeddown until you know the area well. You must knowthe terrain you intend to drive on and be familiar withyour machine and its handling characteristics. Useexisting trails and stay away from hazardous areassuch as steep, rocky slopes or swamps. Be cau-tious when visibility is limited, as you may not beable to see obstacles in your path.

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Driving in Reverse

Start the engine following the procedure in the“Starting the Engine” section. Before shifting into re-verse, stop the vehicle completely. Refer to the“Gear Shift Lever” in the “GENERAL INFORMA-TION” chapter and “Shifting Gears” section in the“HOW TO OPERATE” chapter.Turn around and look behind you before backing

up to be sure there are no obstacles or people inyour way. Gradually open the throttle and beginbacking up cautiously.To stop while driving in reverse, close the throttle

and gradually apply the brake. Avoid sudden appli-cation of the brake.

NOTICEDo not operate the gear shift lever to changegears while driving the vehicle in reverse, orthe transmission may be damaged.

Remember

• Look behind you before backing up.

• Open the throttle gradually.

• To stop, gradually apply the brake.

Driving in “4WD”

“4WD” gives greater traction when you are climb-ing steep inclines, or driving on bumpy, sandy orsnowy surfaces. It also helps break loose, with thedifferential locked under certain circumstances, forexample, when the vehicle is stuck in the mud. Ifmaximum torque is needed in these situations, shiftinto the “L” (Low) position with the gear shift lever.Refer to the “Shifting Gears” section, “2WD/4WDShifting” and “Shifting the Differential” sections inthe “HOW TO OPERATE” chapter.

NOTE○Do not drive in “4WD” on paved surfaces, be-cause it increases tire and drive train wear andmakes the steering feel tight.

Remember

• Use “4WD” on steep inclines or loose surfaces, orwhen stuck in the mud, with the differential lockedif necessary.

• For maximum torque shift into low range.

• Do not drive in “4WD” on paved surfaces.

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Turning the Vehicle

The vehicle will turn in a smaller radius with thedifferential unlocked (in differential mode). In thismode, the rear wheels can turn at different speedsallowing the vehicle to turn tighter and moresmoothly. Even in this mode, however, avoid sharpturns to keep the vehicle from tipping. Reduce ve-hicle speed before entering the turn and use thethrottle to maintain an even speed through the turn.

WARNINGIn the differential mode, if either rear wheelleaves the ground it will spin freely, and thewheel on the ground will transmit very littlepower. When a spinning wheel touches theground, it may grab abruptly, causing the op-erator to lose control. Do not make sharpturns, even in the differential mode, in orderto avoid loss of control or tipping.

Remember

• Slow down before entering the turn.

• Maintain an even speed through the turn.

Hills

As with any motor vehicle, loading of the vehicle,and the surface and steepness of the hill are amongthe critical considerations in climbing, descending ortraversing hills. Use extreme caution on hills. Keepin mind that loading changes a vehicle's center ofgravity and that the higher the center of gravity, themore likely the vehicle is to tip on uneven surfaces.Slippery, loose, or bumpy surfaces on hills are espe-cially hazardous. Some hills are just too steep toclimb. Always use common sense and practicegood judgement.

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Climbing Hills

Do not attempt to climb hills or steep inclines untilyou have mastered the controls and basic operatingmaneuvers of this vehicle. Always go straight uphilland, if the incline is steep and/or the surface isloose, use “4WD” with the differential locked forgreater traction, and in low range for maximum tor-que.Avoid hills with slippery sides that will cause you

to lose traction. Do not climb hills where you cannotsee far enough ahead. If you cannot see what is onthe other side of the crest of a hill, slow down untilyou can get a clear view. Don't apply power sud-denly while climbing, or the front wheels might riseoff the ground. If the vehicle does not have enoughpower to reach the top of the hill and stalls, allowthe vehicle to roll slowly straight back down the hillcontrolling its descent with the brakes. Leave thegear shift lever in the “H” (High) or “L” (Low) positionuntil you stop at the bottom of the hill.

WARNINGRiding sideways across a hill may cause thevehicle to overturn, causing severe injury ordeath. Do not turn sideways to the hill.

Remember

• Some hills are too steep. Use common sense.

• Never drive past your limit of visibility. If you can'tsee what is on the other side of the crest of a hill,slow down until you can get a clear view.

• Don't turn sideways to the hill.

• If you get stuck on a hill, roll slowly straight backdown, using the brake, with the gear shift lever leftin the “H” (High) or “L” (Low) position.

NOTE○When the throttle pedal is released completelyand the engine speed drops near an idle, the ve-hicle has no engine braking. This is caused by thevehicle's automatic transmission which releasesthe engine at very low speed to prevent it fromstalling. Use the brakes to control the vehicle'sspeed.

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Descending Hills

Slow down or stop at the top of a hill so you canpick a straight, safe path for descent to avoid anyobstacles. Normally you should descend straightdown a hill since driving at an angle could cause thevehicle to lean to one side and possibly tip over.Proceed slowly and cautiously. Apply the brake asnecessary. Be careful if the surface is loose be-cause the tires are more likely to skid and brakingeffectiveness will be reduced.Turning while descending a slope must be done

very carefully and gradually to avoid tipping the ve-hicle over.

WARNINGRiding sideways across a hill may cause thevehicle to overturn, causing severe injury ordeath. Do not turn sideways to the hill.

Remember

• Stop and look for obstacles before descending ahill.

• Go straight downhill.

• Go slowly.

• If you must turn, do so carefully and gradually.

NOTE○When the throttle pedal is released completelyand the engine speed drops near an idle, the ve-hicle has no engine braking. This is caused by the

vehicle's automatic transmission which releasesthe engine at very low speed to prevent it fromstalling. Use the brakes to control the vehicle'sspeed.

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Traversing Hillsides

When driving across the side of a hill, reduce ve-hicle speed and exercise extreme caution to preventtipping or loss of control. Avoid hills with slipperysides that will cause you to lose traction. Also avoidtraversing hillsides covered with rocks or other ob-stacles which may cause you to lose your balanceor tip over.When driving on soft terrain, steer slightly uphill to

keep the vehicle on a straight line across the hill-side.If the vehicle begins to tip, steer downhill if possi-

ble to regain control.

Sliding and Skidding

Obviously, on slippery or loose surfaces, specialcare is required. Sliding any vehicle may be hazard-ous because the wheels may suddenly regain trac-tion and cause the vehicle to tip or overturn.Therefore, never drive “over your head” or whenyou are unsure or unprepared for the surface.Often you can correct a skid by turning the wheels

in the direction of the skid. Do not apply heavy brak-ing force or accelerate when skidding, since thismay cause further loss of control.Use caution and maintain low speeds to avoid un-

controlled skidding on areas covered with clay,mud, ice, or snow. Use “4WD” and low range gear-ing efficiently. These conditions are particularly haz-ardous when descending a hill or making a turn.Remember that this vehicle is not for use on publicstreets, roads, or highways.

Remember

• Be especially careful on very slippery surfaces.

• Don't drive on public streets, roads, or highways.

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Driving through Water

Avoid driving through water whenever it is possi-ble. When driving across shallow water, choose alocation to enter and exit the water where the banksare not too steep or slippery. Check before enteringfor rocks, holes or other obstacles which may causeyou to overturn or become stuck or submerged.Observe the following rules for operating the ve-

hicle in water.

A. Axle Nut

WARNINGOperating the vehicle in rivers or streamswhere water is flowing quickly can cause thetires to lose traction and allow the vehicle tobe swept into the current. Never operate thevehicle in fast-flowing water or in water deep-er than the bottom edge of the axle nuts.

After prolonged exposure to water, the wheelbearings may require lubrication or replacement.Wash the vehicle in fresh water if it has been ex-

posed to salt water or operated in muddy condi-tions.

WARNINGWet brakes provide greatly reduced efficiencyand could lead to an accident and injury. Afteroperation in water, always apply the brakeslong enough for friction to dry the linings. Al-so, the brake that gets wet may wear out fast-er. Check for brake wear more frequently ifthe vehicle is used in water.

Remember

• Avoid driving through water whenever possible.

• Don't drive in deep and fast moving water.

• Dry out the brakes.

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Operator and Passenger Requirements

All operators of this vehicle should possess a validdriver's license.The operator and passenger(s) must be able to

place both feet flat on the floorboards while seatedupright with their backs against the seatbacks whenfirmly holding the steering wheel, handgrip or hand-hold.

WARNINGTo avoid injury in the event of a roll-over, keeparms and legs inside the vehicle at all times.The operator should firmly grip the steeringwheel at all times, and the front passengershould hold onto the handgrips. The rear pas-sengers should hold the handhold firmly withboth hands.

Close all the doors. Wear the seat belts (for an op-erator and passenger(s)). The doors, handgrip, andhandhold are not a substitute for the seat belts.

A. Front Right HandgripB. Rear Handhold

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This vehicle is designed for an operator and up tothree passengers.Never carry persons in the cargo bed. Refer to

the “LOADING INFORMATION” chapter before op-erating this vehicle.

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NOISE AND VIBRATION CONTROL INFORMATION

Control Information

Noise Level

Acceleration 78 dB (A)

Stationary 96 dB (A)

Driver's Ear 82 dB (A)

Test method: “Acceleration”, “Stationary”:97/24/EEC Chapter 9, Annex III

“Driver's Ear”: 77/311/EEC Annex II

Vibration Values

Steering Wheel 2.0 m/s²

Seat 0.3 m/s²

Test method: EN15997: 2011, Annex I

Please Do Not Tamper with Noise Control Sys-temTo minimize the noise emissions from this prod-

uct, Kawasaki has equipped it with effective intakeand exhaust silencing systems. They are designedto give optimum performance while maintaining alow noise level. Please do not remove these sys-tems, or alter them in any way which results in an in-crease in noise level.

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MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accord-ance with the Periodic Maintenance Chart to keep the Mule in good running condition. The initial maintenanceis 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-

nance or improper adjustment done by the owner.

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Periodic Maintenance Chart

In addition to the following items, always perform the Daily Checks listed in the HOW TO OPERATE chapter.

• = Clean, adjust, lubricate, replace parts as necessary.D = Service to be performed by an authorized Kawasaki Dealer or someone equally competent.* = Service more frequently when operated in mud, dust, or other harsh driving conditions.

FREQUENCY First Service Regular Service

OPERATION

After 20h, or 200km (120mile) ofuse

After 50h, or 1000 km(600

mile) ofuse

Every 50h, or 1000 km(600

mile) ofuse

Every 100h, or 2

000 km (1200 mile)of use

Every 200h, or 4


Everyyear ofuse

ENGINE

Throttle pedal play - inspect • •Fuel hose and connections - inspect D

Fuel hose - replace 2 years (D)

Idle speed - inspect D D

Air cleaner - clean and inspect* • •Valve clearance - inspect* D D

Spark arrester - clean and inspect •

Engine oil - change* •

•or every 6months

whichevercomesfirst

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OPERATION



mile) ofuse


mile) ofuse

Every 100h, or 2


Every 200h, or 4


Everyyear ofuse

Oil filter - replace* D

Dor every 6months

whichevercomesfirst

Front final gear case oil and transmissioncase oil - change • •Radiator - clean* • •Radiator hoses and connections - check* D

Coolant - change* D

Cooling fan belt - inspect* D D

Converter drive belt wear - inspect* D D

Converter drive belt deflection - inspect * D D

Converter drive pulley shoe - inspect* D D

Drive pulley coupling - apply grease D D

Fuel filter element - change* D

Water separator water - drain* D

Water separator water - clean* D


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OPERATION



mile) ofuse


mile) ofuse

Every 100h, or 2


Every 200h, or 4


Everyyear ofuse

CHASSIS

Brake pad wear - inspect* D D

Brake light switch - inspect • •Brake fluid - change 2 years (D)

Brake caliper piston seal and dust seal - re-place

2 years (D)

Brake hoses - replace 4 years (D)

Brake fluid level - inspect • •Brake pedal play - inspect • •Brake hoses and pipes - inspect D D

Parking brake - inspect* D D

Tire wear - inspect* • •Wheel nuts tightness - inspect • •Wheels - inspect D

Wheel hub bearings - inspect D

Joint boots - inspect • •Shock absorbers - inspect D

Suspension arms - inspect D


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OPERATION



mile) ofuse


mile) ofuse

Every 100h, or 2


Every 200h, or 4


Everyyear ofuse

Steering - inspect D D

Steering joint dust boots - inspect • •General lubrication - perform* D

Bolts, nuts, and fasteners tightness - in-spect

D D

Seat belts - inspect •Cables - inspect D

Cargo bed latch - inspect •


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Engine Oil

In order for the engine to function properly, main-tain the engine oil at the proper level, and changethe oil and oil filter in accordance with the PeriodicMaintenance Chart. Not only do dirt and metal par-ticles collect in the oil, but the oil itself loses its lubri-cative quality if used too long.

WARNINGVehicle operation with insufficient, deterio-rated, or contaminated engine oil will causeaccelerated wear and may result in engineseizure, accident, and injury. Check the oillevel before each use and change the oil andfilter according to the periodic maintenancechart in the owner’s manual.

Oil Level InspectionCheck the oil level when the engine is cold (room

or atmospheric temperature).

• Park the vehicle on level ground.

• Remove the battery cover (see Battery Removal).

• Pull up the dipstick out of the dipstick tube, wipe itdry, and insert the dipstick till it bottoms into thetube securely.

A. Dipstick

• Pull out the dipstick and check the oil level. Theoil level should be between the Full and Low holeson the dipstick.


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A. DipstickB. Full HoleC. Low Hole

• If the oil level is too high, remove the excess oil,using a syringe or other suitable device.

• If the oil level is too low, unscrew the oil filler cap 1and add slowly the correct amount of oil. Use thesame type and brand of oil that is already in theengine.

NOTICENever overfill. Overfilling may result in whiteexhaust smoke, engine overspeed or internaldamage.

• Apply engine oil to the rubber portion of the dip-stick.

• Reinsert the dipstick until it bottoms into the tubesecurely.

• Install the oil filler cap 1.

Oil and/or Oil Filter Change• Lift the cargo bed and support it with the support-ing rod.

• Warm up the engine thoroughly, and then stop theengine.

• Remove the oil filler cap 1.

A. Oil Filler Cap 1B. Oil Filler Cap 2

NOTE○There is another oil filler cap 2 on the engine. Thecap 2 is not required to be removed.

• Place an oil pan beneath the engine.

• Remove the drain bolt and gasket.


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A. Engine Oil Drain Bolt and Gasket

• Let the oil completely drain with the vehicle on lev-el ground.

WARNINGEngine oil is a toxic substance. Dispose ofused oil properly. Contact your local author-ities for approved disposal methods or possi-ble recycling.

• The oil filter should be replaced periodically by anauthorized Kawasaki dealer in accordance withthe Periodic Maintenance Chart.

• Replace the gasket with a new one.

• Install the drain bolt with its gasket. Tighten it tothe specified torque.

Tightening Torque

Engine Oil Drain Bolt:29.4 N·m (3.00 kgf·m, 21.7 ft·lb)

• Raise the filling funnel a little from the cylinderhead to allow the air in the crankcase to escape.

A. Funnel

• Fill the engine up to the Full hole on the dipstickwith high quality engine oil as specified in the ta-ble.


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NOTICETo fill the engine oil, fill slowly after removingthe cap. If the oil level in the cylinder headcover gets too high because of filling too fastor filling too much (overfilling), oil may over-flow into the intake manifold. Oil in the intakemanifold may flow into the combustion cham-bers and cause hydraulic lock, resulting in se-vere engine damage.

NOTICENever overfill. Overfilling may result in whiteexhaust smoke, engine overspeed or internaldamage.

Engine Oil

Type: API CD, CF, CF-4, CI-4 or CJ-4*Viscosity: SAE 10W-40Capacity: 2.1 L (2.2 US qt)

[when filter is not removed]

*: When using CJ-4 oil (low ash oil) in your en-gine, use fuel with less than 0.05% sulfur con-tent to avoid engine oil deterioration.

NOTE○Do not add any chemical additives to the oil. Oilsfulfilling the above requirements are fully

formulated and provide adequate lubrication forthe engine.

Although 10W-40 engine oil is the recommendedoil for most conditions, the oil viscosity may need tobe changed to accommodate atmospheric condi-tions in your driving area.STARTING TEMPERATURE RANGE ANTICI-PATED BEFORE NEXT OIL CHANGE

• After filling, wait several minutes until the oil set-tles.

• Reinstall the removed parts as before.

• Check the oil level.

• Start the engine and check for oil leakage.


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Front Final Gear Case Oil

In order for the differential, pinion, and ring gearsto function properly, check the oil level and changethe oil in accordance with the Periodic MaintenanceChart.

WARNINGVehicle operation with insufficient, deterio-rated, or contaminated oil causes acceleratedwear of the differential, pinion, and ring gearsand may result in seizure. Seizure can lockthe front wheels and skid the front tires, caus-ing loss of control. To prevent seizure, checkthe differential oil according to the periodicmaintenance chart.

Oil Level Inspection• With the vehicle level front-to-rear and side-to-side, remove the oil filler cap and O-ring from thefront final gear case.

A. Front Final Gear CaseB. Oil Filler Cap and O-ring

NOTICEBe careful not to allow any dirt or foreign ma-terials to enter the gear case.

• Check the oil level. The oil level should come tothe bottom of the filler opening. If it is low, add oilthrough the oil filler opening as necessary.


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A. Front Final Gear CaseB. Filler OpeningC. Bottom of the Filler Opening

• Replace the O-ring with a new one, and applygrease to it.

• Install the oil filler cap with the new O-ring andtighten it to the specified torque.

Tightening Torque

Front Final Gear Case Oil Filler Cap:16 N·m (1.6 kgf·m, 12 ft·lb)

• Clean any oil and grease from the oil filler cap andsurrounding area after tightening the oil filler cap.

NOTE○Use the same type and brand of oil that is alreadyin the gear case.

Oil Change

NOTE○Before draining the oil, warm it up by running thevehicle. Warm oil drains easily and picks up anysediment.

• With the vehicle level, place an oil pan beneaththe gear case.

• Remove the oil filler cap, drain plug and O-rings.

WARNINGGear case oil is a toxic substance. Dispose ofused oil properly. Contact your local author-ities for approved disposal methods or possi-ble recycling.

WARNINGOil on tires can make them slippery whichcan cause an accident and injury. When drain-ing or filling the gear case, be careful that nooil gets on the tires or rims. Clean off any oilthat inadvertently gets on them with soap andwater.


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A. Front Final Gear Case Oil Drain Plug and O-ring

• After the oil has completely drained, replace theO-ring with a new one, and apply grease to it.

• Install the drain plug with the new O-ring and tight-en it to the specified torque.

Tightening Torque

Front Final Gear Case Oil Drain Plug:16 N·m (1.6 kgf·m, 12 ft·lb)

• Fill the gear case to the bottom of the filler open-ing with a high quality oil as specified in the table.

Front Final Gear Case Oil


Type API “GL-5” Hypoid gear oil

Viscosityabove 5°C (41°F) SAE 90below 5°C (41°F) SAE 80



Tightening Torque

Front Final Gear Case Oil Filler Cap:16 N·m (1.6 kgf·m, 12 ft·lb)


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Transmission Case Oil

In order for the transmission, differential, pinion,and ring gears to function properly, check the oil lev-el and change the oil in accordance with the Peri-odic Maintenance Chart.

WARNINGVehicle operation with insufficient, deterio-rated, or contaminated oil causes acceleratedwear of the transmission, differential, pinion,and ring gears and may result in seizure.Seizure can lock the rear wheels and skid therear tires, causing loss of control. To preventseizure, check the transmission case oil ac-cording to the periodic maintenance chart.

Oil Level Inspection• Park the vehicle on level ground.

• Remove the oil filler cap and O-ring.

A. Transmission CaseB. Oil Filler Cap and O-ring

NOTICEBe careful not to allow any dirt or foreign ma-terials to enter the transmission case.

• Check the oil level view from the slit of the rib. Theoil level should be between the high and low lev-els on the rib as shown.


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A. SlitB. RibC. High LevelD. Low Level

• If the oil level is too high, remove the excess oil,using a syringe or other suitable device, throughthe oil filler opening.

• If the oil level is too low, add the correct amount ofoil.

NOTE○Use the same type and brand of oil that is alreadyin the transmission case.

○When adding oil, do not exceed the high level ofrib.



Tightening Torque

Transmission Case Oil Filler Cap:20 N·m (2.0 kgf·m, 15 ft·lb)

Oil Change

NOTE○Before draining the oil, warm it up by running thevehicle. Warm oil drains easily and picks up anysediment.

• With the vehicle level, place an oil pan beneaththe transmission case.

• Remove the drain bolt and gasket.

A. Transmission CaseB. Oil Drain Bolt and Gasket


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WARNINGThe exhaust system can get extremely hotduring normal operation and cause seriousburns. To avoid a serious burn, never touch ahot muffler or exhaust pipe during oil drain-ing.

• Remove the oil filler cap and O-ring.

WARNINGOil on tires can make them slippery whichcan cause an accident and injury. When drain-ing or filling the transmission case, be carefulthat no oil gets on the tires or rims. Clean offany oil that inadvertently gets on them withsoap and water.

• After the oil has completely drained, replace thegasket with a new one.

• Install the drain bolt with the new gasket and tight-en it to the specified torque.

Tightening Torque

Transmission Case Oil Drain Bolt:20 N·m (2.0 kgf·m, 15 ft·lb)

• Fill the transmission case to the high level on therib with a high quality oil as specified in the table.

Transmission Case Oil


Type API “GL-5” Hypoid gear oil

Viscosity above 5°C (41°F) SAE 90below 5°C (41°F) SAE 80



Tightening Torque

Transmission Case Oil Filler Cap:20 N·m (2.0 kgf·m, 15 ft·lb)


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Cooling System

WARNINGThe cooling system is pressurized and canget extremely hot during normal operationand cause serious burns. To prevent burns,do not touch the radiator when it is hot. Donot attempt to open the radiator cap when hotsince steam and hot coolant can forcefullyerupt when the cap is even loosened slightly.

Radiator and Cooling FanCheck and clean the screen and radiator fins for

obstruction by insects or mud in accordance withthe Periodic Maintenance Chart. In dusty areas, theradiator should be cleaned more frequently than therecommended interval.

WARNINGTo avoid injury, keep your hands and clothingaway from the fan blades at all times.

A. ScreenB. Radiator

• Clean the screen, and radiator fins of any obstruc-tions with a stream of low-pressure water.

• If insects or mud can not be completely removed,it should be cleaned by an authorized Kawasakidealer.

NOTICEUsing high-pressure water, as from a carwash facility, could damage the radiator finsand impair the radiator's effectiveness.Do not obstruct or deflect airflow through theradiator by installing unauthorized accesso-ries in front of the radiator or behind the cool-ing fan. Interference with the radiator airflowcan lead to overheating and consequent en-gine damage.


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CoolantCoolant absorbs excessive heat from the engine

and transfers it to the air at the radiator. If the cool-ant level becomes low, the engine overheats andmay suffer damage. Check the coolant level eachday before operating the vehicle, and replenishcoolant if the level is low. Change the coolant in ac-cordance with the Periodic Maintenance Chart.

NOTE○A permanent type of antifreeze is installed in thecooling system when shipped. It is colored greenand contains ethylene glycol. It is mixed at 50%with water and has a freezing point of –35°C (–31°F).

Coolant Level Inspection• Situate the vehicle on level ground.

• Remove the front access cover. Refer to the“Front Access Cover” section in the “GENERALINFORMATION” chapter.

• Check the coolant level through the coolant levelgauge on the reserve tank. The coolant levelshould be between the “F” (Full) and “L” (Low)marks.

NOTE○Check the level when the engine is cold (room oratmospheric temperature).

Coolant Capacity

6.1 L (6.4 US qt)

A. Reserve TankB. “F” (Full) MarkC. “L” (Low) MarkD. Cap

• If the amount of coolant is insufficient, unscrewthe cap from the reserve tank and add coolantthrough the filler opening to the “F” (Full) mark. In-stall the cap.

Recommended Coolant Solution

Coolant Mixture Ratio:

Water 50% : Antifreeze 50% (1 : 1)

Recommended Antifreeze:Permanent type antifreeze (ethylene glycol pluscorrosion and rust inhibitor chemicals for alumi-num engines and radiator).


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NOTE○In an emergency you can add water alone to thecoolant reserve tank, however it must be returnedto the correct mixture ratio by the addition of anti-freeze concentrate as soon as possible.

NOTICEIf coolant must be added often, or the reservetank completely runs dry, there is probablyleakage in the system. Have the cooling sys-tem inspected by your authorized Kawasakidealer.

Coolant ChangeHave the coolant changed by an authorized Ka-

wasaki dealer.

Cooling Fan BeltThe fan belt becomes loose and may crack after a

period of use. Inspect it in accordance with the Peri-odic Maintenance Chart. It may break if operatedwithout maintenance.Inspection should be done by an authorized Ka-

wasaki dealer.

A. Cooling Fan BeltB. Cooling Fan


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Valve Clearance

Valve and valve seat wear decrease valve clear-ance, upsetting valve timing.

NOTICEIf valve clearance is left unadjusted, wear willeventually cause the valves to remain partlyopen; which lowers performance, burns thevalves and valve seats, and may cause seri-ous engine damage.

Valve clearance for each valve should be checkedand adjusted in accordance with the Periodic Main-tenance Chart.Inspection and adjustment should be done by an

authorized Kawasaki dealer.

Valve Clearance (Engine Cold)

Intake 0.15 ~ 0.25 mm (0.0059 ~ 0.0098 in.)

Exhaust 0.15 ~ 0.25 mm (0.0059 ~ 0.0098 in.)

Engine Air Cleaner

A clogged engine air cleaner restricts the engine'sair intake, increasing fuel consumption, reducing en-gine power.

WARNINGA clogged air cleaner may allow dirt and dustto enter the fuel injection system and thethrottle may stick resulting in a hazardous op-erating condition. Clean the air filter accord-ing to the periodic maintenance chart; moreoften if the vehicle is used in extremely dustyconditions.

NOTICEA clogged air cleaner may allow dirt and dustto enter the engine causing excessive wearand possible engine damage.

The air filter element should be cleaned in accord-ance with the Periodic Maintenance Chart. In dustyareas, the element should be cleaned more fre-quently than the recommended interval.

Element Removal• Remove the battery cover (see Battery Removal).


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NOTE○If there is dust or mud around the battery and aircleaner housing, clean them using compressedair.

• Pull up the snaps and remove the air cleanerhousing cap.

A. SnapsB. Air Cleaner Housing Cap

• Pull the air cleaner element and adapter out of thehousing.

• Remove the element from the adapter.

A. ElementB. Adapter

• Push a clean lint-free towel into the air cleanerhousing to keep dirt or other foreign material fromentering.

WARNINGIf dirt or dust is allowed to pass through intothe fuel injection system, the throttle maystick or become inoperable resulting in a haz-ardous operating condition.

NOTICEIf dirt gets into the engine, excessive enginewear and possible engine damage may occur.


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Element Cleaning• Remove the element (see Element Removal).

• Clean the paper element by tapping it lightly toloosen dust.

• Blow away the remaining dust by applying com-pressed air from the inside to the outside (fromthe clean side to the dirty side).

• Inspect the element material for damage. If anypart of the element is damaged, the element mustbe replaced.

Element Installation• If there is dust and mud in the air cleaner housing,blow out the inside of the air cleaner housing withcompressed air. Be sure the air intake is com-pletely sealed with a clean cloth or other plugwhen air blowing.

• Remove the cloth or plug in the air intake.

• Install the element to the adapter.

• Fit the grooves of the adapter to the tabs of the aircleaner housing.

A. ElementB. AdapterC. GroovesD. TabsE. Air Cleaner Housing

• Install the air cleaner housing cap.

• Hold the air cleaner housing cap by snaps se-curely.

• Clean the inside of the battery cover and install it(see Battery Installation).


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Spark Arrester

This vehicle is equipped with a spark arrester. Itmust be properly maintained to ensure its efficiency.Clean the spark arrester in accordance with the Pe-riodic Maintenance Chart.

WARNINGAn incorrectly installed spark arrester canemit sparks and cause a fire. Be sure thespark arrester and muffler are installed se-curely.

Spark Arrester Cleaning and Inspection

WARNINGThe muffler can become extremely hot duringnormal operation and cause severe burns.Since the engine must be running during thisprocedure, wear heat-resistant gloves whilecleaning the spark arrester.

• Remove the spark arrester mounting bolts.

• Remove the spark arrester and gasket.

A. MufflerB. Spark Arrester Mounting BoltsC. Spark Arrester


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• Clean the spark arrester in a bath of high flash-point solvent and if necessary use a fine wirebrush to gently remove any particles in thescreen.

A. Spark Arrester Screen

• Inspect the spark arrester screen. If it is damaged,replace the spark arrester.

• In an open area away from combustible materials,start the engine with the transmission in neutral.

WARNINGHot carbon particles are emitted when thespark arrester is cleaned and can cause a fireresulting in severe burns and damage. Do notclean the spark arrester or run the enginewith the spark arrester disassembled nearcombustible materials.

• Raise and lower engine speed while tapping onthe muffler with a rubber mallet until carbon par-ticles are purged from the muffler.


• Stop the engine.

• Replace the gasket with a new one.

• Install the new gasket and paste it on the mufflerwith grease before installing the spark arrester.

A. MufflerB. Gasket


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• Install the spark arrester in place and tighten thespark arrester mounting bolts to the specified tor-que.

Tightening Torque

Spark Arrester Mounting Bolts:

13 N·m (1.3 kgf·m, 115 in·lb)

Throttle Pedal

If the throttle pedal has excessive play due to ei-ther cable stretch or misadjustment, it will cause adelay in throttle response, especially at low enginespeed. Also, the throttle may not open fully. If thethrottle pedal has no play, the throttle may be hardto control, and the idle speed may be erratic. Checkthe throttle pedal play periodically in accordancewith the Periodic Maintenance Chart.

Throttle Pedal Play Inspection• Apply the parking brake.


• Start the engine, and warm it up thoroughly.

• Measure the distance the throttle pedal moves be-fore the engine begins to pick up speed. Free playshould be 2 ~ 10 mm (0.08 ~ 0.39 in.). If the freeplay is out of specification, have your authorizedKawasaki dealer adjust the throttle pedal play.


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A. Throttle PedalB. 2 ~ 10 mm (0.08 ~ 0.39 in.)

Idle Adjustment

Idle speed should be checked and adjusted peri-odically by an authorized Kawasaki dealer in ac-cordance with the periodic Maintenance Chart.


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Fuel Hose

Fuel hose and connections should be checkedand replaced periodically by an authorized Kawasa-ki dealer in accordance with the Periodic Mainte-nance Chart.

Fuel Filter

Accumulation of moisture or sediment in the fuelsystem can restrict the flow of fuel and cause injec-tion pump damage. The fuel filter should bechecked in accordance with the Periodic Mainte-nance Chart.

Fuel Filter Inspection• Remove the seat (see Front Seat Removal).

• Inspect the fuel filter element for contamination.

A.Fuel Filter

• If the filter element is contaminated, have the fuelfilter cleaned or replaced by an authorized Kawa-saki dealer.


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Water Separator

Accumulation of moisture or sediment in the fuelsystem can restrict the flow of fuel and cause injec-tion pump damage. The water separator should bechecked in accordance with the Periodic Mainte-nance Chart.

Water Separator Inspection• Remove the seat (see Front Seat Removal).

• Inspect the water separator to see if water is accu-mulated at the bottom of the water separator cupand to see if the filter element is contaminated.

A.Water SeparatorB. Filter ElementC. Float Ring

NOTE○The red float ring in the cup is at the bottom of theseparator cup when there is little water in it. Whenwater accumulates, the float ring floats on thewater top level.

• If there is water in the cup or the filter element iscontaminated, have the water separator or the fil-ter element cleaned by an authorized Kawasakidealer.


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Fuel Tank Vent

The fuel tank vent hoses must be routed as speci-fied.The engine may stall or lose power if the fuel tank

vent is plugged or if the vent hose is pinched. In-spect the vent hose before riding and whenever theengine seems to lose power. If the fuel tank is fullbut the engine feels as if it is running out of fuel,check the vent and vent hose.

A. Fuel Tank Vent HoseB. Check ValveC. Fuel Tank

Belt Drive Transmission (CVT)

This vehicle is equipped with a belt-driven Contin-uously Variable Transmission (CVT). This automaticdrive system, although simple to operate, does re-quire periodic inspection since the drive belt wearswith normal use.Inspection should be done by an authorized Ka-

wasaki dealer.

A. Belt Drive Transmission (CVT)

Periodic Drive Belt Inspection RequirementsDrive belt wears with normal use. Inspection of

the drive belt is required at least every 100 hours ofvehicle use or 2 000 km (1 200 mile) whichevercomes first. More frequent inspection is necessary ifthe vehicle is subjected to hard usage.


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IMPORTANT INFORMATION

Neglect, abuse, or failure to maintain the trans-mission can result in a severely worn or dam-aged drive belt locking up the transmission andwheels. Inspect the drive belt at least every 100hours of vehicle use or 2 000 km (1 200 mile)whichever comes first, since drive belt wearwith normal use. More frequent inspection isnecessary if the vehicle is subjected to hard us-age such as pulling a trailer, operating in mudor deep water, or in extremely dusty conditions.If excessive belt slippage occurs, do not drivethe vehicle until damaged components are re-paired.

Causes of accelerated Belt WearAvoid these hard usage conditions to obtain maxi-

mum belt life and prevent accelerated belt wear anddeterioration.

• Operating the vehicle in high range while climbinghills, carrying heavy loads, or pulling a trailer.

• Exceeding maximum vehicle load or trailerweight.

• Operating in mud or water deeper than recom-mended.

• Operating in extremely dusty conditions.

• Continued operation with excessive belt slippage.

• Failure to apply the brake controls while descend-ing hills.

Indications of Excessive Belt SlippageExcessive slippage will accelerate belt wear and

lead to failure. Recognize these symptoms of ex-cessive belt slippage. If excessive slippage occurs,do not continue to drive the vehicle until all dam-aged components are repaired.

• Smell of burning rubber.

• Visible white smoke.

• Sluggish initial acceleration or loss of power.

• Engine rpm is higher for the same vehicle speed.

• Engine vibration.

When SwampedIf a large amount of water accidentally has en-

tered the CVT housing, it will cause drive belt slip-page and loss of power. If this occurs, consult anauthorized Kawasaki dealer.


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Brakes

The vehicle is equipped with hydraulically acti-vated disc brakes on all four wheels.

Brake Pedal

Brake Pedal Free Play InspectionIn accordance with the Periodic Maintenance

Chart, check the brake pedal free play.

• Before the brake pedal free play inspection, checkthat the brake pedal contacts with the stopper.

A. Brake PedalB. Stopper

• Depress the brake pedal lightly by hand.

• There should be 2 ~ 10 mm (0.08 ~ 0.39 in.) offree play.

A. Brake PedalB. 2 ~ 10 mm (0.08 ~ 0.39 in.)

• If the brake pedal has more or less free play thanspecified or the pedal action feels rough or“catchy,” have the brake system inspected imme-diately by an authorized Kawasaki dealer.

Brake FluidIn accordance with the Periodic Maintenance

Chart, inspect the brake fluid level in the brake fluidreservoir and change the brake fluid. The brake fluidshould also be changed if it becomes contaminatedwith dirt or water.

Fluid RequirementUse heavy-duty brake fluid only from a fresh, un-

opened container marked DOT4.


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WARNINGOver time, brake fluid can absorb moisture,lowering its boiling point and reducing brakeeffectiveness. Do not use fluid from a contain-er that has been left unsealed or that hasbeen open for a long time. Do not mix twotypes and brands of fluid for use in thebrakes. Don’t leave the reservoir cap off forany length of time to avoid moisture contami-nation of the fluid. Don’t add or change brakefluid in the rain or during conditions of blow-ing dust or debris.

NOTICEBrake fluid quickly damages painted surfa-ces. Wipe up any spilled fluid immediately.

Fluid Level Inspection• With the vehicle on level ground, check throughthe cover that the fluid level in the reservoir is be-tween the upper (marked MAX) and lower(marked MIN) level lines.

A. Brake Fluid ReservoirB. Upper Level Line (MAX)C. Lower Level Line (MIN)D. Cover

• If the fluid level is lower than the lower level line,check for fluid leaks in the brake lines and fill thereservoir to the upper level line.

WARNINGMixing two types and brands of fluid for usein the brake lowers the brake fluid boilingpoint and could reduce brake effectiveness.Change the fluid in the brake system com-pletely if the fluid level is low but the type andbrand of the fluid already in the reservoir areunknown.


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• Apply the brake forcefully for a few seconds andcheck for fluid leakage around the fittings.

WARNINGAir in brake line can make the brake feelmushy or soft. This may cause reduced brak-ing performance or brake failure and result inan accident. If brake lever travel is excessiveor the brake feels mushy, have an authorizedKawasaki dealer inspect it immediately.

Fluid ChangeHave the brake fluid changed by an authorized

Kawasaki dealer.

Brake Disc and Brake Pad

Disc and brake pad wear is automatically com-pensated for and has no effect on the brake pedalaction. There are no parts that require adjustmenton the brake.

WARNINGAir in brake line can make the brake feelmushy or soft. This may cause reduced brak-ing performance or brake failure and result inan accident. If brake lever travel is excessiveor the brake feels mushy, have an authorizedKawasaki dealer inspect it immediately.

Brake Pad Wear InspectionIn accordance with the Periodic Maintenance

Chart, inspect the brakes for wear. For each discbrake caliper, if the thickness of either pad lining isless than 1 mm (0.04 in.), replace both pads in thecaliper as a set. Pad wear inspection and pad re-placement should be done by an authorized Kawa-saki dealer.

A. Lining ThicknessB. 1 mm (0.04 in.)

Brake HosesBrake hoses, pipes, and other components should

be checked and replaced periodically by an author-ized Kawasaki dealer in accordance with the Peri-odic Maintenance Chart.


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Brake Light Switch

When the brake pedal is depressed, the brakelight goes on. The brake light switch should be in-spected in accordance with the Periodic Mainte-nance Chart.

Inspection• Turn the main switch to the “ON” position.

• Depress the brake pedal. The brake light shouldgo on after about 10 mm (0.39 in.) of pedal travel.

A. Brake PedalB. 10 mm (0.39 in.)

• If it does not, check the bulb and, if necessary, ad-just the brake light switch.

Adjustment• Adjustment is best performed by an authorizedKawasaki dealer since the brake light switch ishard to adjust.


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Parking Brake

The parking brake helps hold the vehicle from roll-ing while parked.In accordance with the Periodic Maintenance

Chart, check the parking brake as follows.

Parking Brake Lever Inspection• Pull the parking brake lever to the rear.

A. Parking Brake Lever

• After 6 to 14 clicks of lever travel, the vehicleshould not roll while parked.

• If it does, have the parking brake cable adjustedby an authorized Kawasaki dealer.

Return Spring Inspection• Visually check the return springs for damage.

A. Parking Brake Lever Return Springs

• If it is damaged, have it replaced with a new oneby an authorized Kawasaki dealer.


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Steering Wheel

In accordance with the Periodic MaintenanceChart, check the steering wheel for the specifiedfree play and smooth operation.

Free Play Inspection• Park the vehicle on level ground.

• Lightly turn the steering wheel left and right.

• There should be 0 ~ 20 mm (0 ~ 0.79 in.) of freeplay.

• If there is excessive free play or strange noises,or the steering feels rough or “catchy,” have thesteering system checked by an authorized Kawa-saki dealer.

A. Steering WheelB. 0 ~ 20 mm (0 ~ 0.79 in.)

Power Steering System

Steering may become more difficult than usual forthe following reasons:

• The steering wheel was continuously turned orheld to the full turn stops with torque applied byoperator. In this case the ECU works to protectthe system from overheating by stopping thepower assisting. Stop turning the steering wheeland wait until the system temperature drops, andthe power steering recovers.

• Fuses in the harness may have blown. There areseveral reasons that the fuses may blow. Refer tothe “Fuse” section in this chapter for details.

• Battery voltage has dropped. Voltage drop canhappen when the engine starts; inspect the bat-tery voltage.

• Cables, harness or connectors may have beendisconnected. Contact an authorized Kawasakidealer for service.

NOTE○If the steering becomes irregular or unusual forany reason other than above, have an authorizedKawasaki dealer check the steering and relevantcomponents immediately. In some cases thepower steering’s neutral position can be affectedby an accident or bump.


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Wheels

Rims

The rims are a drop-center, tubeless tire design.Take care not to damage the sealing surfaces of thetire or rim when removing or installing tires. Notethat the rims, like automotive rims, are not symmetri-cal. All wheels must be installed so that the valvestems are on the outside of the vehicle.

Wheel Nuts

Check for wheel nut tightness in accordance withthe Periodic Maintenance Chart.

Tightening Torque

Wheel Nuts:

120 N·m (12.2 kgf·m, 88.5 ft·lb)

Tires

The front and rear tires are knobby tubeless tires.When replacing tires, check the valve stems andcores for damage. Take care not to damage the tiresealing surfaces of the rims.

Standard Tire (Tubeless)

Front

Make, Type:DURO, FRONTIER DI2037

Size:26 × 9.00-12 4PR

Rear

Make, Type:DURO, FRONTIER DI2037

Size:26 × 11.00-12 4PR

Tire Air Pressure (when cold)

Front Up to 733 kg (1 616lb) Load

78.4 kPa (0.80kgf/cm², 11.4 psi)

Rear

Up to 590 kg (1 300lb) Load

110 kPa (1.12kgf/cm², 16.0 psi)

590 ~ 733 kg (1 300~ 1 616 lb) Load

130 kPa (1.33kgf/cm², 18.9 psi)

NOTE○Tires are an important part of the suspension ofthe vehicle. Tire construction characteristics andtire inflation pressure can greatly influence vehiclehandling. Kawasaki recommends that you alwaysreplace tires with standard replacement tires asshown above. It is also very important to havetires of the same type and size on all axles, and atthe same inflation pressure, on each axle.

○Installation of non-standard tires, or use of differ-ent tires on one axle, can change or impair thehandling of the vehicle.


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○Installation of tubeless tires on rims requires com-pressed air and is normally recommended as adealer service operation. Nevertheless, a tubecan be inserted into the tire by the operator as anemergency repair.

Maximum Tire Air Pressure for Seating Beads

Front and Rear 250 kPa (2.5 kgf/cm², 36 psi)

Payload and Tire PressureFailure to maintain proper inflation pressures or

observe payload limits for your tires can change orimpair handling and performance of the vehicle. Themaximum vehicle load is 733 kg (1 616 lb).Use a tire pressure gauge to accurately set tire

pressure.

WARNINGOperating with unequally or improperly pres-surized tires can adversely affect steering orhandling. Inflate both front tires to the samepressure and both rear tires to the same pres-sure.

Tire Wear, DamageAs tire tread wears down, tires become more sus-

ceptible to puncture and failure.

• In accordance with the Periodic MaintenanceChart, measure the depth of the tread with a depth

gauge, and replace any tire that has worn down tothe minimum allowable tread depth.

A. Tire Depth Gauge

Minimum Tread Depth

4 mm (0.16 in.)

• Visually inspect the tire for cracks and cuts, re-placing the tire in case of bad damage. Swellingor high spots indicate internal damage, requiringtire replacement.

• Remove any imbedded stones or other foreignparticles from the tread.


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Joint Boots

In accordance with the Periodic MaintenanceChart, inspect the joint boots on the front axles, tie-rod ends, steering knuckles, and rear axles forcracks, holes, damage or deterioration. If there isany one of them, have the joint boot replaced by anauthorized Kawasaki dealer.

A. Steering KnuckleB. Tie-RodC. Front AxleD. Joint Boots

A. Rear AxleB. Joint Boots


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Suspension

Shock Absorber Spring Force AdjustmentThe spring adjusting sleeves on the shock absorb-

ers have 5 positions so that the springs can be ad-justed for different driving and loading conditions.

A. Shock Absorber (Rear)B. Spring Adjusting Sleeve

A. Spring Adjusting Sleeve (Turn with a hookwrench)

If the spring action feels too soft or too stiff, havethe sleeves adjusted by an authorized Kawasakidealer in accordance with the following table.

• Turn the spring adjusting sleeves on the shockabsorbers to the desired position.


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Spring Action (Front Shock Absorber) Up to 590kg (1 300 lb) Load

Position SpringForce

Setting Load Sur-face

Speed

1 Weak Soft Light Good Low

2 (STD) ↑ ↑ ↑ ↑ ↑

3 | | | | |

4 ↓ ↓ ↓ ↓ ↓

5 Strong Hard Heavy Bad High

Spring Action (Front Shock Absorber) 590 ~ 733kg (1 300 ~ 1 616 lb) Load

PositionSpringForce

Setting LoadSur-face

Speed


2 (STD) ↑ ↑ ↑ ↑ ↑

3 | | | | |

4 ↓ ↓ ↓ ↓ ↓


Spring Action (Rear Shock Absorber) Up to 590kg (1 300 lb) Load

Position SpringForce

Setting Load Sur-face

Speed


2 (STD) ↑ ↑ ↑ ↑ ↑

3 | | | | |

4 ↓ ↓ ↓ ↓ ↓


Spring Action (Rear Shock Absorber) 590 ~ 733kg (1 300 ~ 1 616 lb) Load

PositionSpringForce

Setting LoadSur-face

Speed


2 ↑ ↑ ↑ ↑ ↑

3 | | | | |

4 ↓ ↓ ↓ ↓ ↓

5 (STD) Strong Hard Heavy Bad High

WARNINGImproper shock absorber adjustment cancause poor handling and loss of stability,which could lead to an accident.Always adjust the shock absorbers on the leftand right side to the same setting.


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Seat Belts

In accordance with the Periodic MaintenanceChart, check that each seat belt functions properly.Push the latch plate into the buckle until it clicks.The latch plate must slide smoothly into the buckle.The click sound indicates it is securely latched. Pullthe belt vigorously to make sure the retractor locksthe seat belt.

A. Seat BeltB. BuckleC. Red Button

Push the red button in the buckle to make surethe latch plate is released freely and the belt iswound into the retractor freely. Also check the beltwebbing for wear, cuts or damage. If any

irregularities are found, have the seat belt systemchecked or replaced by an authorized Kawasakidealer.

A. RetractorB. Seat BeltC. Latch Plate


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Cargo Bed Latches

Depending on the cargo loading and/or passengerriding conditions, latch lever compression needs tobe adjusted.Loosen the latch lever bolts and adjust the posi-

tion of the latch assembly so that the latch lever willbe secured without rattling and tighten the bolts.

A. Latch AssemblyB. Latch LeverC. Latch Lever Bolts

NOTE○Adjustment should be made for both sides.

Headlight Beam

The headlight beams can be adjusted vertically.

• Remove the front access cover. Refer to the“Front Access Cover” section in the “GENERALINFORMATION” chapter.

• Turn the adjusting screw on each headlight rim inor out to adjust the headlight vertically.

A. Adjusting ScrewsB. HeadlightC. LED Sub Headlight


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Battery

The battery is located under the right end of therear seat.

DANGERBattery contains sulfuric acid and produceshydrogen gas. Sulfuric acid can cause burnsand hydrogen gas can cause an explosion.Read and heed the battery safety label.

Battery Removal• Push the locking tab to clear the hook.

• Unlatch the latch (right side) as shown. A. Battery CoverB. LatchC. Locking Tab1. Push the locking tab.2. Pull3. Slide4. Open

• Unlatch the latch (front side).


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A. Battery CoverB. Latch

• Clear the tabs of the battery cover as shown.

A. Battery CoverB. Tabs1. Slide2. Pull

• Clear the hooks of the battery cover as shown,and remove the battery cover rightward.


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A. HooksB. Battery Cover1. Slide2. Pull

NOTE○If there is dust or mud around the battery and aircleaner housing, clean them using compressedair.

• Remove the screws and washers.

A. Screws and Washers

• Remove the battery holder nut.

• Remove the shaft and collar.

• Remove the battery holder as shown.

• Disconnect the negative (–) cable from the (–) ter-minal.

• Slide the red cap.

• Disconnect the positive (+) cable from the (+) ter-minal.

NOTE○There is no need to separate the smaller cablesclamped with the positive (+) cable.


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A. BandB. Battery Holder NutC. ShaftD. CollarE. Battery HolderF. Negative (–) CableG. Red CapH. Positive (+) Cable1. Lift2. Pull

• Take the battery out.

• Clean the battery using a solution of baking sodaand water. Be sure that the cable connections areclean.

• Perform a visual inspection. Inspect for defectiveor cracked case and cover, and loose or damagedterminal posts or cables. Replace battery and/orcables immediately if any damage is found.

Battery Installation• Check that the rubber dampers on the batteryholder and the floorboard are properly in place.

• Put the battery in place on the rubber damper.

• Connect the three positive (+) cables to the (+)terminal, and then connect the negative (–) cableto the (–) terminal.

• Put a light coat of grease on the terminals to pre-vent corrosion.

• Cover the positive (+) terminal with the red cap.

WARNINGLoose battery cables can create sparks whichcan cause a fire or explosion resulting in in-jury or death.Make sure the battery terminal bolts are tight-ened securely and the cap is installed overthe positive (+) terminal.

• Install the battery holder, collar and shaft.

• Tighten the battery holder nut securely.

• Run the breather hoses into the holes of the floor-board.

• Hold the collar and breather hoses at the whitepainted mark of the breather hoses with a band.


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A. CollarB. Breather HosesC. BandD. 60 mm (2.4 in.)

• Tighten the screws with washers securely.

• Insert the hooks of the battery cover into the slotsas shown.

A. Battery CoverB. HooksC. Slots

• Insert the tabs of the battery cover into the slotsas shown.


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A. Battery CoverB. TabsC. Slots

• Insert the tabs of the battery cover into the slotsas shown.

A. Battery CoverB. TabsC. Slots

• Lock the latch (front side).

• Lock the latch (right side) as shown.


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A. LatchB. Battery Cover1. Close2. Pull3. Push

Battery CharacteristicsThe battery installed in this vehicle is a sealed

type, and the sealing strip should not be removed atany time after the specified electrolyte has been in-stalled in the battery for initial service. It is not nec-essary to check the battery electrolyte level or adddistilled water.However, in order to maximize battery life and en-

sure that it will provide the power needed to startyour vehicle you must properly maintain the bat-tery's charge. When used regularly, the chargingsystem in your vehicle helps keep the battery fullycharged. If your vehicle is only used occasionally or

for short periods of time, the battery is more likely todischarge.Due to their internal composition, batteries contin-

ually self-discharge. The discharge rate depends onthe type of battery and ambient temperature. Astemperatures rise, so does the discharge rate.Every 15°C (59°F) doubles the rate.Electrical accessories, such as digital clocks and

computer memory, also draw current from the bat-tery even when the key is switched off. Combinesuch “key-off” draws with hot temperature, and abattery can go from fully charged to completely dis-charged in a matter of days.

Self-discharge

Temperature

Approx. Number of Days From100% Charged to 100% discharged

Lead-AntimonyBattery

Lead-CalciumBattery

40°C (104°F) 100 Days 300 Days

25°C (77°F) 200 Days 600 Days

0°C (32°F) 550 Days 950 Days


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Current Drain

Discharg-ing Ampere

Days from 100%Charged to 50%Discharged

Days from 100%Charged to 100%Discharged

7 mA 60 Days 119 Days





In extremely cold weather the fluid in an inad-equately charged battery can easily freeze, whichcan crack the case and buckle the plates. A fullycharged battery can withstand sub-freezing temper-atures with no damage.

Battery SulfationA common cause of battery failure is sulfation.Sulfation occurs when the battery is left in a dis-

charged condition for an extended time. Sulfate is anormal by product of the chemical reactions within abattery. But when continuous discharge allows thesulfate to crystallize in the cells, the battery platesbecome permanently damaged and will not hold acharge. Battery failure due to sulfation is not war-rantable.

Battery MaintenanceIt is the owner's responsibility to keep the battery

fully charged. Failure to do so can lead to batteryfailure and leave you stranded.

If you are driving your vehicle infrequently, inspectthe battery voltage weekly using a voltmeter. If itdrops below 12.6 volts, the battery should becharged using an appropriate charger (check withyour kawasaki dealer or visit by kawasaki.com). Ifyou will not be using your vehicle for longer than twoweeks, the battery should be charged using an ap-propriate charger. Do not use an automotive-typequick charger that may overcharge the battery anddamage it.

NOTE○Leaving the battery connected causes the electri-cal components (clock etc) to make the batterydischarged, resulting the over discharge of thebattery. In this case, the repair or replacement ofthe battery is not included in the warranty. If youdo not drive for four weeks or more, disconnectthe battery from the vehicle.

Kawasaki-recommended chargers are:Battery Mate 150-9OptiMate 4Yuasa MB-2040/2060Christie C10122SIf the above chargers are not available, use equiv-

alent one.For more details, ask your Kawasaki dealer.

Battery Charging

• Remove the battery from the vehicle (see BatteryRemoval).

• Attach the leads from the charger and charge thebattery at a rate (amperage × hours) that is


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indicated on the battery. If it is not possible to readthe rate, charge the battery at an amperage that isabout 1/10th of the battery capacity.

• The charger will keep the battery fully charged un-til you are ready to reinstall the battery in the ve-hicle (see Battery Installation).

NOTICENever remove the sealing strip, or the batterycan be damaged.Do not install a conventional battery in thisvehicle, or the electrical system cannot workproperly.

Make East Penn Manufacturing

Type 526RMF

NOTE○If you charge the sealed battery, never fail to ob-serve the instructions shown on the label on thebattery and charger.

Fuse

Fuses are arranged in 3 fuse boxes. The fuse box1 is located under the front access cover. The fusebox 2 and fuse box 3 are located over the battery. Ifthe electrical systems do not function, inspect thefuses. Before replacing a fuse, check the wiring har-ness and electrical equipment for bare wires or oth-er possible causes for the blown fuse.

NOTICEDo not use a fuse of a higher capacity thanthe specified fuse rating, or damage to theelectrical system could result. Refer to theFuse Location label on the other side fusebox lid.

Fuse Box 1• Remove the front access cover. Refer to the“Front Access Cover” section in the “GENERALINFORMATION” chapter.

• Pull the cover forward to clear the projections, andremove the cover.


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A. CoverB. ProjectionsC. Pull forward.

• Open the fuse box 1 lid and check the fuse ele-ment. If it is blown out, replace the fuse with anew one.

A. Fuse Box 1B. Fuse Box 1 Lid


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A. FusesB. Spare Fuses

Fuse Box 2• Remove the battery cover (see Battery Removal).

• Remove the fuse box 2 from the bracket.

• Open the fuse box 2 lid, and check the fuse ele-ment. if it is blown out, replace the fuse with a newone.

A. Fuse Box 2B. Fuse Box 2 Lid


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A. FusesB. Spare Fuses

A. NormalB. Failed

Main Power FuseThe main power fuse is in the fuse box 3.



• Open the fuse box 3 lid and remove the mainpower fuse.

• Check the fuse element. If it is blown out, replacethe fuse with a new one.


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A. Fuse Box 2B. Fuse Box 3 LidC. Fuse Box 3

A. 60 A Main Power Fuse

There is a spare fuse for the main power fuseunder the front access cover.


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A. 60 A Spare Fuse

Before replacing a fuse, check the wiring harnessand electrical equipment for bare wires or other pos-sible causes for the blown fuse.

WARNINGThe electrical system can produce painfulelectrical shocks. When replacing the 60 Afuse, first remove the cables from the batteryterminals to avoid electric shock.

Power Steering System FuseThe power steering system fuse is in the fuse box

3.



• Open the fuse box 3 lid and remove the 40 Afuse.

• Check the fuse element.

A. Fuse Box 2B. Fuse Box 3 LidC. Fuse Box 3


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A. 40 A Fuse

There is a spare fuse for the power steering sys-tem under the front access cover.

A. 40 A Spare Fuse

If the fuse is blown, steering becomes heavy. Re-place the blown fuse with a fuse of the same specif-ic amperage and type. If a replaced fuse blowsagain, there can be trouble with the ECU or har-ness/connectors. Contact an authorized Kawasakidealer for inspection.

WARNINGThe electrical system can produce painfulelectrical shocks. When replacing the 40 Afuse, first remove the cables from the batteryterminals to avoid electric shock.


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Breaker

The breaker for the radiator fan is located underthe front access cover. If the fan does not function,inspect the breaker. In order to reset the breaker,push the reset button at the side of the breakercase. Before resetting, however, check that the radi-ator fan is free from mud or other obstacle as wellas the wiring harness and electrical equipment forbare wires or other possible causes for the trippedbreaker.

A. BreakerB. Reset Button

General Lubrication

In accordance with the Periodic MaintenanceChart, have the general lubrication performed by anauthorized Kawasaki dealer or perform it referring tothe Service Manual for this vehicle.


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Cleaning

General Precautions

Frequent and proper care of your vehicle will en-hance its appearance, optimize overall perform-ance, and extend its useful life. Covering yourvehicle with a high quality, breathable vehicle coverwill help protect its finish from harmful UV rays, pol-lutants, and reduce the amount of dust reaching itssurfaces.

WARNINGBuild-up of debris or flammable material inand around the vehicle chassis, engine, andexhaust can cause mechanical problems andincrease the risk of fire. When operating thevehicle in conditions that allow debris orflammable material to collect in and aroundthe vehicle, inspect the engine, electricalcomponent and exhaust areas frequently. Ifdebris or flammable materials have collected,park the vehicle outside and stop the engine.Allow the engine to cool, then remove anycollected debris. Do not park or store the ve-hicle in an enclosed space prior to inspectingfor build-up of debris or flammable materials.

• Be sure the engine and exhaust are cool beforewashing.

• When washing the vehicle, always use a mildneutral detergent and water.

• Avoid applying all harsh chemicals, solvents, de-greaser, oil remover, electrical contact cleaner,and household cleaning products such as ammo-nia-based window cleaners. They will damage ordeteriorate painted parts, plastic parts, rubberparts and other synthetic parts including coversand LED headlight lens.

• Avoid applying degreaser to seals, brake pads,and tires.

• Diesel fuel, brake fluid, and coolant will damagethe finish of painted and plastic surfaces: washthem off immediately.

• Avoid wire brushes, steel wool, and all other abra-sive pads or brushes.

• Take care when washing the headlight lens andother plastic parts as they can easily bescratched.

NOTE○After driving in an area where the roads are saltedor near the ocean, immediately wash your vehiclewith cold water. Do not use warm water as it ac-celerates the chemical reaction of the salt. Afterdrying, apply a corrosion protection spray on allmetal and chrome surfaces to prevent corrosion.

○Condensation may form on the inside of the head-light lens after riding in the rain, washing the ve-hicle or humid weather. To remove the moisture,start the engine and turn on the headlight. Gradu-ally the condensation on the inside of the lens willclear off.


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RadiatorClean off any obstructions with a stream of low-

pressure water.

NOTICEUsing high-pressure water, as from a carwash facility, could damage the radiator finsand impair the radiator’s effectiveness. Donot obstruct or deflect airflow through the ra-diator by installing unauthorized accessoriesin front of the radiator or behind the coolingfan. Interference with the radiator airflow canlead to overheating and consequent enginedamage.

Matte Paint Parts• When washing the vehicle, always use a mildneutral detergent and water, or cleaners for mattepaint.

• The matte paint effect may be lost when the paintis excessively rubbed.

• If any doubt, consult an authorized Kawasakidealer.

Plastic PartsAfter washing, use a soft cloth to gently dry plastic

parts. When dry, treat the headlight lens and othernonpainted plastic parts with an approved plasticcleaner/polisher product.

NOTICEPlastic parts may deteriorate and break if theycome in contact with chemical substances orhousehold cleaning products such as dieselfuel, brake fluid, window cleaners, thread-locking agents, or other harsh chemicals. If aplastic part comes in contact with any harshchemical substance, wash it off immediatelywith water and a mild neutral detergent, andthen inspect for damage. Avoid using abra-sive pads or brushes to clean plastic parts, asthey will damage the part’s finish.

Chrome and AluminumChrome and uncoated aluminum parts can be

treated with a chrome/aluminum polish. Coated alu-minum should be washed with a mild neutral deter-gent and finished with a spray polish. Aluminumwheels, both painted and unpainted can be cleanedwith special non-acid based wheel spray cleaners.

Leather, Vinyl, and RubberIf your vehicle has leather accessories, special

care must be taken. Use a leather cleaner/treatmentto clean and care for leather accessories. Washingleather parts with detergent and water will damagethem, shortening their life.Vinyl parts should be washed with the rest of the

vehicle, then treated with a vinyl treatment.


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The sidewalls of tires and other rubber compo-nents should be treated with a rubber protectant tohelp prolong their useful life.

Where to be Careful

Avoid spraying water with any great force nearthe following places.

• Disc brake master cylinder and caliper.

• Under the cargo bed - if water gets into the glowplugs, it can ground out the spark. When this hap-pens the vehicle will not operate properly and theaffected parts must be wiped dry.

• Power Steering System - if water gets into the ac-tuator or is sprayed over the ECU, they maycause malfunction.

NOTICECoin operated, high pressure spray washersare not recommended. Water may be forcedinto bearings and other components causingeventual failure from rust and corrosion.Some soaps are highly alkaline and mayleave a residue or cause spotting.

NOTE○Abrasive cleanser or high pressure washer willdamage the surface finish on the bodywork.

Washing Your Vehicle

• Before washing, precautions must be taken tokeep water off the following parts.

Muffler rear opening - cover with a plastic bag.Main switch - cover the keyhole with tape.

• Rinse your vehicle with cold water from a gardenhose to remove any loose dirt.

• Mix a mild neutral detergent (designed for motor-cycles or automobiles) and water in a bucket. Usea soft cloth or sponge to wash your vehicle.

• After washing, rinse your vehicle thoroughly withclean water to remove any residue (residue fromthe detergent can damage parts of your vehicle).

• Remove the plastic bag and tape.

• Use a soft cloth to dry your vehicle. As you dry, in-spect your vehicle for chips and scratches. Do notlet the water air dry as this can damage thepainted surfaces.

• Carefully ride your vehicle at a slow speed andapply the brakes several times. This helps dry thebrakes and restores them to normal operating per-formance.


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Bolt and Nut Tightening

In accordance with the Periodic MaintenanceChart, have the tightness of the bolts, nuts, and fas-teners checked by an authorized Kawasaki dealer.


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TRANSPORTING AND STORAGE

Transporting the Vehicle

Note the following points

NOTICE

• To avoid damage and the wind adversely af-fecting the vehicle, transport it in an en-closed truck or trailer.

• If an enclosed transporter is not available,remove the plastic hard top and positionthe vehicle facing forward.

• Never tow the vehicle or use a car type dollywith the front or rear wheels on the dolly asthis could damage the differential and/ortransmission.

• Secure the fuel tank cap.

• Make sure that the cargo bed is latched and thetailgate is closed.

• Before loading the vehicle on the transporter, se-lect a firm level surface.

• Secure loading ramps to the transporter whenloading and unloading.

• Always position the vehicle level when transport-ing.

• Set the parking brake.

• Stop the engine and remove the main switch keyto prevent loss during transport.

• Fasten the vehicle to the transporter with a heavy-duty strap or rope using tie down points on front[A] and rear [B] of the vehicle. Do not attach tiestraps or ropes to the A-arms, other suspensionparts, or drive shafts. Straps must be directeddownwards and outwards from the vehicle.

Front Tie Down Points

A. Tie down points on the front of vehicle

164 TRANSPORTING AND STORAGE

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Rear Tie Down Points

B. Tie down points on the rear of vehicle

• Equip the transporter with all the necessary lightsand signs required by local, state, provincial, orfederal laws.

Storage

Preparation for Storage

• Clean the entire vehicle thoroughly.

• Run the engine for about five minutes to warm theoil, shut it off and drain the engine oil.

WARNINGEngine oil is a toxic substance. Dispose ofused oil properly. Contact your local author-ities for approved disposal methods or possi-ble recycling.

• Put in fresh engine oil.

• Empty the fuel from the fuel tank.

WARNINGFuel is extremely flammable and can be ex-plosive under certain conditions. Turn themain switch off. Do not smoke. Make sure thearea is well ventilated and free from anysource of flame or sparks; this includes anyappliance with a pilot light.

WARNINGFuel is a toxic substance. Dispose of fuelproperly. Contact your local authorities forapproved disposal methods.

TRANSPORTING AND STORAGE 165

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NOTE○As an alternative to draining the fuel system, afuel stabilizer designed specifically for diesel fuelmay be used. Follow the manufacturer's instruc-tions for use.

WARNINGFuel stabilizers may contain poisonous sub-stances. Heed the manufacturer's warningsfor use.

• Put boards under the front and rear wheels tokeep dampness away from the tire rubber.

• Spray oil on all unpainted metal surfaces to pre-vent rusting. Avoid getting oil on rubber parts or inthe brakes.

• Lubricate all the cables as indicated in the “Gener-al Lubrication” section in the “MAINTENANCEAND ADJUSTMENT” chapter.

• Remove the battery, and store it where it will notbe exposed to direct sunlight, moisture, or freez-ing temperatures. During storage it should be giv-en a slow charge (one ampere or less) aboutonce a month.

NOTICEKeep the battery well charged during coldweather so that the electrolyte does notfreeze and crack open the battery. The moredischarged a battery becomes, the moreeasily it freezes.Never remove the sealing strip, or the batterycan be damaged.

• Tie a plastic bag over the exhaust pipe to preventmoisture or small animals from entering.

• Put a cover over the vehicle to keep dust and dirtfrom collecting on it.

Engine Care during Long Storage

Kawasaki recommends the engine to be run atidling speed for about 15 minutes every 4 to 6months during long storage (longer than 4 months)to periodically bathe internal engine parts with en-gine oil.



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NOTICEEngine oil at engine sliding parts such ascrankshaft, camshaft, rocker arms, cylinderbores, etc. will coming down to the enginebottom during long storage by gravity. Thiscould cause insufficient lubrication of theseparts and cause engine seizure if the engineis started and runs at high speed or underload.

Removal from Storage


• Remove the plastic bag from the exhaust pipe.

• Clean the terminals of the battery, charge the bat-tery if necessary, and install it in the vehicle.

• Fill the fuel tank with fuel.

• Check all the points listed in the “Daily Checks”section in the “HOW TO OPERATE” chapter.

• Lubricate as indicated in the “General Lubrication”section in the “MAINTENANCE AND ADJUST-MENT” chapter.

Before Starting Engine after Long Storage

Kawasaki recommends following engine prepara-tion to be performed before starting the engine if it isnot being run for 1 year or longer to prevent engineseizure.(1) Check to see if the coolant level in the reserve

tank is between level lines. If the amount ofcoolant is insufficient, add coolant in the reservetank.

(2) Park the vehicle on a firm level surface and setthe parking brake.

(3) Make sure the gear shift lever is in the “N” (neu-tral) position.

(4) Turn the fuel filter lever to the “CLOSE” positionto prevent engine starting.

(5) Turn the main switch key to the “START” posi-tion for 15 seconds maximum to turn over theengine and release the main switch key. If theengine starts running with the remaining fuel inthe fuel line, stop it after 15 seconds running.

(6) Wait for 30 seconds to let the starter motor cool.(7) Repeat procedures (5) and (6) 4 times, and turn

the main switch key to the “OFF” position.(8) Turn the fuel filter lever to the “OPEN” position.(9) Turn the main switch key to the “ON” position

and keep it on for 4 seconds. Turn the key tothe “OFF” position. Repeat this procedure 5times at least to replenish the fuel line with thefuel.

After above preparation start the engine and run itfor about 15 minutes at idle speed. While the engineis running check for engine oil and coolant leaks,and no warning indicator goes on.

TRANSPORTING AND STORAGE 167

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A. Fuel FilterB. Fuel Filter LeverC. “CLOSE” PositionD. “OPEN” Position


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TROUBLESHOOTING GUIDE

Starter Motor Won't Turn

• Fuse failed (be sure to check for cause of failure)

• Battery cables do not make good electrical con-tact with battery terminals

• Battery discharged

Engine Cranks, But Won't Start

• No fuel in tank

• Fuel filter clogged

• Water in fuel

• Air filter clogged or intake blocked

• Engine flooded

• Fuel tank vent clogged

• Valve clearance incorrect

• Fuel line clogged

• Air in fuel system

Engine Stops

• For cold weather starting, after the engine isstarted, keep the throttle pedal partially pusheddown for one minute maximum until idling speedbecomes steady.

• No fuel in tank

• Water in fuel


• Fuel line clogged


• Fuel tank vent clogged

• Engine overheated

• Too much idling or low speed running (notenough air flow)

• Overloaded

• Radiator clogged

• Coolant level too low

• Coolant deteriorated

• Radiator fan breaker functioned

• Engine oil level too low

TROUBLESHOOTING GUIDE 169

Black plate (170,1)

No Power

• Engine overheated

• Too much idling or low speed running (notenough air flow)

• Overloaded

• Radiator clogged

• Coolant level too low

• Coolant deteriorated

• Radiator fan breaker functioned

• Engine oil level too low

• Compression leakage

• Valve clearance insufficient



• Engine oil incorrect

• Water in fuel

• Drive belt slipping

• Water in belt drive torque converter housing

• The high-altitude injection control may be acti-vated. If engine power is reduced at high altitudemore than 800 m (2 600 ft), it is considered nor-mal.

Power Steering Won't Work

• ECU functioned to prevent overheating

• Fuse failed

• Battery discharged

• Cables/harness connectors disconnected

Selectable 2WD/4WD or DIFF-LOCK SystemsMalfunction

• Actuators failed

• Vehicle controller failed

• Battery disconnected

170 TROUBLESHOOTING GUIDE

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ENVIRONMENTAL PROTECTION

To help preserve the environment, properly discard used batteries, tires, oils and fluids, or other vehicle com-ponents that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmen-tal waste agency for their proper disposal procedure. This also applies to disposal of the entire vehicle at theend of its life.

ENVIRONMENTAL PROTECTION 171

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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

172 MAINTENANCE RECORD

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MAINTENANCE RECORD 173

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MAINTENANCE RECORD 175

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