Kawasaki MUL PRO-DX, Mule Pro-DXT, MY 2016 Owner's Manual
Utility Vehicle
Owner's Manual
ENGLISH
Original instructions
Quick Reference Guide
GENERAL INFORMATION
This Quick Reference Guide will assist you in
finding the information you're looking for.
BREAK-IN
HOW TO OPERATE
SAFE OPERATION
MAINTENANCE AND ADJUSTMENT
TRANSPORTING AND STORAGE
TROUBLESHOOTING GUIDE
A Table of Contents is included after the Foreword.
Whenever you see the symbols shown below,
heed their instructions! Always follow safe operating
and maintenance practices.
DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
NOTICE
NOTICE is used to address practices not related to personal injury.
NOTE
NOTE indicates information that may help or
○
guide you in the operation or service of the ve-
hicle.
BASIC SAFE DRIVING
Knowing and following these rules for safe operation will increase your satisfaction with your new Kawasaki v ehicle.
Perform the Daily Checks
Refer to the Daily Checks section for a list of items
to check each day before use. Habitual performance of these checks will help to insure safer, more
reliable usage. Be sure that any irregularities found
during these checks are corrected before operating
the vehicle.
Drive Carefully and with Good Judgement
We want you to be satisfied with your new Kawasaki vehicle, so drive carefully, safely, and exercise
good judgement. Practice basic maneuvers so you
can drive confidently and safely.
Improper use of this vehicle can be hazardous.
Never operate at speeds too fast for your skills or
conditions. Handling charac teristics of this vehicle
change depending upon cargo load and driving
modes.
Read the Owner's Manual
Read and understand this Owner's Manual. This
is especially important for inexperienced operators.
Refer to this Owner's Manual if you have any questions.
Off-Highway Use Only
This vehicle is not an all-terrain vehicle; it is designed and equipped to be a multiuse utility vehicle
for off-highway use only. Use of this veh icle on public roads and paved surfaces is hazardous. Do not
operate this vehicle on public roads or paved surfaces.
Occupant Capacity
Make sure operators are 16 years or older with a
valid driver's license.
Each occupant must be able to sit with back
against seat, feet flat on floor, and hands on steering
wheel or handgrip.
The operator should be tall enough to wear the
seat belt properly and reach all controls.
Passenger should also be tall enough for the seat
belt to fit properly and to be able to brace themselves, as necessary, by placing both feet firmly on
the floor while gripping the handgrip. Stay completely inside the vehicle.
Never Drink and Drive
Alcohol and drugs impair your judgement and
slow your reactions. Even drugs prescribed by a
physician can be dangerous. Check with your doctor.
Use Proper Riding Gear
Proper protective gear can reduce the severity of
injury in the event of an accident.
Choose a helmet most appropriate for your use of
this utility vehicle. A helmet can reduce the risk of
head injuries. Wear appropriate eye protection and
protective clothing.
Wearing Seat Belts
Both the operator and passenger should always
wear their seat belts pro perly. Seat belts cannot
completely protect you in every accident, but in
many cases a seat belt can reduce the risk of serious injury. Also, to avoid injury, do not put any part
of your body outside of the vehicle for any reason.
Close the Doors
Be sure all doors are securely closed during operation and never remove a door.
The doors prevent branches, gravel, and debris
from getting inside the passenger compartment.
Before Starting the Engine
Three “musts” before starting the engine are:
1. Apply the parking brake,
2. Put the gear shift lever in the “N” (neutral) posi-
tion,
3. Check the throttle pedal for proper operation. It
should return to its rest position when released.
Use the Parking Brake
Always apply the parking brake before getting out
of your vehicle.
Obey Local Laws
Know and obey all laws and regulations governing
the use of off-highway vehicles in your area. Respect private property. Always try to preserve nature
and the environment.
Refueling
Before refueling the vehicle, shut the engine off
and make sure the area is well ventilated and free of
any source of flame or sparks. Diesel fuel is very
flammable.
Tire Air Pressure
Tire inflation and type can affect the vehicle's handling characteristics. Check the tire pressure frequently. Use only the recommended tires for
replacement.
Maximum Seating Capacity
Do not exceed seating capacity: 2 occupants.
Occupants shall only ride in designated seating
positions and with maximum 2 persons in the seat.
Do not carry small children on lap.
Reduce Speed When Carrying Cargo, Passenger, and/or Pulling a Trailer
Carrying cargo, passenger and/or pulling a trailer
can make the vehicle difficult to steer and may affect
vehicle handling in an unpredictable manner.
Braking distance is increased when carrying cargo, passenger, and/or pulling a trailer. Reduce
speed and allow greater dist ance for braking when
carrying cargo, passenger, and/or pulling a trailer.
Use extreme caution when climbing and descending hills, and traversing slopes.
FOREWORD
Congratulations on your purchase of a new Kawasaki Mule. It is the result of Kawasaki's engineering exper-
tise and a tradition of manufacturing high-quality consumer products.
Please read this Owner's Manual carefully before starting your new Mule so that you will be thoroughly
familiar with the proper operation of your vehicle's controls, its features, capabilities, and limitations.
To ensure a long, trouble–free life for your Mule, give it the proper care and maintenance described in this
manual.
For those who would like more detailed information on their Mule, a Service Manual is available for purchase
from any authorized Kawasaki Mule dealer. The Service Manual con tains detailed disassembly and maintenance information. Those who plan to do their own work should, of course, be competent mechanics and possess the special tools described in the Service Manual.
Keep this Owner's Manual aboard your Mule at all times so that you can refer to it whenever you need information.
This manual should be considered a permanent part of the Mule and should remain with the Mule when it is
sold.
All rights reserved. No part of this publication may be reproduced without our prior written permission.
This publication includes the latest information available at the time of printing. However, there may be minor
differences betw een the actual product and illustrations and text in this manual.
All products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.
Motorcycle & Engine Company
© 2015 Kawasaki Heavy Industries, Ltd. Oct. 9, 2015. (1)
TABLE OF CONTENTS
SPECIFICATIONS .............................................. 13
DECLARATION OF CONFORMITY ................... 17
SERIAL NUMBER LOCATIONS ........................ 19
LOCATION OF PARTS ....................................... 20
LOCATION OF LABELS .................................... 23
LOADING INFORMATION ................................. 34
GENERAL INFORMATION ................................ 36
Multifunction Meter ........................................... 36
Speedometer ................................................. 37
Fuel Level Gauge .......................................... 38
Clock .............................................................. 38
Odometer ...................................................... 39
Trip Meters (Trip Meter A/B) .......................... 39
Hour Meter ..................................................... 40
2WD/4WD Indicator Symbol ......................... 40
Amber Glow Plug Indicator Light ................... 41
Red EPS Warning Indicator Light .................. 42
Red Parking Brake Indicator Light ................ 42
Red Reverse Indicator Light .......................... 42
Green Neutral Indicator Light ........................ 42
Red Seat-Belt Use Reminder ........................ 42
Red Coolant Temperature Warning Indicator
Light ............................................................
Red Oil Pressure Warning Indicator Light ..... 43
Lighting/Electrical Accessory Socket ............... 43
Light Switches .................................................. 44
Steering Wheel ................................................. 45
Brake Pedal ...................................................... 47
Cargo Bed ........................................................ 47
Tailgate .......................................................... 47
Lifting and Lowering the Cargo Bed .............. 48
42
Loading Cargo Bed ....................................... 50
Fuel ................................................................... 51
Diesel Fuel Requirements ............................. 51
Cold Weather Information ............................. 51
Using Biodiesel Fuel ..................................... 52
Filling the Fuel tank ....................................... 52
Glove Compartment/Tool Kit ............................ 54
Cupholders ................................................ ....... 55
Front Acc ess Cover .......................................... 55
Horn Switch ...................................................... 57
Main Switch ...................................................... 57
Gear Shift Lever ............................................... 58
Selectable 2WD/4WD Shift Switch .................. 60
Selectable DIFF-LOCK Shift Switch ................ 61
Belt Drive Transmission ................................... 62
Parking Brake Lever ......................................... 62
Doors ................................................................ 63
Seat .................................................................. 64
Seat Belts ......................................................... 65
Throttle Pedal ................................................... 67
Trailer Hitch Bracket ......................................... 68
BREAK-IN ........................................................... 69
HOW TO OPERATE ........................................... 70
Daily Checks .................................................... 70
Starting the Engine ........................................... 73
Cold Weather Starting ............... ....................... 74
Jump Starting ................................................... 75
Moving Off ........................................................ 77
Braking ............................................................. 78
Stopping the Engine ......................................... 78
Parking the Mule .............................................. 79
Shifting Gears .................................................... 80
2WD/4WD Shifting ............................................ 81
Shifting the Differential ...................................... 82
When Stuck ....................................................... 83
SAFE OPERATION ............................................. 84
Unfamiliar Terrain .............................................. 84
Driving in Reverse ............................................. 85
Driving in “4WD” ................................................ 85
Turning the Vehicle ............................................ 86
Hills .................................................................... 86
Climbing Hills ......................... ............................ 87
Descending Hills ............................................... 88
Traversing Hillsides ........................................... 89
Sliding and Skidding .......................................... 89
Driving through Water ....................................... 90
Operator and Passenger Requirements ........... 91
NOISE AND VIBRATION CONTROL INFORMA-
TION ..................................................................
92
Control Information ............................................ 92
MAINTENANCE AND ADJUSTMENT ................ 93
Periodic Maintenance Chart .............................. 94
Engine Oil .......................................................... 98
Front Final Gear Case Oil .................................102
Transmission Case Oil ......................................105
Cooling System .................................................108
Valve Clearance .................... ............................ 111
Engine Air Cleaner ............................................ 111
Spark Arrester ................................................... 114
Throttle Pedal ....................................................116
Idle Adjustment ..................................................117
Fuel Hose .......................................................... 11 8
Fuel Filter ........................................................... 11 8
Water Separator ................................................ 119
Fuel Tank Vent ...................................................120
Belt Drive Transmission (CVT) ..........................120
Brakes ...............................................................122
Brake Pedal ....................................................122
Brake Disc and Brake Pad .............................124
Brake Light Switch .............................................125
Parking Brake ....................................................126
Steering Wheel ..................................................127
Power Steering System .................................. 127
Wheels ..............................................................128
Rims ...............................................................128
Wheel Nuts .....................................................128
Tires ................................................................128
Joint Boots .........................................................130
Suspension ........................................................131
Seat Belts ..........................................................133
Cargo Bed Latches ............................................134
Headlight Beam .................................................134
Battery ...............................................................135
Fuse ...................................................................143
Breaker ..............................................................149
General Lubrication ...........................................150
Cleaning ............................................................150
General Precautions ......................................150
Where to be Careful .......................................152
Washing Your Vehicle ....................................152
Bolt and Nut Tightening .....................................153
TRANSPORTING AND STORAGE ....................154
Transporting the Vehicle ....................................154
Storage ..............................................................155
Preparation for Storage ..................................155
Engine Care during Long Storage ..................156
Removal from Storage ...................................157
Before Starting Engine after Long Storage ....157
TROUBLESHOOTING GUIDE ............................159
ENVIRONMENTAL PROTECTION ....................161
MAINTENANCE RECORD ................................. 162
SPECIFICATIONS 13
SPECIFICATIONS
PERFORMANCE
Maximum Torque 52 N·m (5.3 kgf·m, 38 ft·lb) @2 400 r/min (rpm)
Minimum Turning Radius Differential Mode 4.8 m (15.7 ft)
Seating Capacity 2 persons
DIMENSIONS
Overall Length 3 385 mm (133.3 in.)
Overall Width 1 625 mm (63.98 in.)
Overall Height 1 965 mm (77.36 in.)
Wheelbase 2 345 mm (92.32 in.)
Tread: Front 1 385 mm (54.53 in.)
Rear 1 315 mm (51.77 in.)
Ground Clearance 265 mm (10.4 in.)
Curb Mass 828 kg (1 826 lb)
Cargo Bed (L × W × H) 1 375 × 1 355 × 280 mm (54.13 × 53.35 × 11.02 in.)
ENGINE
Type Diesel, OHV, 3-cylinder, 4-stroke, liquid-cooled
Displacement
Bore × Stroke
Compression Ratio
Starting System Electric starter
Cylinder Numbering Method
Firing Order
993 cm³ (60.6 cu in.)
74.0 × 77.0 mm (2.91 × 3.03 in.)
23.5:1
Left to right, 1-2-3
1-3-2
14 SPECIFICATIONS
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 engine oil deterioration.
Viscosity SAE 10W-40
Capacity 2.4 L (2.5 US qt)
Coolant Capacity 6.1 L (6.4 US qt)
DRIVE TRAIN
Driving Type: Primary Belt drive torque converter (CVT)
Final 2WD/4WD system with drive shafts
Transmission Type 2-speed & reverse, automatic
Primary Reduction Ratio 3.334 ~ 0.756 (Belt drive torque converter)
Final Reduction Ratio: Front 6.382
Rear 6.245
Overall Drive Ratio: Forward
12.192 (High)
24.205 (Low)
Reverse
Transmission Gear Ratio: Forward
18.794
1.952 (High)
3.876 (Lo w)
Reverse
3.009
Front Final Gear Case Oil API GL-5 Hypoid gear oil
SAE 90 [above 5°C (41°F)]
SAE 80 [below 5°C (41°F)]
SPECIFICATIONS 15
Front Final Gear Case Oil Capacity 0.43 L (0.45 US qt)
Transmission Case Oil API GL-5 Hypoid gear oil
SAE 90 [above 5°C (41°F)]
SAE 80 [below 5°C (41°F)]
Transmission Case Oil Capacity 2.00 L (2.1 US qt)
FRAME
Type Steel tube, ladder type
Steering Rack and pinion with Electric Power Steering (EPS) system
Caster 4.4°
Tire Size: Front 26 × 9.00-12 4PR
Rear 26 × 11.00-12 4PR
Rim Size:
Front
Rear
12 × 7.0AT
12 × 8.0AT
Fuel Tank Capacity 30 L (7.9 US gal)
ELECTRICAL EQUIPMENT
Battery 12 V 540CCA @0°F RC80
Headlight:
High Beam 12 V 60 W × 2, LED × 2
Low Beam 12 V 55 W × 2, LED × 2
Brake/Tail Light 12 V 21/5 W × 2
Reverse Light 12 V 10 W
LOAD CAPACITY
Maximum Vehicle Load (Including occupants,
733 kg (1 616 lb)
cargo and accessories)
Maximum Cargo Bed Load 453 kg (1 000 lb)
16 SPECIFICATIONS
Specifications are subject to change without notice.
DECLARATION OF CONFORMITY 17
DECLARATION OF CONFORMITY
18 DECLARATION OF CONFORMITY
SERIAL NUMBER LOCATIONS 19
SERIAL NUMBER LOCATIONS
The engine and frame serial numbers are used to register the vehicle. They are the only means of identifying
your particular machine from others of the same model type. These serial numbers may be needed by your
dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well
as the model type and any peculiar features of your machine that can help them identify it.
Frame No.
A. Frame Number
B. Right Front Axle
Engine No.
A. Engine Number
20 LOCATION OF PARTS
LOCATION OF PARTS
1. LED Sub Headlights
2. Headlights
3. Front Access Cover
4. ROPS (Roll Over Protective
Structure)
5. Steering Wheel
6. Seat
7. Seat Belts
8. Cargo Bed
9. Front Guard
10. Coolant Reserve Tank
11. Brake Fluid Reservoir
12. Steering Wheel Tilt Lock Lever
13. Door
14. Cargo Bed Latch
15. Cargo Bed Handgrip
16. Muffler (Spark Arrester)
17. Trailer Hitch Bracket
LOCATION OF PARTS 21
1. Tailgate Latch Handle
2. Tailgate
3. Screen
4. Handgrip for Right Seat Passenger
5. Tail/Brake Light
6. Rear Shock Absorber
7. Air Cleaner
8. Battery
9. Fuel Tank Cap
10. Dashboard
11. Front Shock Absorber
12. Radiator
22 LOCATION OF PARTS
1. Parking Brake Lever
2. Horn Switch
3. Selectable DIFF-LOCK Shift
Switch
4. Selectable 2WD/4WD Shift
Switch
5. Headlight Switch
6. LED Sub Headlight Switch
7. Multifunction Meter
8. Power Outlet Sockets
9. Glove Compartment
10. Cupholders
11. Main Switch
12. Brake Pedal
13. Throttle Pedal
14. Gear Shift Lever
15. Tool Kit
LOCATION OF LABELS
All warning labels which are on your vehicle are
repeated here. Read labels on your vehicle and
understand them thoroughly. They contain information which is important for your safety and the safety
of anyone else who may operate your vehicle.
Therefore, it is very important that all warning labels
be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement
from your Kawasaki dealer and install it in the correct position.
NOTE
The sample warning labels in this section have
○
part numbers to help you and your dealer obtain
the correct replacem ent.
Refer to the actual vehicle label for model specific
○
data grayed out in the illustration.
LOCATION OF LABELS 23
1. Warning (General)
2. CE Mark
24 LOCATION OF LABELS
3. Specification (ROPS)
4. Specification (Model)
5. Danger (Radiator Cap)
6. Danger (Radiator Cap)
7. Warning (Brake Fluid)
LOCATION OF LABELS 25
8. Danger/Poison (Battery)
9. Warning (Refueling)
10. Warning (Cargo Bed Lifting: both sides)
26 LOCATION OF LABELS
11. Warning (Trailer Towing)
12. Warning (Cargo Bed Loading)
13. Important Information (Tires/Max. Load)
(1)
1. Read Owner’s Manual
2. Safety alert symbol
3. Maximum seating capacity: 2 persons, see
“BASIC SAFE DRIVING” section
4. Fasten seat belts. Wear an approved helmet
and protective gear, see “BASIC SAFE DRIVING” section
5. Never use on public roads, see “BASIC SAFE
DRIVING” section
6. Never use with drugs or alcohol, see “BASIC
SAFE DRIVING” section
7. Make sure operators are 16 years or older with
a valid driver’s license, see “BASIC SAFE
DRIVING” section
LOCATION OF LABELS 27
28 LOCATION OF LABELS
(2)
(3)
(4)
(5)
1. Safety alert symbol
2. Read Owner’s Manual
3. Hot liquid. Never open when engine is hot, see
page 108
LOCATION OF LABELS 29
(6)
(7)
(8)
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