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)

30 LOCATION OF LABELS

(9)

1. Read Owner’s Manual

2. Use diesel fuel only, see page 51

(10)

1. Safety alert symbol

2. Read Owner’s Manual

3. Hand crush, see page 48

LOCATION OF LABELS 31

(11)

1. Safety alert symbol

2. Read Owner’s Manual

3. Maximum arm length

4. Vertical force limitation, see page 68

5. Horizontal force limitation, see page 68

32 LOCATION OF LABELS

(12)

1. Safety alert symbol

2. Read Owner’s Manual

3. Maximum cargo bed load, see page 35

4. Never carry passengers in cargo bed, see page
51

(13)

1. Read Owner’s Manual

2. Tire pressure, see page 128

3. Safety alert symbol

4. Load condition (including occupants and car­go), see page 128

5. Front tire size, see page 128

6. Rear tire size, see page 128

LOCATION OF LABELS 33

34 LOADING INFORMATION

LOADING INFORMATION

WARNING

Incorrect loading, improper installation or use
of accessories, or modification of your ve­hicle may result in an unsafe operating condi­tion. Before you operate it, make sure that the
vehicle is not overloaded and that you have
followed these instructions.

With the exception of genuine Kawasaki Parts
and Accessories, Kawasaki has no control over the
design or application of accessories. In some cases,
improper installation or use of accessories, or ve­hicle modifications, will void the utility vehicle war­ranty. In selecting and using accessories, and in
loading the vehicle, you are personally responsible
for your own safety and the safety of other person
involved.

NOTE

Kawasaki Parts and Accessories have been spe-

○

cially designed for us e on Kawasaki utility ve-

hicles. We strongly recommend that all parts and

accessories you add to your vehicle be genuine

Kawasaki components.

Because any vehicle is sensitive to increases in
weight and change s in weight distribution, you must
take ca re in carrying cargo. Always follow these pre­cautions:

Carrying cargo, passenger and/or pulling a trailer

•

can make the vehicle difficult to steer and may af­fect vehicle handling in an unpredictable manner.
Use extreme caution when climbing and descend­ing hills, and traversing slopes.
Braking distance is increased when carrying car-

•

go, passenger, and/or pulling a trailer. Reduce
speed and allow greater distance for braking.
All cargo should be carried as low as possible to

•

reduce the effect on the vehicle’s center of gravity.
Cargo weight should be equally distributed from
side to side. This helps maintain stability by cen­tralizing weight. Avoid carrying cargo that extends
beyond the rear of the vehicle. Do not carry cargo
on top of the ROPS.
Cargo should be securely anchored. Make sure

•

the cargo will not move around while the vehicle is
moving. Recheck cargo security as often as pos­sible (while the vehicle is stopped) and adjust as
necessary.

NOTICE

The front body work and fenders are not de­signed to carry cargo or to support weight.
Do not place cargo, lean or sit on them, or
they may break.

This vehicle is not designed to carry passengers

•

in the cargo bed. Installing additional passen ger

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

WARNING

Passengers transported in the cargo bed can
be tossed about or even thrown out causing
serious injury or death. Do not install seating
or trans port passengers in the cargo bed.

(Maximum Cargo Bed Load) Do not carry more

•

than maxi mum cargo bed load as specified below.

Maximum Cargo Bed Load: 453 kg (1 000 lb)

(Maximum Vehicle Load) Weight of operator, pas-

•

senger, cargo, accessories, and trailer tongue
must 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 “GENERAL
INFORMATION” chapter.

LOADING INFORMATION 35

36 GENERAL INFORMATION

GENERAL INFORMATION

Multifunction Meter

1. Amber Glow Plug Indicator Light

2. Red EPS Warning Indicator Light

3. Speedometer

4. Fuel Level Gauge

5. Red Parking Brake Indicator Light

6. Red Reverse Indicator Light

7. Green Neutral Indicator Light

8. Right Button

9. Odometer/Trip Meters (Trip Meter A and B)/Hour
Meter

10.Clock

11. Left Button

12.“2WD” Indicator Symbol

13.Red Seat-Belt Use Reminder

14.Red Coolant Temperature Warning Indicator
Light

15.Red Oil Pressure Warning Indicator Light

16.“4WD” Indicator Symbol

Pushing the left button shifts the display in the
odometer/trip meters/hour meter through the 4
modes; odometer, trip meter A and B, and hour me­ter.

When the main switch is turned on, all the “LCD”
segments and “LED” lights are displayed for a sec­ond, then the clock and meters operate normally de­pending on the mode selected.

GENERAL INFORMATION 37

Speedometer

The speed ometer 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 me­ter. Make sure that mph or km/h is correctly dis­played according to local regulations before driving.
Shift the mph·km/h display in the digital meter as fol­lows.

The mph·km/h display shifts by pushing and hold-

•

ing the left button and pushing the right button
within two seconds.

A. mph·km/h Display
B. Left Button
C. Right Button

The mph·km/h display shifts as follows.

•

NOTE

Do not operate the vehicle with the digital meter

○

displaying in the wrong unit (mph or km/h).

Display the odometer in the digital meter.

•

NOTE

The data is maintained even if the battery is dis-

○

connected.

38 GENERAL INFORMATION

Fuel Level Gauge

The fuel in the fuel tank is shown in segments. All
6 segments are displayed when the fuel tank is full.
As fuel is consumed the segments go out accord­ingly. When the bottom segment is reached, it will
begin 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 possible
because there is no reserve tank in this vehicle (see
Fuel section).

A. Hour Display
B. Minute Display

Push the right button. The hour display only

•

blinks. Push the left button to advance the hours.

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 Display

Push the right button. The hour display stops

•

blinking and the minute display starts blinking.
Push the left button to advance the minutes.

A. Minute Display

Push the right button. Both the hour and minute

•

displays start blinking again.
Push the left button. The displays stop blinking

•

and the clock starts working.

GENERAL INFORMATION 39

NOTE

When the figures come to 999999, they are

○

stopped and locked.

A. Odometer

NOTE

Pushing the left button momentarily advances the

○

hour or minute step by step. Pushing and holding
the button advances the hour or minute continu­ously.
The clock works normally from the back-up power

○

while the main switch is turned off.
When the battery is disconnected, the clock re-

○

sets to 1:00, and starts working again when the
battery is connected.

Odometer

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

Trip Meters (Trip Meter A/B)

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

Push the left button to display the trip meter A or

•

B.

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 starts

counting again.

40 GENERAL INFORMATION

A. Trip Meter A

Hour Meter

The hour meter shows the total hours that the ve­hicle has been operated. This meter cannot be re­set.

NOTE

When the figures come to 99999.9, they are

○

stopped 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.

GENERAL INFORMATION 41

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

A. Amber Glow Plug Indicator Light
B. Red EPS Warning Indicator Light
C. Red Parking Brake Indicator Light
D. Red Reverse Indicator Light
E. Green Neutral Indicator Light
F. Red Seat-Belt Use Reminder
G. Red Coolant Temperature Warning Indicator

Light

H. Red Oil Pressure Warning Indicator Light

Amber Glow Plug Indicator Light

The glow plug indicator light goes on for 4 sec­onds when the main switch key is turned to the “ON”
position. The indicator light also goes on whenever
the key is in the “START” position. The indicator light
goes off after the plug is fully heated. If it does not
go on or go off, have the glow plug and related sys­tem checked by an authorized Kawasaki dealer.

42 GENERAL INFORMATION

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 momentarily
illuminate when the engine starts, then go off in a
second if the system is in order. If this warning indi­cator light illuminates any other time, it indicates the
ECU or actuator has malfunctioned, or the wiring
harness has become disconnected. Stop driving im­mediately and contact an authorized Kawasaki
dealer to have the system checked.

NOTE

If this warning indicator light does not go on when

○

the 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 main
switch in the “ON” position, the parking brake indica­tor light illuminates.

Red Reverse Indicator Light

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

Green Neutral Indicator Light

When the transmission is in neutral, the neutral in­dicator light illuminates.

Red Seat-Belt Use Reminder

When the main switch is turned on, the seat-belt
use reminder will illuminate and stay on for approxi­mately 8 seconds, even if the operator's belt is
buckled. The light is a reminder to the operator to
make sure that passengers have buckled their seat
belts.

Red Coolant Temperature Warning Indicator

Light

The coolant temperature warning indicator light il­luminates whenever the coolant temperature rises
too high while the vehicle is in operation. If it stays
on, stop the engine and check the coolant level in
the coolant reserve tank after the engine cools
down.

Be sure to check that the radiator fan is free from
mud and other obstacles. Refer to the “Breaker”
section in the “MAINTENANCE AND ADJUST­MENT” chapter.

NOTICE

Do not continue running the engine with the
temperature warning indicator light continu­ously illuminated. Prolonged engine opera­tion can result in engine damage from
overheating.

NOTE

When you touch the fan, be sure to disconnect

○

the negative ( –) battery cable, since the fan can

GENERAL INFORMATION 43

operate automatically even with the main switch
off.

Red Oil Pressure Warning Indicator Light

The oil pressure warning indicator light blinks to
warn the oper ator whenever the oil pressure is dan­gerously low or the main switch is in the “ON” posi­tion with the engine not running, and goes off when
the proper engine oil pressure is reached. Refer to
the “MAINTENANCE AND ADJUSTMENT” chapter
for more detailed engine oil information.

Lighting/Electrical Accessory Socket

The lighting/electrical accessory 12 volt sockets

are located on the dashboard.

An auxiliary light or an accessory may be con-

nected to these connectors.

A. Power Outlet Sockets

NOTICE

Do not connect a light or load of more than
120 watts on one or both sockets, or the bat­tery may rapidly discharge.

44 GENERAL INFORMATION

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 “
when the main switch is in the “ON” position.

: Low Beam
: High Beam

When the headlights are on high beam, the high
beam indicator light in the switch goes on as a re­minder. The headlights go off when the headlight
switch is pushed in “OFF” position.

” or “ ” position

A. High Beam Position
B. Low Beam Position
C. OFF Position
D. High Beam Indicator Lights
E. Headlight Switch
F. LED Sub Headlight Switch

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

A. Headlights
B. LED Sub Headlights

GENERAL INFORMATION 45

Steering Wheel

This vehicle is equipped with an electric power
steering system. The system does not require regu­lar maintenance by users. Do not tamper with the
electronic control unit (ECU) or loosen the fittings of
steering actuator, or the neutral position setting of
the steering will be adversely affected and will
cause serious driving problems. If such components
need service, contact an authorized Kawasaki deal­er.

If the steering becomes more difficult than usual
or you feel a steering problem, refer to the “Steering
Wheel” section in the “MAINTENANCE AND AD­JUSTMENT” chapter.

A. Steering Wheel

46 GENERAL INFORMATION

NOTE

The power steering system functions only when

○

engine is running.
If you install wireless equipment on board, contact

○

an authorized Kawasaki dealer. Installing such
equipment improperly may affect the ECU.

Steering Position Adjustment

The steering wheel position can be adjusted to

suit the operator.

Make any steering wheel adjustment before start-

ing the vehicle.

WARNING

Adjusting the steering wheel position while
driving could cause loss of control and an ac­cident resulting in serious injury or death. To
prevent loss of control, do not adjust the
steering wheel position unless the vehicle is
stopped.

Move the steering wheel up or down while pulling

•

up the tilt lock lever under the steering wheel.
Release the tilt lock lever to lock the steering

•

wheel in position.

A. Tilt Lock Lever
B. Pull up.
C. Steering Wheel
D. Adjusting Direction

NOTE

Make sure you have securely locked the steering

○

wheel in place by moving it up and down.

GENERAL INFORMATION 47

Brake Pedal

The brake pedal is the left pedal on the floorboard.

Depress the pedal to slow or stop the vehicle.

A. Brake Pedal
B. Floorboard

Cargo Bed

Tailgate

The tailgate of the cargo bed can be lowered. Be­fore lowering the tailgate, park on a firm level sur­face and set the parking brake.

To open the tailgate, release the latches and lower
the tailgate. Cables hold the tailgate level with the
cargo bed.

A. Tailgate

B. Latch Handle (Both Sides)

To close the tailgate, lift to the upright position and
secure firmly with the latches.

Push the tailgate latch handles forward to make
sure the latches stay securely closed. Do not drive
the vehicle with the tailgate lowered.

48 GENERAL INFORMATION

A. Tailgate
B. Cable

Lifting and Lowering the Cargo Bed

WARNING

Reduced clearance between the cargo bed
and the cargo screen ma y trap and seriously
injure an arm while lifting or lowering the car­go bed. To avoid possible injury, do not place
hands on any part of the cargo screen when
lifting or lowering the cargo bed.

The cargo bed can be tilted by releasing the
latches on each side, and then lifting the bed with
the handgr ips.

A. Cargo Bed Latch (Both Sides)
B. Handgrip (Both Sides)

Lifting the Cargo Bed

Before tilting the cargo bed, park on a firm level

•

surface and set the parking brake.
Empty the cargo bed prior to raising the cargo

•

bed.
Lift the bed with the handgrips. The supporting

•

damper under the cargo bed helps lifting the bed.
Pull the supporting rod out of its mounting clip on

•

the front of the cargo bed.

GENERAL INFORMATION 49

A. Supporting Rod
B. Pull here to free rod from clip.
C. Cargo Bed
D. Clip
E. Forward

With the cargo bed at the highest position, hook

•

the ring of the supporting rod on the stopper pin of
the bottom horizont al bar of the screen.

A. Supporting Damper
B. Cargo Bed (Tilted Position)
C. Supporting Rod
D. Ring of the supporting rod
E. Screen
F. Stopper Pin

WARNING

Using only the bed supporting damper for
cargo bed support may allow the cargo bed to
suddenly lower. To prevent injury caused by
sudden lowering of the cargo bed, support
the cargo bed with the support rod whenever
lifting the cargo bed.

50 GENERAL INFORMATION

Lowering the Cargo Bed

Before lowering the bed, check to be sure the

•

area under it is clear.

Return the supporting rod to its original position

•

and secure it with the clip.

To lower the cargo bed pus h down the side rail of

•

the cargo bed. And then hold the handgrip with

another hand and carefully lower the bed in place.

Latch both latches and check that the bed is prop-

•

erly locked into place. Do not leave the cargo bed

unlatched.

A. Cargo Bed Latch (Locked Position)

B. Side Rail

Do not drive the vehicle with the front end of the

•

cargo bed raised or unlatched.

WARNING

The front of the cargo bed becomes heavier
as it lowers into position and can suddenly
lower, trapping arms between the bed and
frame causing serious injury. To prevent the
bed from suddenly lowering, use the hand­grips to properly support the bed when lower­ing or lifting the bed.

Loading Cargo Bed

NOTICE

Do not carry more than 453 kg (1 000 lb) in the
cargo bed.

GENERAL INFORMATION 51

WARNING

Overloading, failure to properly secure car-

•

go, or improper use of the cargo bed can
cause changes in handling which can lead
to an accident. Follow guidelines provided
in the “LOADING INFORMATION” chapter.
Passengers transported in the cargo bed

•

can be tossed about or even thrown out
causing serious injury or death. Do not in­stall seating or transport passengers in the
cargo bed.
Driving with the cargo bed tilted may be

•

hazardous. Failure to lower and lock the
bed into place may cause serious injury or
death. Al ways lower and latch the bed after
tilting.

Fuel

Diesel Fuel Requirements

Kawasaki recommends diesel fuels that meet the
following requirements for use in this vehicle. Use
clean, fresh diesel fuel to maintain performance and
life 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 in
your area, a high cetane “premium” diesel fuel
may offer improved cold-starting and warm-up

performance.
Fuel type: Diesel fuel for vehicle

Minimum cetane number: 45

Lower Sulfur

A sulfur content less than 0.05% by volume is rec­ommended. To avoid engine corrosion, and engine
oil contamination, do not use fuel with more than

0.5% sulfur content.

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.

Cold Weather Information

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

52 GENERAL INFORMATION

as it gets colder. If the engine starts but stalls after a
short time and will not restart, the fuel filter may be
clogged. For best results in cold weather use winter
diesel fuel.

WARNING

Starting fluids such as ether are explosive
and may cause severe injury. Do not use
starting fluids containing ether in the air in­take system.

NOTICE

Do not add gasoline, gasohol, alcohol or
aftermarket cetane improver additives to die­sel fuel. Damage to the fuel injection system
may result.

NOTICE

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

Using Biodiesel Fuel

Biodiesel fuels blended with diesel fuel may be
used in this vehicle only if the blended fuel meets
the following conditions:

(1) Biodiesel fuel concentration must not exceed

7% by volume (B7).

(2) The petroleum diesel fuel base must meet the

European EN590 specification. The pure bio­diesel base must meet the European Standard
EN14214. Raw pressed vegetable oils are NOT
acceptable 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 mois ture and

may contain higher water content than conven­tional diesel fuels. Keep storage and vehicle
tanks as full as possible and ensure all caps
and covers are installed properly to prevent
water from entering and collecting in the fuel
system.

(3) Clean up any spilled fuel immediately to prevent

damage to painted surfaces.

(4) To avoid damage caused by fuel degrada tion,

biodiesel blended fuel should not be used if it
has been stored for more than 3 months. If an
engine is going to be placed in storage, the bio­diesel blended fuel should be flushed out by op­erating the engine for at least 30 minutes on
conventional diesel fuel after replacing biodiesel
fuel in the vehicle fuel tank with petroleum­based diesel fuel.

Filling the Fuel tank

The fuel tank is mounted under the right side of
the seat. Use only fresh diesel fuel with the recom­mended cetane number from an uncontaminated

source to ensure proper running of your vehicle.
Avoid filling the tank in the rain or where heavy dust
is blowing so that the fuel does not get contami­nated.

GENERAL INFORMATION 53

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

A. Fuel Tank Cap

Never fill the tank completely to the top. After refu­eling, make sure the fuel tank cap is closed se­curely.

NOTICE

Always clean dirt/mud/debris/water from the
fuel tank cap and surrounding area prior to
filling the tank to prevent dirt/mud/debris/­water from entering the fuel tank. Accumula­tion of moisture or sediment in the fuel
system can restrict the flow of fuel and cause
fuel system and/or engine damage.

54 GENERAL INFORMATION

WARNING

Diesel fuel is extremely flammable and can
ignite under certain conditions. To avoid the
potential for burns or other injuries when re­fueling, turn the main switch key off. Do not
smoke. Make sure the area is well ventilated
and free from any source of flame or sparks;
this includes any appliance with a pilot light.
Never fill the tank completely to the top. After
refueling, make sur e the fuel tank cap is
closed securely. If diesel fuel is spilled on the
fuel tank, wipe it off immediately.

Glove Compartment/Tool Kit

A glove compartment is provided at the right side
of the dashboard. Store only light items to avoid
damage to the inside of the compartment. Do not
store items which must not get wet or dirty.

The tool kit is located at the inside of the glove
compartment.

A. Glove Compartment

B. Tool Kit

GENERAL INFORMATION 55

Cupholders

Cupholders are provided at the left and right sides

of the dashboard.

A. Cupholder (Both Sides)

Front Access Cover

The front access cover can be removed for main-

tenance such as a coolant level inspection.

NOTICE

Do not store items under the front access
cover. This area is not designed for storage.

Cover Opening

Turn the knobs counterclockwise 90° to release

•

the locks.
Pull the front of the front access cover up and

•

open the cover.

A. Front Access Cover
B. Knobs

56 GENERAL INFORMATION

Pull the front access cover forward to disengage

•

the tabs from the slits of the front hood.

A. Front Access Cover
B. Tabs
C. Slits

Cover Closing

Insert the tabs on the front access cover to the

•

slits of the front hood.
Lower the front access cover and turn the knobs

•

clockwise until they stop to lock the front access
cover.

A. Front Access Cover

B. Knob (Both Sides)

Pull up the front ends of the front access cover to

•

make su re the cover is locked securely.

WARNING

An open front access cover can distract or
impair visibility of the operator, causing loss
of vehicle control and potential serious injury
or death.
Lock the front access cover securely before
operating the vehicle.

GENERAL INFORMATION 57

Horn Switch

Push the horn switch to sound the horn.

A. Horn Switch

Main Switch

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

A. Main Switch

B. “OFF” Position

C. “ON” Position

D. “START” Position

58 GENERAL INFORMATION

OFF Engine off. All electrical circuits off.

ON

START

All electrical equipment can be used.
Hour meter works.

Electric starter is engaged by holding
main swi tch key in this position, only
when gear shift lever is in “N” (neutral)
position or applying brake pedal. Upon
release, key will return to “ON” position.

NOTICE

Do not operate the starter continuously for
more than 5 seconds, or the starter will over­heat and the battery power will drop tempora­rily. Wait 15 seconds between each operation
of the starter to let it cool and for the battery
to recover power.
Do not turn the main switch key to the
“START” position with the engine running, or
damage to the starter can result.

NOTE

The vehicle is equipped with a starter lockout sys-

○

tem. This system prevents the electric starter from
operating when the gear shift lever is in the “H”
(High), “L” (Low) or “R” (Reverse) position, unless
the brake is applied.

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

Gear Shift Lever

The gear shift lever is located on the dashboard,
to the right side of the steering wheel. The gear shift
lever 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 ver­sa. Move the gear shift lever up or down as indi­cated on the embossed mark next to the gear shift
lever.

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

A. Gear Shift Lever
B. “L” (Low) Position
C. “H” (High) Position
D. “N” (Neutral) Position
E. “R” (Reverse) Position

NOTICE

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 running
above idling speed, or the transmission could
be damag ed.

GENERAL INFORMATION 59

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

NOTICE

Use of the high range for heavy loads, climb­ing hills, and pulling a trailer can lead to pre­mature wear of the torque converter belt and
pulleys. Use low range for these conditions.

Refer to the “Shifting Gears” section in the “HOW

TO OPERATE” chapter.

This vehicle is equipped with a sub-transmission
to allow maximum transmission efficiency. Use the
low gearing for maximum torque at low speeds, for
climbing hills, pulling a trailer, or keeping constant
low sp eeds. The high gearing raises the speed

60 GENERAL INFORMATION

Selectable 2WD/4WD Shift Switch

You can select “2WD” or “4WD” to suit various
driving conditions. The selectable 2WD/4WD shift
switch is located on the dashboard.

A. Selectable 2WD/4WD Shift Switch

B. “2WD” Position

C. “4WD” Position

The current operating condition is indicated with
the 2WD/4WD indicator symbols in the multifunction
meter.

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

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

WARNING

The handling characteristics of this vehicle
differs between “2WD” and “4WD” according
to terrain. Changing the operating mode while
moving can cause sudden changes in han­dling performance which can cause the oper­ator to lose control and have an accident.
Always stop the vehicle before changing from
“2WD” to “4WD” and vice versa.

GENERAL INFORMATION 61

NOTICE

Shifting from “2WD” to “4WD” (or “4WD ” to
“2WD”) when the vehicle is in motion could

cause drive train damage.

Selectable DIFF-LOCK Shift Switch

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

A. Selectable DIFF-LOCK Shift Switch

B. “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 indi­cated by a light in the switch as a reminder. Refer to
the “Shifting the Differential” section in the “HOW
TO OPERATE” chapter.

62 GENERAL INFORMATION

Belt Drive Transmission

This vehicle is equipped with a belt-driven Contin­uously Variable Transmission (CVT). This automatic
drive system , although simple to operate, does re­quire periodic inspection. Refer to the “MAINTE­NANCE AND ADJUSTMENT” chapter.

Parking Brake Lever

The parking brake lever is located at the left side
of the steering wheel. Pull the lever rearward to ap­ply the parking brake.

To release, push in and hold the knob on the end
of the lever and push the lever all the way forward.
Spring pressure helps return the lever to the re­leased pos ition.

Be sure to release the parking brake before driv­ing off. Failure to do so may result in poor perform­ance and premature wearing of the rear brakes and
belt converter system.

The alarm buzzer will sound if the vehicle is run­ning with the parking brake applied. Stop the vehicle
and release the parking brake.

A. Parking Brake Lever

B. Knob

GENERAL INFORMATION 63

WARNING

If the vehicle should move after it is parked, it
might be damag ed or cause injury. Be sure to
apply the parking brake before leaving the ve­hicle.

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 to
check that the latch is securely locked. If a door is
damaged or does not close securely, contact an au­thorized Kawasaki dealer for repair or replacement.

A. Door Handle

B. Door

C. Latch

NOTE

Make su re that the all doors are properly closed

○

before starting the vehicle.

64 GENERAL INFORMATION

NOTICE

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

Seat

The seat can be removed for vehicle maintenance

and adjustment.

Seat Removal

Pull up the right and left ends of the seat to clear

•

the projections.
Remove the seat.

•

A. Seat
B. Projections
C. Pull up.

Seat Installation

Make su re that grommets are in position.

•

Insert the projections of the seat into the grom-

•

mets.

A. Seat
B. Projection (Both Sides)
C. Grommet (Both Sides)

GENERAL INFORMATION 65

Seat Belts

The vehicle is equipped with retractable three­point seat belts for all occupants - operator and pas­senger. Always wear the seat belts when operating
and riding in the vehicle.

A. Seat Belt

B. Latch Plate

C. Buckle

WARNING

Not wearing a seat belt, or wearing one im­properly can result in serious injury or death
in the event of an accident. Make certain the
operator and passenger always wear their
seat belts properly.

66 GENERAL INFORMATION

WARNING

Operator and passenger must be able to
place both feet flat on the floorboards while
seated upright with their backs against the
seatbacks.

To wear the seat belt properly, follow this proce-

dure:

1. Place the belt across your lap 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 se­cure.

3. Put the lap portion of the belt low on your hips.
Push down on the buckle end of the belt as you
pull up on the shoulder part so the belt is snug
across yo ur hips.

4. Place the shoulder belt over your shoulder and
across your chest. The shoulder belt should fit
against your chest. If it is loose, pull the belt out
all the way and then let it retract.

A. Lap Portion of Belt
B. Shoulder Belt

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

A. Seat Belt
B. Latch Plate
C. Buckle
D. Red Button

WARNING

Too much seat belt slack could reduce its pro­tection effectiveness in an accident. Always
verify that the belt is at a SNUG FIT.

GENERAL INFORMATION 67

The seat belt is equipped with a dual mode latch
plate. Under normal driving conditions the belt will
self adjust to the seat occupant so that it is snug
around both the occupant's waist and shoulder.
Under rough driving situations the dual mode latch
plate will lock the seat belt in place.

To release the lock:

Move the slider in the direction of the arrow mark.

•

A. Slider

B. Arrow Marks

Throttle Pedal

The throttle pedal is the right pedal on the floor­board. Push the pedal down to increase engine
speed. Spring pressure returns the pedal to the rest
position when released. Always check that the throt­tle pedal returns normally before starting the engine.
In addition, there must be adequate throttle pedal
play and correct throttle stop position adjustment.
Refer to the “MAINTENANCE AND ADJUSTMENT”
chapter for the throttle pedal adjustment procedure.

A. Throttle Pedal

B. Floorboard

68 GENERAL INFORMATION

Trailer Hitch Bracket

This vehicle is equipped with a bracket for a trailer
hitch. Trailer towing equipment is not supplied with
this vehicle.

To avoid injury and property damage, observe the
following precautions:

WARNING

Improper towing of a loaded trailer could
cause an accident resulting in serious injury
or death.

Never carry a passenger in a trailer.

•

Never load more than 68.1 kg (150 lb)

•

tongue weight on the towing bracket.
Do not operate the vehicle faster than 16

•

km/h (10 mph) when towing. Remember that
towing 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 bracket

•

only. Do not attach a trailer to any other lo­cation or you may lose control of the ve­hicle and have an accident.

A. Trailer Hitch Bracket

BREAK-IN

The first 20 hours or 200 km (120 mile) of vehicle
operation is designated as the break-in period. Do
not exceed 1/2 throttle during the break-in period. If
the 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 or
200 km (120 mile)

Do not start moving or race the engine immedi-

○

ately after starting it, even if the engine is already

warm.

Do not race the engine while the transmission is

○

in neutral.

It is important to perform the initial service after

○

the first 20 hours or 200 km (120 mile) of opera-

tion as described in this manual and the service

manual for this vehicle. See the “Periodic Mainte-

nance Chart” in the “MAINTENANCE AND AD-

JUSTMENT” chapter.

1/2 throttle

NOTE

BREAK-IN 69

70 HOW TO OPERATE

HOW TO OPERATE

Daily Checks

Check the following items each day before operation. The time required is minimal, and habitual performance

of these checks will help ensure safe, reliable operation.

If any irregularities are found during these checks, refer to the “MAINTENANCE AND ADJUSTMENT” chap­ter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operat­ing condition.

WARNING

Failure to perform these checks before operation may result in serious damage or an accident. Al­ways per form daily checks before operation.

DANGER

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

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

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):

HOW TO OPERATE 71

Tire Load Cold Tire Pressure

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

Rear

Up 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 exce ssive 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 the

return 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 latch

plate should click securely with the buckle and release when the re-

lease button is pushed firmly.

72 HOW TO OPERATE

Doors ................................................ Make sure there is no damage to the structure or loose bolts and all

doors are latched securely they are closed.

HOW TO OPERATE 73

Starting the Engine

DANGER

Exhaust gas contains carbon monoxide, a
colorless, odorless poisonous gas. Inhaling
carbon monoxide can cause serious brain in­jury or death. DO NOT run the engine in en­closed areas. Operate only in a well­ventilated area.

Close all doors.

•

Wear the seat belts (for an operator and passen-

•

ger).
Make su re 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. The

•

glow plug system is designed so that the glow
plug indicator light goes on at that time, and turn
off after 4 seconds.
After the glow plug indicator light turns off, turn the

•

main switch key to the “START” position to acti-
vate the electric starter. Repeat until the engine
starts.

NOTICE

Do not operate the electric starter continu­ously for more than 5 seconds, or the starter
may overheat and the battery power will drop
temporarily. Wait 15 seconds between each
operation of the starter to let it cool and for
battery power to recover.

NOTE

The vehicle is equipped with a starter lockout sys-

○

tem. This system prevents the electric starter from
operating when the gear shift lever is in the “H”
(High) , “L” (Low) or “R” (Reverse) position, unless
the brake is applied.

High-Altitude Injection Control Device

This vehicle has a high-altitude injection control
device installed. It suppresses black smoke when
operating at high altitudes and at the same time
aims to control particulate matter.

The control device measures the atmospheric
pressure just after the engine has started. If at this
time the control device determines that the altitude
is 800 m (2 600 ft) or more, it reduces the fuel injec­tion amount and thus controls the occurrence of
black smoke.

Because of this reduction in the injection amount,
the engine output decreases.

74 HOW TO OPERATE

NOTE

The high-altitude injection control device does not

○

actuate during engine operation. Therefore, when
the machine is moved to a high altitude or to a low
altitude during operation, turn the main switch key
to the “OFF” position. This resets the control de­vice. After re-starting the engine, the necessity for
injection control is again determined.

Cold Weather Starting

Idling speed may not be stable and/or the engine
could stall when it is started in cold weather. How­ever this is not engine failure.

If the ambient temperature is 0°C (32°F) or lower,
use the following starting procedure to make idling
speed steady.

Close all doors.

•

Wear the seat belts (for an operator and passen-

•

ger).

Make su re 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.

•

The glow plug indicator goes on for 4 seconds.

•

When the glow plug indicator goes off, push down

•

the throttle pedal partially, and turn the main

switch key to the “START” position. The glow plug

indicator 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 pedal

•

partially pushed down for one minute maximum

until idling speed becomes steady.

After idling speed is steady, release the throttle

•

pedal.

Jump Starting

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

DANGER

Battery acid generates hydrogen gas which is
flammable and explosive under certain condi­tions. It is present within a battery at all times,
even in a discharged condition. Keep all
flames and sparks (cigarettes) away from the
battery. Wear eye protection when working
with a battery. In the event of battery acid con­tact with skin, eyes, or clothing, wash the af­fected areas immediately with water for at
least 5 minutes. Seek medical attention.

Connecting Jumper Cables

Make su re the main switch is turned off.

•

Remove the battery cover located under the front

•

right side of the cargo bed. Refer to the “Battery”

section in the “MAINTENANCE AND ADJUST-

MENT” chapter.

HOW TO OPERATE 75

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 (+) ter­minal of the vehicle battery.

76 HOW TO OPERATE

A. Vehicle Battery Positive (+) Terminal
B. From Booster Battery Positive (+) Terminal
C. From Booster Battery Negative (–) Terminal
D. Bracket

Connect another jumper cable from the negative

•

(–) terminal of the booster battery to the bracket.

NOTICE

Do not connect the booster battery to the fol­lowing portions as a ground.

Battery negative ( –) terminal

•

Electrical components or leads

•

Fuel line or fuel relative components

•

DANGER

Batteries contain sulfuric acid that can cause
burns and produce hydrogen gas which is
highly explosive.

Do not make this last connection at the fuel

•

system or battery.
Take care not to touch the positive and neg-

•

ative cables together, and do not lean over
the battery when making this last connec­tion.
Do not connect to a frozen battery. It could

•

explode.
Do not reverse polarity by connecting posi-

•

tive (+) to negative (–), or a battery explo­sion and serious damage to the electrical
system may occur.

Follow the standard engine starting procedure.

•

NOTICE

Do not operate the starter continuously for
more than 5 seconds, or the starter overheat
and the battery power will drop temporarily.
Wait 15 seconds between each operation of
the starter to let it cool and for the battery to
recover power.

After the engine starts, disconnect the jumper ca-

•

bles. Disconnect the negative (–) cable from the
vehicle first.

Reinstall the battery cover. Refer to the “Battery”

•

section in the “MAINTENANCE AND ADJUST-

MENT” chapter.

Lower the cargo bed and secure it with the

•

latches. Refer to the “Cargo Bed” section in the

“GENERAL INFORMATION” chapter.

HOW TO OPERATE 77

Moving Off

Make su re 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 on

•

the throttle pedal.

NOTE

Practice starting and stopping (using the brakes)

○

until you are familiar with the controls.

78 HOW TO OPERATE

Braking

NOTE

When the throttle pedal is released completely

○

and the engine speed drops near an idle, the ve­hicle has no engine braking. This is caused by the
vehicle's automatic transmission which releases
the engine at very low speed to prevent it from
stalling. Employ the brakes to control the vehicle's
speed.

Release the throttle pedal completely.

•

Press on the brake pedal evenly and firmly.

•

WARNING

Carrying cargo or towing a trailer will in­crease braking distances. Failure to allow for
increased braking distance may result in acci­dent and injury. Always allow more distance
to stop when carrying cargo or towing a
trailer.

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.

•

Parking the Mule

WARNING

Operating or parking the vehicle near flamma­ble materials can cause a fire, and can result
in property damage or severe personal injury.
Do not idle or park your vehicle in an area
where tall or dry vegetation, or other flamma­ble materials could come into contact with
the muffler or exhaust pipe.

HOW TO OPERATE 79

WARNING

The engine and exhaust system get extremely
hot during normal operation and can cause
serious burns.
Never touch a hot engine, exhaust pipe, or
muffler during operation or after stopping the
engine.

Stop the vehicle on a level surface.

•

NOTICE

Avoid parking on steeply inclined surfaces.

When the engine has stopped, apply the parking

•

brake to help prevent the vehicle from rolling.

A. Parking Brake Lever

WARNING

If the vehicle should move after it is parked, it
might be damag ed or cause injury. Be sure to
apply the parking brake before leaving the ve­hicle.

Remove the main switch key to prevent unaut hor-

•

ized use.
When parking inside a garage or other structure,

•

be sure the structure is well ventilated and the ve­hicle is not close to any source of flame or sparks.
This includes any appliance with a pilot light.

80 HOW TO OPERATE

WARNING

Diesel fuel is extremely flammable and can be
explosive under certain conditions, creating
the potential for serious burns. Do not smoke.
Make sure the area is well ventilated and free
from any source of flame or sparks; this in­cludes any appliance with a pilot light.

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” section
in the “SAFE OPERATION” chapter.
Gradually increase engine speed by depressing

•

the throttle pedal.

A. Gear Shift Lever
B. “L” (Low) Position
C. “H” (High) Position
D. “N” (Neutral) Position
E. “R” (Reverse) Position

HOW TO OPERATE 81

WARNING

Shifting the transmission while the vehicle is
moving can cause abrupt changes in speed
and direction resulting in loss of control and
accident with severe personal injury or death.
Do not shift the transmission while the ve­hicle is moving. Stop the vehicle to shift the
transmission.

NOTICE

Shifting to high or low range when the vehicle
is in motion could cause engine damage.
Do not shift from “H” (High) or “L” (Low) to
“R” (Reverse) and vice versa when the ve­hicle is moving or with the engine running
above idling speed, or the transmission could
be damag ed.

NOTICE

Use of the high range for heavy loads, climb­ing hills, pulling a trailer, and sustained low­speed riding can lead to premature wear of
the torque converter belt and pulleys. Use the
low range for these condition.

2WD/4WD Shifting

Stop the vehicle completely.

•

Push the selectable 2WD/4WD shift switch to se-

•

lect the drive modes.

A. Selectable 2WD/4WD Shift Switch
B. “2WD” Position
C. “4WD” Position

NOTE

The “4WD” operating mode is indicated with the

○

“4WD” indicator symbol. Refer to the “Multifunc­tion Meter” section in the “GENERAL INFORMA­TION” chapter.
When the shift switch is changed from “4WD” to

○

“2WD” and vice versa, the transmission shifts
when the vehicle has rolled a short distance.
Drive off slowly to allow “4WD” to engage or

82 HOW TO OPERATE

disengage. As it engages, the “4WD” indicator
symbol will appear.
It is normal to hear a small clanking noise when

○

“4WD” engages or disengages while rolling on
hard surfaces, such as hard-packed dirt.

WARNING

The handling characteristics of this vehicle
differs between “2WD” and “4WD” according
to terrain. Changing the operating mode while
moving can cause sudden changes in han­dling performance which can cause the oper­ator to lose control and have an accident.
Always stop the vehicle before changing from
“2WD” to “4WD” and vice versa.

NOTICE

Shifting from “2WD” to “4WD” (or “4WD ” to
“2WD”) when the vehicle is in motion could

cause drive train damage.

Shifting the Differential

Stop the vehicle completely.

•

Push the selectable DIFF-LOCK shift switch to

•

“LOCK” position.

A. Selectable DIFF-LOCK Shift Switch
B. “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 switch

•

to “UNLOCK” (Unlocked-Rear Axle) position.

HOW TO OPERATE 83

WARNING

Shifting to Locked-Axle Mode while turning or
before entering a turn can reduce steering re­sponse, increasing the effort to turn. An unex­pected change in direction can cause the
operator to lose control, resulting in an acci­dent and injury. Do not shift to Locked-Axle
Mode while turning or before entering a turn.

NOTE

By pushing the shift switch to “LOCK” position, ro-

○

tational speed of both wheels is equalized thereby

increasing traction.

Shifting to Differential (Unlocked-Rear Axle)

Mode

Stop the vehicle completely.

•

Turn the selectable DIFF-LOCK shift switch to

•

“UNLOCK” position.

NOTICE

Shifting from “UNLOCK” to “LOCK” (or
“LOCK” to “UNLOCK”) when the vehicle is in

motion could cause drive train damage.

When Stuck

Release the throttle pedal immediately to protect
the drive belt and take the following actions to es­cape from the stuck condition.

Change the gear shift lever to the “L” (Low) posi-

•

tion, push the selectable DIFF-LOCK shift switch

to “LOCK” position, push the selectable

2WD/4WD shift switch to “4WD” position, and try

to escape by slowly revving up the engine. Refer

to the “Shifting the Differential” section in this

chapter.

If it the above method is not successful, you can

•

use a winch installed at the front of the vehicle

(Winch is an optional part.) or seek help from an-

other vehicle for towing.

84 SAFE OPERATION

SAFE OPERATION

Safety is an attitude. Your common sense and
good judgement are your best defenses against ac­cident and injury in everything you do. Your safety
and the safety of others depends on you and your
common sense. Use good judgement in the opera­tion of this or any other motor vehicle.

This vehicle is designed for an operator and pas­senger. Never carry persons in the cargo bed. Refer
to the “LOADING INFORMATION” chapter before
operating this vehicle.

Novice operators should practice braking and
turning in an open, off-highway area away from oth­er vehicles and persons. The terrain should be flat
and free of obstacles, with either a loose or hard dirt
surface, but not a mixture of both.

WARNING

Incorrect loading, improper installation or use
of accessories, or modification of your ve­hicle may result in an unsafe operating condi­tion. Before operation, make sure that the
vehicle is not overloaded and that you have
followed the instructions in the “LOADING IN­FORMATION” chapter.

Unfamiliar Terrain

Before driving in a new area be sure to check for
hidden obstacles or hazards. Keep your speed
down until you know the area well. You must know
the terrain you intend to drive on and be familiar with
your machine and its handling characteristics. Use
existing trails and stay away from hazardous areas
such as steep, rocky slopes or swamps. Be cau­tious when visibility is limited, as you may not be
able to see obstacles in your path.

SAFE OPERATION 85

Driving in Reverse

Start the engine following the procedure in the
“Starting the Engine” section. Before shifting into re­verse, stop the vehicle completely. Refer to the
“Gear Shift Lever” in the “GENERAL INFORMA­TION” 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 in
your way. Gradually open the throttle and begin
backing up cautiously.

To stop while driving in reverse, close the throttle
and gradually apply the brake. Avoid sudden appli­cation of the brake.

NOTICE

Do not operate the gear shift lever to change
gears while driving th e vehicle in reverse, or
the 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 climb­ing steep inclines, or driving on bumpy, sandy or
snowy surfaces. It also helps break loose, with the
differential locked under certain circumstances, for
example, when the vehicle is stuck in the mud. If
maximum torque is needed in these situations, shift
into the “L” (Low) pos ition with the gear shift lever.
Refer to the “Shifting Gears” section, “2WD/4WD
Shifting” and “Shifting the Differential” sections in
the “HOW TO OPERATE” chapter.

NOTE

Do not drive in “4WD” on pave d surfaces, be-

○

cause it increases tire and drive train wear and

makes the steering feel tight.

Remember

Use “4WD” on steep inclines or loose surfaces, or

•

when stuck in the mud, with the differential locked

if necessary.

For maximum torque shift into low range.

•

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

•

86 SAFE OPERATION

Turning the Vehicle

The vehicle will turn in a smaller radius with the
differential unlocked (in differential mode). In this
mode, the rear wheels can turn at different speeds
allowing the vehicle to turn tighter and more
smoothly. Even in this mode, however, avoid sharp
turns to keep the vehicle from tipping. Reduce ve­hicle speed before entering the turn and use the
throttle to maintain an even speed through the turn.

WARNING

In the differential mode, if either rear wheel
leaves the ground it will spin freely, and the
wheel on the ground will transmit very little
power. When a spinning wheel touches the
ground, it may grab abruptly, causing the op­erator to lose control. Do not make sharp
turns, even in the differential mode, in order
to avoid loss of control or tipping.

Remember

Slow down before entering the turn.

•

Maintain an even speed through the turn.

•

Hills

As with any motor vehicle, loading of the vehicle,
and the surface and steepness of the hill are among
the critical considerations in climbing, descending or
traversing hills. Use extreme caution on hills. Keep
in mind that loading changes a vehicle's center of
gravity and that the higher the center of gravity, the
more likely the vehicle is to tip on uneven surfaces.
Slippery, loose, or bumpy surfaces on hills are espe­cially hazardous. Some hills are just too steep to
climb. Always use common sense and practice
good judgement.

Climbing Hills

Do not attempt to climb hills or steep inclines until
you have mastered the controls and basic operating
maneuvers of this vehicle. Always go straight uphill
and, if the incline is steep and/or the surface is
loose, use “4WD” with the differential locked for
greater traction, and in low range for maximum tor­que.

Avoid hills with slippery sides that will cause you
to lose traction. Do not climb hills where you cannot
see far enough ahead. If you cannot see what is on
the other side of the crest of a hill, slow down until
you can get a clear view. Don't apply power sud­denly while climbing, or the front wheels might rise
off the ground. If the vehicle does not have enough
power to reach the top of the hill and stalls, allow
the vehicle to roll slowly straight back down the hill
controlling its descent with the brakes. Leave the
gear shift lever in the “H” (High) or “L” (Low) position
until you stop at the bottom of the hill.

WARNING

Riding sideways across a hill may cause the
vehicle to overturn, causing severe injury or
death. Do not turn sideways to the hill.

SAFE OPERATION 87

Never drive past your limit of visibility. If you can't

•

see 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 back

•

down, using the brake, with the gear shift lever left
in the “H” (High) or “L” (Low) position.

NOTE

When the throttle pedal is released completely

○

and the engine speed drops near an idle, the ve­hicle has no engine braking. This is caused by the
vehicle's automatic transmission which releases
the engine at very low speed to prevent it from
stalling. Use the brakes to control the vehicle's
speed.

Remember

Some hills are too steep. Use common sense.

•

88 SAFE OPERATION

Descending Hills

Slow down or stop at the top of a hill so you can
pick a straight, safe path for descent to avoid any
obstacles. Normally you should descend straight
down a hill since driving at an angle could cause the
vehicle to lean to one side and possibly tip over.
Proceed slowly and cautiously. Apply the brake as
necessary. Be careful if the surface is loose be­cause the tires are more likely to skid and braking
effectiveness will be reduced.

Turning while descending a slope must be done
very carefully and gradually to avoid tipping the ve­hicle over.

WARNING

Riding sideways across a hill may cause the
vehicle to overturn, causing severe injury or
death. Do not turn sideways to the hill.

Remember

Stop and look for obstacles before descending a

•

hill.

Go straight downhill.

•

Go slowly.

•

If you must turn, do so carefully and gradually.

•

NOTE

When the throttle pedal is released completely

○

and the engine speed drops near an idle, the ve-

hicle has no engine braking. This is caused by the

vehicle's automatic transmission which releases
the engine at very low speed to prevent it from
stalling. Use the brakes to control the vehicle's
speed.

SAFE OPERATION 89

Traversing Hillsides

When driving across the side of a hill, reduce ve­hicle speed and exercise extreme caution to prevent
tipping or loss of control. Avoid hills with slippery
sides that will cause you to lose traction. Also avoid
traversing hillsides covered with rocks or other ob­stacles which may cause you to lose your balance
or tip over.

When driving on soft terrain, steer slightly uphill to
keep the vehicle on a straight line across the hill­side.

If the vehicle begins to tip, steer downhill if possi­ble to regain control.

Sliding and Skidding

Obviously, on slippery or loose surfaces, special
care is required. Sliding any vehicle may be hazard­ous because the wheels may suddenly regain trac­tion and cause the vehicle to tip or overturn.
Therefore, never drive “over your head” or when
you 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 brak­ing force or accelerate when skidding, since this
may cau se further loss of control.

Use caution and maintain low speeds to avoid un­controlled skidding on areas covered with clay,
mud, ice, or snow. Use “4WD” and low range gear­ing efficiently. These conditions are particularly haz­ardous when descending a hill or making a turn.
Remember that this vehicle is not for use on public
streets, roads, or highways.

Remember

Be especially careful on very slippery surfaces.

•

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

•

90 SAFE OPERATION

Driving through Water

Avoid driving through water whenever it is possi­ble. When driving across shallow water, choose a
location to enter and exit the wat er where the banks
are not too steep or slippery. Check before entering
for rocks, holes or other obs tacles which may cause
you to overturn or become stuck or submerged.

Observe the following rules for operating the ve­hicle in water.

A. Axle Nut

WARNING

Operating the vehicle in rivers or streams
where water is flowing quickly can cause the
tires to lose traction and allow the vehicle to
be swept into the current. Never operate the
vehicle in fast-flowing water or in water deep­er than the bottom edge of the axle nuts.

After prolonged exposure to water, the wheel

bearings may require lubrication or replacement.

Wash the vehicle in fresh water if it has been ex­posed to salt water or operated in muddy condi­tions.

WARNING

Wet brakes provide greatly reduced efficiency
and could lead to an accident and injury. After
operation in water, always apply the brakes
long enough for friction to dry the linings. Al­so, the brake that gets wet may wear out fast­er. Check for brake wear more frequently if
the vehicle is used in water.

Remember

Avoid driving through water whenever possible.

•

Don't drive in deep and fast moving water.

•

Dry out the brakes.

•

Operator and Passenger Requirements

All operators of this vehicle should possess a valid

driver's license.

The operator and passenger must be able to
place both feet flat on the floorboard while seated
upright with their backs against the seatback when
firmly holding the steering wheel or handgrip.

WARNING

To avoid injury in the event of a roll-over, keep
arms and legs inside the vehicle at all times.
The operator should firmly grip the steering
wheel at all times, and the passenger should
hold onto the handgrips.

Close all the doors. Wear the seat belts (for an op­erator and passenger). The doors and handgrip are
not a substitute for the seat belts.

SAFE OPERATION 91

A. Right Handgrip

This vehicle is designed for an operator and up to

one passenger.

Never carry persons in the cargo bed. Refer to the
“LOADING INFORMATION” chapter before operat-
ing this vehicle.

92 NOISE AND VIBRATION CONTROL INFORMATION

NOISE AND VIBRATION CONTROL INFORMATION

Control Information

Noise Level

Acceleration 79 dB (A)

Stationary 97 dB (A)
Driver's Ear

84 dB (A)

Test method:

Vibration Values

Steering Wheel 1.5 m/s²

Seat 0.3 m/s²

Test method:

Please Do Not Tamper with Noise Con trol Sys­tem

To minimize the noise emissions from this prod­uct, Kawasaki has equipped it with effective intake
and exhaust silencing systems. They are designed
to give optimum performance while maintaining a
low noise level. Please do not remove these sys­tems, or alter them in any way which results in an in­crease in noise level.

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

“Driver's Ear”: 77/311/EEC Annex II

EN15997: 2011, Annex I

MAINTENANCE AND ADJUSTMENT 93

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 maintenance

is vitally important and must not be neglected.

If you are in doubt as to any adjustment or vehicle operation, please ask your authorized Kawasaki dealer to

check the Mule.

Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect mainte-

nance or improper adjustment done by the owner.

94 MAINTENANCE AND ADJUSTMENT

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

OPERATION

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 clearan ce - inspect* D D

Spark ar rester - clean and inspect

Engine oil - change*

First Ser vice Regular Service

After 20

h, or 200

km (120

mile) of

use

After 50

h, or 1

000 km

(600

mile) of

use

Every 50

h, or 1

000 km

(600

mile) of

use

Every 100

000 km (1

••

••

or every 6

•

whichever

h, or 2

200 mile)

of use

•

•

months

comes

first

Every 200

h, or 4

000 km (2

500 mile)

of use

Every

year of

use

MAINTENANCE AND ADJUSTMENT 95

FREQUENCY

OPERATION

Oil filter - replace* D

Front final gear case oil and transmission
case 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

First Ser vice Regular Service

After 20

h, or 200

km (120

mile) of

use

After 50

h, or 1

000 km

(600

mile) of

use

Every 50

h, or 1

000 km

(600

mile) of

use

Every 100

h, or 2

000 km (1

200 mile)

of use

D

or every 6

months

whichever

comes

first

Every 200

h, or 4

000 km (2

500 mile)

of use

••

••

Every

year of

use

96 MAINTENANCE AND ADJUSTMENT

FREQUENCY

OPERATION

CHASSIS

Brake pad wear - inspect* D D

Brake li ght switch - inspect

Brake fluid - change 2 years (D)

Brake caliper piston seal and dust seal - re­place

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 boot s - inspect

Shock absorbers - inspect D

Suspension arms - inspect D

First Ser vice Regular Service

After 20

h, or 200

km (120

mile) of

use

After 50

h, or 1

000 km

(600

mile) of

use

Every 50

h, or 1

000 km

(600

mile) of

use

Every 100

h, or 2

000 km (1

200 mile)

of use

••

2 years (D)

••

••

••

••

••

Every 200

000 km (2

h, or 4

500 mile)

of use

Every

year of

use

MAINTENANCE AND ADJUSTMENT 97

FREQUENCY

OPERATION

Steering - inspect D D

Steering joint dust boots - inspect

General lubrication - perform* D

Bolts, nuts, and fasteners tightness - in­spect

Seat belts - inspect

Cables - inspect D

Cargo bed latch - inspect

First Ser vice Regular Service

After 20

h, or 200

km (120

mile) of

use

After 50

h, or 1

000 km

(600

mile) of

use

Every 50

h, or 1

000 km

(600

mile) of

use

Every 100

h, or 2

000 km (1

200 mile)

of use

••

DD

Every 200

000 km (2

h, or 4

500 mile)

of use

•

•

Every

year of

use

98 MAINTENANCE AND ADJUSTMENT

Engine Oil

In order for the engine to function properly, main­tain the engine oil at the proper level, and change
the oil and oil filter in ac cordance with the Periodic
Maintenance Chart. Not only do dirt and metal par­ticles collect in the oil, but the oil itself loses its lubri­cative quality if used too long.

WARNING

Vehicle operation wit h insufficient, deterio­rated, or contaminated engine oil will cause
accelerated wear and may result in engine
seizure, accident, and injury. Check the oil
level before each use and change the oil and
filter according to the periodic maintenance
chart in the owner’s manual.

Oil Level Inspection

Check 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 it

•

dry, and insert the dipstick till it bottoms into the

tube securely.

A. Dipstick

Pull out the dipstick and check the oil level. The

•

oil level should be between the Full and Low holes
on the dipstick.

A. Dipstick
B. Full Hole
C. 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 1

•

and add slowly the correct amount of oil. Use the
same type and brand of oil that is already in the
engine.

MAINTENANCE AND ADJUSTMENT 99

Reinsert the dipstick until it bottoms into the tube

•

securely.
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 the

•

engine.
Remove the oil filler cap 1.

•

NOTICE

Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.

Apply engine oil to the rubber portion of the dip-

•

stick.

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

NOTE

There is another oil filler cap 2 on the engine. The

○

cap 2 is not required to be removed.

Place an oil pan beneath the engine.

•

Remove the drain bolt and gasket.

•