GENERAL INFORMATION j

Quick Reference Guide

This Quick Reference Guide will assist you in BREAK-IN j
finding the information you’re looking for.
HOW TO OPERATE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

TRANSPORTING AND STORAGE j

TROUBLESHOOTING GUIDE j

A Table of Contents is included after the

Foreword.
 Whenever you see the symbols shown below,
heed their instructions! Always follow safe operat-
ing and maintenance practices.

DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.

WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.

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

NOTE
○NOTE indicates information that may help or guide
you in the operation or service of the vehicle.
 WARNING
Engine exhaust, some of its constituents,
and certain vehicle components contain or
emit chemicals known to the State of Cali-
fornia to cause cancer and birth defects or
other reproductive harm.
 BASIC SAFE DRIVING
Knowing and following these rules for safe oper- for off-highway use only. Use of this vehicle on pub-
ation will increase your satisfaction with your new lic roads and paved surfaces is hazardous. Do not
Kawasaki vehicle. operate this vehicle on public roads or paved sur-
faces.
Perform the Daily Checks
Refer to the Daily Checks section for a list of items
Occupant Capacity
to check each day before use. Habitual performance
Make sure operators are 16 years or older with a
of these checks will help to insure safer, more re-
valid driver’s license.
liable usage. Be sure that any irregularities found
Each occupant must be able to sit with back
during these checks are corrected before operating
against seat, feet flat on floor, and hands on steer-
the vehicle.
ing wheel, handgrip or handhold.
The operator should be tall enough to wear the
Drive Carefully and with Good Judgement
seat belt properly and reach all controls.
We want you to be satisfied with your new
Passenger(s) should also be tall enough for the
Kawasaki vehicle, so drive carefully, safely, and ex-
seat belt to fit properly and to be able to brace them-
ercise good judgement. Practice basic maneuvers
selves, as necessary, by placing both feet firmly on
so you can drive confidently and safely.
the floor while gripping the handhold. Stay com-
Improper use of this vehicle can be hazardous.
pletely inside the vehicle.
Never operate at speeds too fast for your skills or
conditions. Handling characteristics of this vehicle
Never Drink and Drive
change depending upon cargo load and driving
Alcohol and drugs impair your judgement and slow
modes.
your reactions. Even drugs prescribed by a physi-
cian can be dangerous. Check with your doctor.
Read the Owner’s Manual
Read and understand this Owner’s Manual. This
Use Proper Riding Gear
is especially important for inexperienced drivers.
Proper protective gear can reduce the severity of
Refer to this Owner’s Manual if you have any ques-
injury in the event of an accident.
tions.
Choose a helmet most appropriate for your use of
this utility vehicle. A helmet can reduce the risk of
Off-Highway Use Only
head injuries. Wear appropriate eye protection and
This vehicle is not an all-terrain vehicle; it is de-
protective clothing.
signed and equipped to be a multiuse utility vehicle
Wearing Seat Belts Refueling
Both the operator and passenger(s) should al- Before refueling the vehicle, shut the engine off
ways wear their seat belts properly. Seat belts and make sure the area is well ventilated and free
cannot completely protect you in every accident, of any source of flame or sparks. Gasoline is very
but in many cases a seat belt can reduce the risk flammable.
of serious injury. Also, to avoid injury, do not put
any part of your body outside of the vehicle for any Tire Air Pressure
reason. Tire inflation and type can affect the vehicle’s han-
dling characteristics. Check the tire pressure fre-
Close the Doors quently. Use only the recommended tires for re-
Be sure all doors are securely closed during oper- placement.
ation and never remove a door.
The doors prevent branches, gravel, and debris Maximum Seating Capacity
from getting inside the passenger compartment. Do not exceed seating capacity: 6 occupants.
Occupants shall only ride in designated seating
Before Starting the Engine positions and with maximum 3 persons in each front
Three “musts” before starting the engine are: and rear seat.
Do not carry small children on lap.
1. Apply the parking brake,
2. Put the gear shift lever in the “N” (neutral) posi-
Reduce Speed When Carrying Cargo,
tion,
Passenger(s), and/or Pulling a Trailer
3. Check the throttle pedal for proper operation. It
Carrying cargo, passenger(s) and/or pulling a
should return to its rest position when released.
trailer can make the vehicle difficult to steer and
Use the Parking Brake may affect vehicle handling in an unpredictable man-
Always apply the parking brake before getting out ner. Braking distance is increased when carrying
of your vehicle. cargo, passenger(s) and/or pulling a trailer. Reduce
speed and allow greater distance for braking when
Obey Local Laws carrying cargo, passenger(s) and/or pulling a trailer.
Know and obey all laws and regulations govern- Use extreme caution when climbing and descending
ing the use of off-highway vehicles in your area. Re- hills, and traversing slopes.
spect private property. Always try to preserve nature
and the environment.
 EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1), exhaust
emission (2) and evaporative emission (3) control systems in compliance with applicable regulations of the
United States Environmental Protection Agency and California Air Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases
are led to the breather chamber through the cylinder head. Then, it is led to the combustion chamber through
the air cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from the cylinder
head.

2. Exhaust Emission Control System

The exhaust emission control system applied to this engine family is engine modifications that consist of a
catalytic converter in the muffler, a fuel injection system and ignition system having optimum ignition timing
characteristics.
The fuel injection system has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel
economy with a suitable air cleaner and exhaust system.
A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thor-
ough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the
atmosphere.

3-1. Evaporative Emission Control System

The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel
tank.

3-2. Evaporative Emission Control System (California)

Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors
are routed into the running engine to be burned, or stored in a canister when the engine is stopped.

An add-on or modified part must be compliant with applicable ARB evaporative emission control standards.
A violation of this requirement is punishable by civil and/or criminal punishment.
Maintenance and Warranty
Proper maintenance is necessary to ensure that your vehicle will continue to have low emission levels. This
Owner’s Manual contains those maintenance recommendations for your vehicle. Those items identified by the
Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards.
As the owner of this vehicle, you have the responsibility to make sure that the recommended maintenance is
carried out according to the instructions in this Owner’s Manual at your own expense.
You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have pro-
vided space at the end of this manual where an authorized Kawasaki dealer, or someone equally competent,
can record the maintenance. You should also retain copies of maintenance work orders, bills, etc., as verifica-
tion of this maintenance.

Tampering with Emission Control System Prohibited

Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by
any person other than for purposes of maintenance, repair, or replacement, of any device or element of design
incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been
removed or rendered inoperative by any person.
Do not tamper with the original emission related parts.
• Throttle body and internal parts
• Magneto or electronic battery ignition system
Spark plugs
• Fuel filter/Fuel injector/Fuel pump
• Air cleaner element
• Electronic Control Unit (ECU)
•
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM
To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust
silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please
do not remove these systems, or alter them in any way which results in an increase in noise level.
 FOREWORD
Congratulations on your purchase of a new Kawasaki Mule. It is the result of Kawasaki’s engineering exper-
tise and a tradition of manufacturing high-quality consumer products.

Please read this Owner’s Manual carefully before starting your new Mule so that you will be thoroughly
familiar with the proper operation of your vehicle’s controls, its features, capabilities, and limitations.

To ensure a long, trouble–free life for your Mule, give it the proper care and maintenance described in this
manual.

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

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

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

This publication includes the latest information available at the time of printing. However, there may be minor
differences between the actual product and illustrations and text in this manual.
All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

© 2017 Kawasaki Heavy Industries, Ltd. Jan. 5, 2017. (5)

 TABLE OF CONTENTS
SPECIFICATIONS............................................ 12 Sun Top (Equipped Model)............................ 51
SERIAL NUMBER LOCATIONS...................... 17 Converting Rear Seat and Cargo Bed........... 52
LOCATION OF PARTS .................................... 18 From 6-Persons to 3-Persons Mode .......... 52
LOCATION OF LABELS.................................. 21 From 3-Persons to 6-Persons Mode .......... 55
LOADING INFORMATION............................... 36 Cargo Bed ..................................................... 56
GENERAL INFORMATION.............................. 38 Tailgate ....................................................... 56
Multifunction Meter ........................................ 38 Loading Cargo Bed .................................... 56
Speedometer:............................................. 39 Lifting & Lowering the Cargo Bed............... 57
Fuel Level Gauge: ...................................... 39 Fuel ............................................................... 63
Clock: ......................................................... 40 Glove Compartment ...................................... 66
Odometer: .................................................. 41 Cupholders .................................................... 66
Trip Meters A/B:.......................................... 41 Front Access Cover....................................... 67
Hour Meter: ................................................ 42 Storage Box................................................... 68
2WD/4WD Indicator Symbol:...................... 42 Ignition Switch ............................................... 69
Red CVT Belt Check Indicator Light:.......... 43 Keys .............................................................. 70
Yellow Engine Warning Indicator Light: ...... 43 Gear Shift Lever ............................................ 71
Red EPS Warning Indicator Light:.............. 43 Selectable 2WD/4WD Shift Switch ................ 72
Red Parking Brake Indicator Light:............. 44 Selectable DIFF-LOCK Shift Switch .............. 74
Red Reverse Indicator Light:...................... 44 Belt Drive Transmission................................. 74
Green Neutral Indicator Light: .................... 44 Parking Brake Lever ...................................... 75
Red Seat-Belt Use Reminder: .................... 44 Doors ............................................................. 76
Red Coolant Temperature Warning Seats ............................................................. 77
Indicator Light:......................................... 44 Seat Belts ...................................................... 79
Red Oil Pressure Warning Indicator Light: . 44 Throttle Pedal ................................................ 81
Lighting/Electrical Accessory Trailer Hitch Bracket ...................................... 82
Socket/Electrical Accessory Connector...... 45 Winch (KAF820J) .......................................... 83
Lighting/Electrical Accessory Socket.......... 45 Safety Precautions ..................................... 85
Electrical Accessory Connector.................. 46 How to Operate Winch ............................... 86
Light Switches ............................................... 47 Winch Maintenance.................................... 87
Steering Wheel.............................................. 49 BREAK-IN ........................................................ 88
Brake Pedal................................................... 50 HOW TO OPERATE......................................... 89
 Daily Checks ................................................. 89 Evaporative Emission Control System
Starting the Engine........................................ 93 (California Model) ....................................... 135
Jump Starting ................................................ 94 Spark Arrester ............................................... 136
Moving Off ..................................................... 96 Throttle Pedal ................................................ 138
Braking .......................................................... 97 Idle Adjustment.............................................. 139
Stopping the Engine ...................................... 97 Fuel Hose ...................................................... 140
Parking the Mule ........................................... 98 Fuel Tank Vent............................................... 140
Shifting Gears................................................ 99 Belt Drive Transmission (CVT) ...................... 141
2WD/4WD Shifting ........................................ 100 Brakes ........................................................... 142
Shifting the Differential .................................. 101 Brake Pedal................................................ 142
When Stuck ................................................... 102 Brake Disc and Brake Pad ......................... 144
Catalytic Converter ........................................ 103 Brake Light Switch......................................... 145
SAFE OPERATION.......................................... 104 Parking Brake................................................ 146
Unfamiliar Terrain .......................................... 104 Steering Wheel.............................................. 147
Driving in Reverse ......................................... 105 Power Steering System (KAF820B/C/D/J) . 148
Driving in “4WD” ............................................ 105 Wheels .......................................................... 148
Turning the Vehicle........................................ 106 Rims ........................................................... 148
Hills................................................................ 106 Wheel Nuts................................................. 148
Climbing Hills................................................. 107 Tires ........................................................... 148
Descending Hills............................................ 108 Joint Boots..................................................... 151
Traversing Hillsides ....................................... 109 Suspension.................................................... 152
Sliding and Skidding ...................................... 109 Seat Belts ...................................................... 155
Driving through Water.................................... 110 Cargo Bed Latches........................................ 156
Operator and Passenger Requirements........ 111 Headlight Beam ............................................. 157
MAINTENANCE AND ADJUSTMENT............. 113 Battery ........................................................... 157
Periodic Maintenance Chart .......................... 113 Fuse .............................................................. 167
Engine Oil...................................................... 118 Breaker.......................................................... 171
Front Final Gear Case Oil (KAF820A/B/C/D) 122 General Lubrication ....................................... 172
Transmission Case Oil .................................. 125 Cleaning ........................................................ 172
Cooling System ............................................. 128 General Precautions................................... 172
Spark Plugs ................................................... 130 Where to be Careful ................................... 174
Valve Clearance ............................................ 131 Washing Your Vehicle................................. 175
Engine Air Cleaner ........................................ 132 Bolt and Nut Tightening ................................. 175
TRANSPORTING AND STORAGE ................. 176
Transporting the Vehicle................................ 176
Storage.......................................................... 177
TROUBLESHOOTING GUIDE......................... 180
YOUR WARRANTY/OWNER SATISFACTION
...................................................................... 182
ENVIRONMENTAL PROTECTION.................. 186
MAINTENANCE RECORD .............................. 187
12 SPECIFICATIONS

SPECIFICATIONS
PERFORMANCE
Maximum Torque 65 N·m (6.6 kgf·m, 48 ft·lb) @3 500 r/min (rpm)
Minimum Turning Radius Differential Mode: 4.8 m (15.7 ft)
Seating Capacity Front 3 persons, Rear 3 persons
DIMENSIONS
Overall Length KAF820A/B/C/D 3 385 mm (133.3 in.)
KAF820J 3 445 mm (135.6 in.)
Overall Width 1 625 mm (63.98 in.)
Overall Height: KAF820A/B/D 1 970 mm (77.56 in.)
KAF820C/J 2 020 mm (79.53 in.)
Wheelbase 2 345 mm (92.32 in.)
Tread: Front 1 389 mm (54.68 in.)
Rear 1 321 mm (52.01 in.)
Ground Clearance KAF820A/B/C/D 260 mm (10.2 in.)
KAF820J 255 mm (10.0 in.)
Dry Mass: KAF820A 821 kg (1 810 lb)
KAF820A (CAL) 822 kg (1 813 lb)
KAF820B 831 kg (1 832 lb)
KAF820B (CAL) 832 kg (1 835 lb)
KAF820C 836 kg (1 843 lb)
KAF820C (CAL) 837 kg (1 846 lb)
 SPECIFICATIONS 13

KAF820D 833 kg (1 837 lb)

KAF820D (CAL) 834 kg (1 839 lb)
KAF820J 854 kg (1 883 lb)
KAF820J (CAL) 856 kg (1 887 lb)
Curb Mass: KAF820A 856 kg (1 887 lb)
KAF820A (CAL) 857 kg (1 890 lb)
KAF820B 867 kg (1 912 lb)
KAF820B (CAL) 868 kg (1 914 lb)
KAF820C 872 kg (1 923 lb)
KAF820C (CAL) 873 kg (1 925 lb)
KAF820D 869 kg (1 916 lb)
KAF820D (CAL) 870 kg (1 918 lb)
KAF820J 890 kg (1 962 lb)
KAF820J (CAL) 892 kg (1 967 lb)
Cargo Bed (L × W × H) Long bed mode 1 085 × 1 363 × 279 mm (42.72 × 53.66
× 10.98 in.)
Short bed mode 560 × 1 363 × 279 (22.05 × 53.66 × 10.98
in.)
ENGINE
Type 4-stroke, DOHC, 3-cylinder, liquid-cooled
Displacement 812 cm³ (49.5 cu in.)
Bore × Stroke 72.0 × 66.5 mm (2.83 × 2.62 in.)
Compression Ratio 9.5:1
14 SPECIFICATIONS

Starting System Electric starter

Cylinder Numbering Method Left to right, 3-2-1
Firing Order 1-2-3
Carburetion System FI (Fuel Injection)
Ignition System Battery and Coil (Transistorized Ignition)
Ignition Timing 9.5° BTDC @1 700 r/min (rpm)
Spark Plug (Standard) TORCH 7026, (Alternative) NGK IFR6B11
Lubrication System Forced lubrication (wet sump)
Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 2.4 L (2.5 US qt)
Coolant Capacity 5.9 L (6.2 US qt)
DRIVE TRAIN
Driving Type: Primary Belt drive torque converter (CVT)
Final 2WD/4WD system with Drive Shafts
Transmission Type 2-speed & reverse, Automatic
Primary Reduction Ratio 3.33  0.76 (Belt drive torque converter)
Final Reduction Ratio: Front 6.382
Rear 6.245
Overall Drive Ratio: Forward 11.261 (High)
22.356 (Low)
Reverse 17.359
 SPECIFICATIONS 15

Transmission Gear Ratio: Forward 1.803 (High)

3.580 (Low)
Reverse 2.779
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)]
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 2.0 L (2.1 US qt)
FRAME
Type Steel tube, ladder type
Steering: KAF820A Rack and Pinion
KAF820B/C/D/J Rack and Pinion with Electric Power Steering (EPS)
System
Caster 4.4°
Tire Size: Front 26 × 9.00R12 4PR
Rear 26 × 11.00R12 4PR
Rim Size: Front 12 × 7.0AT
Rear 12 × 8.0AT
Fuel Tank Capacity 30 L (7.9 US gal)
ELECTRICAL EQUIPMENT
Battery 12 V 32 Ah (20 HR)
16 SPECIFICATIONS

Headlight
High Beam: KAF820A/B 12 V 60 W × 2
KAF820C/D/J 12 V 60 W × 2, LED × 2
Low Beam: KAF820A/B 12 V 55 W × 2
KAF820C/D/J 12 V 55 W × 2, LED × 2
Brake/Tail Light 12 V 21/5 W × 2
LOAD CAPACITY
Maximum Vehicle Load
(Including occupants, KAF820A/B/C/D 733 kg (1 616 lb)
cargo and accessories)
KAF820A/B/C/D (CAL) 573 kg (1 263 lb)
KAF820J 714 kg (1 574 lb)
KAF820J (CAL) 556 kg (1 226 lb)
Maximum Cargo Bed Load Short Bed Mode: 158 kg (350 lb)
Except for
Long Bed Mode: 453 kg (1 000 lb)
California Model:
California Model: Long Bed Mode: 272 kg (600 lb)

CAL: California model

Specifications are subject to change without notice.
 SERIAL NUMBER LOCATIONS 17

SERIAL NUMBER LOCATIONS

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

Frame No. Engine No.

A. Frame Number A. Engine Number (Label)

18 LOCATION OF PARTS

LOCATION OF PARTS
(6-Persons Mode)

1. LED Sub Headlights 9. Rear Seat Belts 17. Front Door

(KAF820C/D/J) 10. Screen Lock Arm 18. Handhold for Rear Seat
2. Headlights 11. Cargo Bed Passengers
3. Front Access Cover 12. Front Guard 19. Rear Power Outlet Sockets
4. ROPS (Roll Over Protective 13. Winch (KAF820J) (KAF820C/D/J)
Structure) 14. Coolant Reserve Tank 20. Rear Door
5. Steering Wheel (KAF820J) 21. Cargo Bed Handgrip
6. Front Seat 15. Brake Fluid Reservoir 22. Cargo Bed Latch
7. Front Seat Belts 16. Steering Wheel Tilt Lock 23. Muffler (Spark Arrester)
8. Rear Seat Lever (KAF820B/C/D/J) 24. Trailer Hitch Bracket
 LOCATION OF PARTS 19

(3-Persons Mode)

1. Tailgate Latch Handle 6. Handgrip for Front Right 11. Battery

2. Tailgate Seat Passenger 12. Rear Seat (Folded Position)
3. Sun Top (KAF820C/J) 7. Tail/Brake Light 13. Fuel Tank Cap
4. Screen 8. Rear Shock Absorber 14. Dashboard
5. Handgrip for Front Center 9. Cargo Bed Side Plate 15. Front Shock Absorber
Seat Passenger 10. Air Cleaner 16. Radiator
20 LOCATION OF PARTS

1. Parking Brake Lever 5. Headlight Switch 11. Cupholders

2. Winch Remote Control 6. LED Sub Headlight Switch 12. Ignition Switch
Switch Socket (KAF820J) (KAF820C/D/J) 13. Brake Pedal
3. Selectable DIFF-LOCK Shift 7. Multifunction Meter 14. Throttle Pedal
Switch 8. Front Power Outlet Sockets 15. Gear Shift Lever
4. Selectable 2WD/4WD Shift 9. Winch Switch
Switch 10. Glove Compartment
 LOCATION OF LABELS 21

LOCATION OF LABELS
All warning labels which are on your vehicle are
repeated here. Read labels on your vehicle and un-
derstand them thoroughly. They contain information
which is important for your safety and the safety of
anyone else who may operate your vehicle. There-
fore, it is very important that all warning labels be on
your vehicle in the locations shown. If any label is
missing, damaged, or worn, get a replacement from
your Kawasaki dealer and install it in the correct po-
sition.
NOTE
○The sample warning labels in this section have
part numbers to help you and your dealer obtain
the correct replacement.
○Refer to the actual vehicle label for model specific 1.
2.
Warning (General)
Certification (ANSI/OPEI)
data grayed out in the illustration. 3. Power Outlet Socket Information
4. Notice (Shifting)
22 LOCATION OF LABELS

5. Specification (ROPS)
6. Notice (No Storage Area)
7. Specification (Model)
8. Danger (Radiator Cap)
9. Brake Fluid Warning
 LOCATION OF LABELS 23

10. Danger/Poison (Battery)

11. Lead-acid Battery
12. Warning (Refueling)
13. Warning (Cargo Bed Lifting: both sides)
24 LOCATION OF LABELS

14. Warning (Trailer Towing)

15. Important Information (Air Cleaner)
16. Important Information (Drive Belt)
17. Power Outlet Socket Information
(KAF820C/D/J)
 LOCATION OF LABELS 25

18. Warning (Cargo Bed Operation)

19. Warning (Cargo Bed Loading)
20. Certification (Emission)
21. Important Information (Tires/Max. Load)
26 LOCATION OF LABELS

22. Instruction (Rear Seat)

23. Storage Box Load Information
 LOCATION OF LABELS 27

(1)

(2) (3)
28 LOCATION OF LABELS
(4) (7)

(8)

(5)

(6)
 LOCATION OF LABELS 29

(9) (11)

(10) (12)
30 LOCATION OF LABELS
(13) (14)
 LOCATION OF LABELS 31

(15) (17) (KAF820C/D/J)

(18)

(16)
32 LOCATION OF LABELS
(19) (Except for California Model)

(19) (California Model Only)

 LOCATION OF LABELS 33

(20) (Except for California Model) (20) (California Model Only)

(21) (KAF820A/B/C/D (Except for California Model))

34 LOCATION OF LABELS
(21) (KAF820J (Except for California Model))

(21) (KAF820A/B/C/D (California Model Only))

 LOCATION OF LABELS 35

(21) (KAF820J (California Model Only))

(22) (23)
36 LOADING INFORMATION

LOADING INFORMATION
WARNING • Carrying cargo, passengers and/or pulling a trailer
can make the vehicle difficult to steer and may af-
Incorrect loading, improper installation or
fect vehicle handling in an unpredictable manner.
use of accessories, or modification of your
Use extreme caution when climbing and descend-
vehicle may result in an unsafe operating
ing hills, and traversing slopes.
condition. Before you operate it, make sure
that the vehicle is not overloaded and that • Braking distance is increased when carrying
cargo, passengers and/or pulling a trailer. Re-
you have followed these instructions.
duce speed and allow greater distance for braking.
With the exception of genuine Kawasaki Parts and • All cargo should be carried as low as possible to
reduce the effect on the vehicle’s center of gravity.
Accessories, Kawasaki has no control over the de-
Cargo weight should be equally distributed from
sign or application of accessories. In some cases,
side to side. This helps maintain stability by cen-
improper installation or use of accessories, or vehi-
tralizing weight. Avoid carrying cargo that extends
cle modifications, will void the utility vehicle warranty.
beyond the rear of the vehicle. Do not carry cargo
In selecting and using accessories, and in loading
on top of the ROPS.
the vehicle, you are personally responsible for your
own safety and the safety of others. • Cargo should be securely anchored. Make sure
the cargo will not move around while the vehicle
NOTE is moving. Recheck cargo security as often as
○Kawasaki Parts and Accessories have been spe- possible (while the vehicle is stopped) and adjust
as necessary.
cially designed for use on Kawasaki utility vehi-
cles. We strongly recommend that all parts and
accessories you add to your vehicle be genuine NOTICE
Kawasaki components. The front body work and fenders are not de-
Because any vehicle is sensitive to increases in signed to carry cargo or to support weight.
weight and changes in weight distribution, you must Do not place cargo, lean or sit on them, or
take care in carrying cargo. Always follow these pre- they may break.
cautions:
• This vehicle is not designed to carry passengers
in the cargo bed. Installing additional passenger
 LOADING INFORMATION 37

seating or carrying passengers in the cargo bed

can cause changes in vehicle handling.
• (Maximum Vehicle Load) Weight of operator, pas-
senger(s), cargo, accessories, and trailer tongue
must not exceed following limits.
WARNING KAF820A/B/C/D
Passengers transported in the cargo bed can Except for California Model: 733 kg (1 616 lb)
be tossed about or even thrown out causing
serious injury or death. Do not install seating California Model: 573 kg (1 263 lb)
or transport passengers in the cargo bed. KAF820J
Except for California Model: 714 kg (1 574 lb)
• (Maximum Cargo Bed Load) Do not carry more
than maximum cargo bed load as follows. California Model: 556 kg (1 226 lb)
Short Cargo Bed Mode: 158 kg (350 lb)
Long Cargo Bed Mode: 453 kg (1 000 lb) [Except
• Do not operate this vehicle faster than 16 km/h (10
mph) when pulling a trailer. Refer to the “Trailer
for California Model], 272 kg (600 lb) [California Hitch Bracket” section in the “GENERAL INFOR-
Model] MATION” chapter.
 38 GENERAL INFORMATION
j
GENERAL INFORMATION
1. Red CVT Belt Check Indicator Light
Multifunction Meter 2. Yellow Engine Warning Indicator Light
3. Red EPS Warning Indicator Light
4. Speedometer
5. Fuel Level Gauge
6. Red Parking Brake Indicator Light
7. Red Reverse Indicator Light
8. Green Neutral Indicator Light
9. Right Button
10. Odometer/Trip Meter/Hour Meter
11. Clock
12. Left Button
13. “2WD” Indicator Symbol
14. Red Seat-Belt Use Reminder
15. Red Coolant Temperature Warning Indicator
Light
16. Red Oil Pressure Warning Indicator Light
17. “4WD” Indicator Symbol

Pushing the left button shifts the display in the

odometer/trip meter/hour meter through the 4
modes; odometer, trip meter A and B, and hour
meter.
When the ignition switch is turned on, all the “LCD”
segments and “LED” lights are displayed for a sec-
ond, then the clock and meters operate normally de-
pending on the mode selected.
 GENERAL INFORMATION 39
j
Speedometer:
The speedometer shows the speed of the vehicle.

A. mph·km/h Display
B. Left Button
C. Right Button
A. Speedometer
• The mph·km/h display shifts as follows.
mph·km/h Display:
mph·km/h Display can alternate between U.S. 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 riding. Shift the
mph·km/h display in the digital meter as follows.
NOTE NOTE
○Do not operate the vehicle with the digital meter ○The data is maintained even if the battery is dis-
displaying in the wrong unit (mph or km/h). connected.
• Display the odometer in the digital meter.
Fuel Level Gauge:
• ing the left button
The mph·km/h display shifts by pushing and hold-
and pushing the right button The fuel in the fuel tank is shown in segments. All 6
within two seconds. segments are displayed when the fuel tank is full. As
 40 GENERAL INFORMATION
j
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 6.8 liters (1.8 US gal) of
fuel remain. 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 ignition switch on. A. Hour Display
• The odometer is displayed.
• Push the right button. The hour display stops
• Push the right button for more than two seconds.
Both the hour and minute displays start blinking.
blinking and the minute display starts blinking.
Push the left button to advance the minutes.
 GENERAL INFORMATION 41
j
NOTE
○When the figures come to 999999, they are
stopped and locked.

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. A. Odometer

NOTE Trip Meters A/B:

○Pushing the left button momentarily advances the The trip meter shows the distance in kilometers or
hour or minute step by step. Pushing and holding miles traveled since it was last reset to zero.
the button advances the hour or minute continu- To reset the trip meter:
ously.
○The clock works normally from the back-up power • Push the left button to display the trip meter A or
B.
while the ignition switch is turned off.
○When the battery is disconnected, the clock resets • Push the right button and hold it in.
to 1:00, and starts working again when the battery • After two seconds, the figure display turns to 0.0,
and then starts counting when the vehicle is oper-
is connected. ated. The meter counts until it is next reset.
Odometer: NOTE
The odometer shows the total distance in kilome- ○When the trip meter reaches 9999.9 when the ve-
ters or miles that the vehicle has been ridden. The hicle is running, it turns back to 0.0 and starts
meter cannot be reset. counting again.
 42 GENERAL INFORMATION
j
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.

A. Trip Meter A

Hour Meter:
The hour meter shows the total hours that the vehi-
cle has been operated. This meter cannot be reset.
NOTE
○When the figures come to 99999.9, they are
stopped and locked.

A. “2WD” Indicator Symbol

B. “4WD” Indicator Symbol

A. Hour Meter
 GENERAL INFORMATION 43
j
When the protection mode is activated, the CVT
belt check indicator light will start flashing. Avoid
such hard usage to protect the drive belt and take
actions to escape from such conditions. Refer to
the “When Stuck” section in the HOW TO OPERATE
chapter and “Belt Drive Transmission (CVT)” section
in the MAINTENANCE AND ADJUSTMENT chap-
ter.
NOTE
○This indicator light will go on when the ignition
switch is turned on and go off in three seconds.

Yellow Engine Warning Indicator Light:

A. Red CVT Belt Check Indicator Light The engine warning indicator light goes on when
B. Yellow Engine Warning Indicator Light engine parts fail to function properly. If this light goes
C. Red EPS Warning Indicator Light on, have your authorized Kawasaki dealer to check
D. Red Parking Brake Indicator Light the vehicle for the problem.
E. Red Reverse Indicator Light
F. Green Neutral Indicator Light Red EPS Warning Indicator Light:
G. Red Seat-Belt Use Reminder The EPS warning indicator light will momentarily il-
H. Red Coolant Temperature Warning Indicator
luminate when the engine starts, then go off in a sec-
Light
I. Red Oil Pressure Warning Indicator Light ond if the system is in order. If this warning indicator
light illuminates any other time, it indicates the ECU
Red CVT Belt Check Indicator Light: or actuator has malfunctioned, or the wiring harness
has become disconnected. Stop driving immediately
This vehicle is equipped with a drive belt protection and contact an authorized Kawasaki dealer to have
system that protects the drive belt from wear/tear the system checked.
and damage from excessive load caused by hard
usage such as engine revving up while the wheels NOTE
are stuck and unable to turn or exceeding maximum ○The KAF820A model does not have the EPS sys-
vehicle loads. tem on it. Therefore, the EPS warning indicator
 44 GENERAL INFORMATION
j
light does not go on except for a second when the Red Coolant Temperature Warning Indicator
ignition switch is turned on. Light:
○If this warning indicator light does not go on when The coolant temperature warning indicator light il-
the ignition switch is turned on, there may be a luminates whenever the coolant temperature rises
problem with the light itself. Contact an authorized too high while the vehicle is in operation. If it stays
Kawasaki dealer for inspection. on, stop the engine and check the coolant level in the
coolant reserve tank after the engine cools down.
Red Parking Brake Indicator Light: Be sure to check that the radiator fan is free from
When the parking brake is applied with the ignition mud and other obstacles. Refer to the “Breaker” sec-
switch in the “ON” position, the parking brake indica- tion in the “MAINTENANCE AND ADJUSTMENT”
tor light illuminates. chapter.
Red Reverse Indicator Light: NOTICE
When the transmission is in reverse gear, the re-
Do not continue running the engine with the
verse indicator light illuminates.
temperature warning indicator light continu-
Green Neutral Indicator Light: ously illuminated. Prolonged engine opera-
When the transmission is in neutral, the neutral tion can result in engine damage from over-
indicator light illuminates. heating.
Red Seat-Belt Use Reminder:
NOTE
When the ignition switch is turned on, the seat-belt
use reminder light will illuminate and stay on for ap- ○When you touch the fan, be sure to disconnect
proximately 8 seconds, even if the operator’s belt is the negative (–) battery cable, since the fan can
buckled. The light is a reminder to the operator to operate automatically even with the ignition switch
make sure that passengers have buckled their seat off.
belts. If the vehicle starts moving without buckling
the operator’s belt, the seat-belt use reminder starts Red Oil Pressure Warning Indicator Light:
blinking. The oil pressure warning indicator light blinks to
warn the operator whenever the oil pressure is dan-
gerously low or the ignition switch is in the “ON” po-
sition with the engine not running, and goes off when
the proper engine oil pressure is reached. Refer to
 GENERAL INFORMATION 45
j
the “MAINTENANCE AND ADJUSTMENT” chapter
for more detailed engine oil information. Lighting/Electrical Accessory
Socket/Electrical Accessory Connector

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

Lighting/Electrical Accessory Socket

The lighting/electrical accessory 12 volt sockets
are located on the dashboard. On KAF820C/D/J
models, the rear power outlet sockets are located
on the footwell of the rear seat.
An auxiliary light or an accessory may be con-
nected to these connectors.
 46 GENERAL INFORMATION
j
Electrical Accessory Connector
On KAF820A/B/C/D models, the front electrical
accessory connectors are located under the front ac-
cess cover. The rear electrical accessory connec-
tors are located under the right side of cargo bed.
An accessory may be connected to these connec-
tors.

A. Power Outlet Sockets

A. Front Electrical Accessory Connectors

(KAF820A/B/C/D)

A. Rear Power Outlet Sockets (KAF820C/D/J)

 GENERAL INFORMATION 47
j
Light Switches
The light switches are 3-position type with a pi-
lot light which illuminates while the ignition switch is
turned on.
The headlights can be turned on by pushing the
headlight switch to the “ ” or “ ” position
when the ignition switch is in the “ON” position.
: Low Beam
: High Beam
When the headlight is on high beam, the high
beam indicator light in the switch comes on as a
reminder. The headlights go off when the headlight
A. Rear Electrical Accessory Connectors
switch is pushed in “OFF” position.
 48 GENERAL INFORMATION
j

A. High Beam Position A. Headlight

B. Low Beam Position B. LED Sub Headlight (KAF820C/D/J)
C. Off Position
D. High Beam Indicator Light
E. Headlight Switch
F. LED Sub Headlight Switch (KAF820C/D/J)
The KAF820C/D/J models are equipped with LED
sub headlights. The operation of the LED sub head-
light switch is similar with the headlight switch.
 GENERAL INFORMATION 49
j
NOTE
Steering Wheel ○The power steering system functions only when
engine is running.
The KAF820B/C/D/J models are equipped with
an electric power steering system. The system
○If you install wireless equipment on board, contact
an authorized Kawasaki dealer. Installing such
does not require regular maintenance by users. Do equipment improperly may affect the ECU.
not tamper with the electronic control unit (ECU) or
loosen the fittings of steering actuator, or the neutral Steering Position Adjustment (KAF820B/C/D/J)
position setting of the steering will be adversely The steering wheel position can be adjusted to suit
affected and will cause serious driving problems. If the operator.
such components need service, contact an autho- Make any steering wheel adjustment before start-
rized Kawasaki dealer. ing the vehicle.
If the steering becomes more difficult than usual
or you feel a steering problem, refer to the “Steer- WARNING
ing Wheel” section in the “MAINTENANCE AND AD-
JUSTMENT” chapter. 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. Steering Wheel
 50 GENERAL INFORMATION
j
Brake Pedal
The brake pedal is the left pedal on the floor board.
Depress the pedal to slow or stop the vehicle.

A. Tilt Lock Lever

B. Pull Up
C. Adjust Steering Wheel

NOTE
○Make sure you have securely locked the steering A. Brake Pedal
wheel in place by moving it up and down.
 GENERAL INFORMATION 51
j
NOTICE
Sun Top (Equipped Model) Do not drive the Mule with the rear of the sun
top flipped forward as it could damage the
The rear of the sun top can be raised and flipped
hinge of the sun top.
forward after unhooking the rubber retaining straps
on both sides so that it does not interfere with the
front of the cargo bed when it is lifted in extended
condition.

A. Rubber Retaining Strap

B. Sun Top
After the cargo bed is lowered and latched, return
the rear of the sun top to its original position. Hook
the rubber retaining straps on both sides to secure
the rear of the sun top.
 52 GENERAL INFORMATION
j
2. Lift the rear seat by holding the handgrip on
Converting Rear Seat and Cargo Bed either side, and turn the rear seat forward.

This vehicle can be converted to accommodate

more passengers and less cargo or fewer passen-
gers and more cargo.
The seats and the cargo bed can be converted in
the following way.

WARNING
The latches must be unlocked during the
converting operation, allowing the possi-
bility for the cargo bed to suddenly lift and
cause serious injury. To prevent the cargo
bed from suddenly lifting, do not convert the
rear seat with the cargo bed loaded.
A. Cargo Bed Latch (Both Sides)
B. Handgrips
NOTICE C. Rear Seat Cushion
Be careful not to pinch your finger between D. Plastic Seat base
the movable components when converting
the rear seat and cargo bed. NOTICE
Do not lift the rear seat using the plastic seat
From 6-Persons to 3-Persons Mode base as it will break the plastic seat base.
1. Open the rear doors and release the cargo bed 3. Push the rear seat frame forward into the stored
latches on both sides. position.
 GENERAL INFORMATION 53
j
5. Turn the screen lock arms upward until lower
locking arm is released from the lock pin in the
cargo bed base.

A. Rear Seat Frame (Stored Position)

4. On both sides, pull the lower end of the screen
lock arms to release it from the cargo bed frame.
A. Screen Lock Arm (Both Sides)
B. Lower Locking Arm (Both Sides)
C. Lock Pin (Both Sides)
 54 GENERAL INFORMATION
j
6. Slide the cargo bed screen forward in conjunc- locking arms with the lock pins in the cargo bed
tion with pushing the hinge between the cargo base.
bed side plates on both sides. 8. Push the screen lock arms into the brackets on
the side plates on both sides until you hear a
click.
9. Secure the cargo bed side plates with the cargo
bed latches on both sides.
10. Close the rear doors.
NOTE
○Pull the screen lock arms lightly to check if they
are locked securely.

WARNING
Failure to properly lock the cargo bed or
screen may allow them to move suddenly
while driving, causing loss of control and
A. Cargo Bed Screen an accident resulting in serious injury or
B. Cargo Bed Side Plates death. To prevent the cargo bed from sud-
NOTE denly moving, make sure that the cargo bed
and screen has been locked properly after
○To move the screen smoothly, push both cargo handling them.
bed side plates evenly as much as possible.
7. After fully extending the cargo bed side plates,
lower both screen lock arms, aligning their lower
 GENERAL INFORMATION 55
j
NOTE
○After folding the cargo bed side plates, push both
screen lock arms to the lock pin until you hear a
click.

A. Cargo Bed Side Plates

B. Screen Lock Arm
C. Bracket
D. Lower Locking Arm
E. Handgrip
F. Cargo Bed Latch A. Screen Lock Arm
B. Lock Pin
From 3-Persons to 6-Persons Mode

NOTICE WARNING
Be careful not to pinch your finger between Failure to properly lock the cargo bed or
the movable components when converting screen may allow them to move suddenly
the rear seat and cargo bed. while driving, causing loss of control and
an accident resulting in serious injury or
death. To prevent the cargo bed from sud-
• Reverse the procedure for 6-persons to 3-persons
mode conversion. denly moving, make sure that the cargo bed
and screen has been locked properly after
handling them.
 56 GENERAL INFORMATION
j
Cargo Bed

Tailgate
The tailgate of the cargo bed can be lowered. Be-
fore 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. Cable

Loading Cargo Bed

WARNING
Loading the cargo bed before the conversion
operation is completed and the cargo bed
is unlocked may cause the bed to suddenly
tilt, resulting in serious injury. To prevent
the bed from suddenly lifting, be sure the
A. Tailgate conversion is complete and the cargo bed
B. Latch Handle
latches are firmly locked.
To close the tailgate, lift to the upright position and
secure firmly with the latches.
Pull the tailgate latch handles to make sure the
latches stay securely closed. Do not drive the ve-
hicle with the tailgate lowered.
 GENERAL INFORMATION 57
j
NOTICE Lifting & Lowering the Cargo Bed
Do not carry more than the maximum load The cargo bed can be tilted by releasing the
stated here in the convertible cargo bed. latches on each side, and then lifting the bed with
the handgrips. Before tilting the cargo bed, park on
• Short bed mode: 158 kg (350 lb)
a firm level surface and set the parking brake.
• Long bed mode (Except for California
Model): 453 kg (1 000 lb) Empty the cargo bed prior to raising the cargo bed.
(California Model): 272 kg (600 lb) Support the bed in the tilted position with the sup-
porting damper provided on the bottom of the cargo
bed. Do not drive the vehicle with the front end of
WARNING the cargo bed raised or unlatched.
To lower the bed, check to be sure the area un-
• Overloading, failure to properly secure
cargo, or improper use of the cargo bed der the front of the cargo bed is clear, then carefully
lower the bed into position.
can cause changes in handling which can
Check that both latches have locked the bed into
lead to an accident. Follow guidelines pro-
vided in the “LOADING INFORMATION” place. Do not leave the cargo bed unlatched.
chapter. Lifting the Cargo Bed while in Short
• Passengers riding in the cargo bed can be
tossed about or even thrown out causing 1.
Configuration
Open the rear doors and release the cargo bed
serious injury or death. Do not install seat- latch on both sides.
ing or carry passengers in the cargo bed.
• Driving with the cargo bed tilted may be
hazardous. Failure to lower and lock the
bed into place may cause severe injury or
death. Always lower and latch the bed after
tilting.
• Lifting and lowering the bed could be dan-
gerous. Be careful not to catch any part
of your body, such as hands or arms, be-
tween the bed and ROPS or vehicle frame
when lifting and lowering the bed.
 58 GENERAL INFORMATION
j
2. Lift the rear seat by holding the handgrip on 3. Push the rear seat frame forward into the stored
either side, and turn the rear seat forward. position.

A. Cargo Bed Latch (Both Sides) A. Rear Seat Frame (Stored Position)
B. Handgrips 4. Hold the handgrip as shown. Holding the hand-
C. Rear Seat Cushion grip, raise the cargo bed carefully.
D. Plastic Seat base

NOTICE
Do not lift the rear seat using the plastic seat
base as it will break the plastic seat base.
 GENERAL INFORMATION 59
j
bar of the ROPS to support the cargo bed. Po-
sition the supporting rod on the back side of the
hook without fail.

A. Handgrip
B. Cargo Bed

WARNING A. Supporting Damper

Reduced clearance between the cargo bed B. Cargo Bed (Raised Position)
and the ROPS can cause arm injury when lift- C. Supporting Rod
ing or lowering the cargo bed. To avoid in- D. Hook
jury, grasp cargo bed at the handle and do NOTE
not hold the ROPS when lifting or lowering
the cargo bed. ○Using only the bed supporting damper for support
may allow the cargo bed to suddenly lower under
particular situations such as a strong wind, slope
NOTE angle or cold weather.
○Do not hold ROPS when lifting or lowering the ○Support the cargo bed with a supporting rod when-
cargo bed. ever lifting the cargo bed.
5. Pull the supporting rod out of its clip and hook
the curved end of the supporting rod onto the
 60 GENERAL INFORMATION
j
Lifting the Cargo Bed in Extended Configuration 2. Open the rear doors. Make sure the screen lock
1. On models equipped with a sun top, unhook the arms are locked properly then release the cargo
rubber retaining straps on both sides, and raise bed latches on both sides.
the rear of the sun top and flip it forward.

A. Cargo Bed Latch

A. Rubber Retaining Strap B. Screen Lock Arm
B. Sun Top
WARNING
Failure to properly lock the screen lock arms
could cause the cargo bed side plates to fold
and allow the screen to slide down while lift-
ing the cargo bed, resulting in serious injury.
To prevent the cargo screen from sliding
down, make sure that the screen lock arms
are locked properly before lifting the cargo
bed.
 GENERAL INFORMATION 61
j
WARNING WARNING
The front of the cargo bed becomes heavier Reduced clearance between the cargo bed
in the extended mode and may raise and and the ROPS can cause arm injury when lift-
lower more quickly, increasing the risk of ing or lowering the cargo bed. To avoid in-
arm injury. To prevent injury, use extra care jury, grasp cargo bed at the handle and do
when raising or lowering the bed in extended not hold the ROPS when lifting or lowering
mode. the cargo bed.
3. Hold the handgrip as shown. Holding the hand-
grip, raise the cargo bed carefully. NOTE
○Do not hold ROPS when lifting or lowering the
cargo bed.
4. Pull the supporting rod out of its clip and hook
the curved end of the supporting rod onto the
bar of the ROPS to support the cargo bed. Po-
sition the supporting rod on the back side of the
hook without fail.

A. Handgrip
B. Cargo Bed
 62 GENERAL INFORMATION
j
supporting rod to the original position and secure it
with the clip. Hold the handgrip and carefully lower
the bed into position. Check that both latches have
locked the bed into place. Do not leave the cargo
bed 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 handles
to properly support the bed when lowering or
lifting the bed.
A. Supporting Damper
B. Cargo Bed (Raised Position) On models equipped with a sun top, return the rear
C. Supporting Rod of the sun top to its original position. Hook the rubber
D. Hook retaining straps on both sides to secure the rear of
the sun top.
NOTE
○Using only the bed supporting damper for support NOTE
may allow the cargo bed to suddenly lower under ○To lower the cargo bed, follow the reverse proce-
particular situations such as a strong wind, slope dure for lifting. Be sure to restore the seat as be-
angle or cold weather. fore and put the latches on. Never drive the Mule
○Support the cargo bed with a supporting rod when- without locking the latches to the cargo bed.
ever lifting the cargo bed.

Lowering the Cargo Bed

Before lowering the bed, check to be sure the area
under the front of the cargo bed is clear. Return the
 GENERAL INFORMATION 63
j
WARNING
Fuel
• Overloading, failure to properly secure
cargo, or improper use of the cargo bed
The fuel tank is mounted under the right side of
can cause changes in handling which can
the front seat. Use only fresh gasoline with the rec-
lead to an accident. Follow guidelines pro-
ommended octane rating from an uncontaminated
vided in the “LOADING INFORMATION”
source to insure proper running of your vehicle.
chapter.
Avoid filling the tank in the rain or where heavy dust
• Passengers riding in the cargo bed can be
tossed about or even thrown out causing
is blowing, so that the fuel does not get contami-
nated.
serious injury or death. Do not install seat-
ing or carry passengers in the cargo bed.
• Driving with the cargo bed tilted may be
hazardous. Failure to lower and lock the
bed into place may cause severe injury or
death. Always lower and latch the bed after
tilting.
• Lifting and lowering the bed could be dan-
gerous. Be careful not to catch any part
of your body, such as hands or arms, be-
tween the bed and ROPS or vehicle frame
when lifting and lowering the bed.

A. Fuel Tank Cap

Never fill the tank completely to the top. As the
fuel expands in a warm tank, it may overflow from
the vent line.
After refueling, make sure the fuel tank cap is
closed securely
 64 GENERAL INFORMATION
j
NOTICE table. The Antiknock Index is posted on service sta-
tion pumps in the U.S.A. and Canada. The octane
Always clean dirt/mud/debris/water from the
rating of a gasoline is a measure of its resistance
fuel tank cap and surrounding area prior to
to detonation or “knocking.” The Antiknock Index is
filling the tank to prevent dirt/mud/debris/wa-
an average of the Research Octane Number (RON)
ter from entering the fuel tank.
and the Motor Octane Number (MON) as shown in
Accumulation of moisture or sediment in the
the table below.
fuel system can restrict the flow of fuel and
cause fuel pump and/or engine damage. Minimum
Octane Rating Method
Rating
(RON + MON)
WARNING Antiknock Index
2
87
Gasoline is extremely flammable and can be
explosive under certain conditions, creating
the potential for serious burns. Turn the ig- NOTICE
nition switch off. Do not smoke. Make sure If engine “knocking” or “pinging” occurs,
the area is well-ventilated and free from any use a different brand of gasoline of a higher
source of flame or sparks; this includes any octane rating. If this condition is allowed to
appliance with a pilot light. Never fill the tank continue it can lead to severe engine dam-
completely to the top. If the tank is filled com- age.
pletely to the top, heat may cause the fuel to Gasoline quality is important. Fuels of low
expand and overflow through the vents in the quality or not meeting standard industry
tank cap. After refueling, make sure the tank specifications may result in unsatisfac-
cap is closed securely. If gasoline is spilled tory performance. Operating problems that
on the fuel tank, wipe it off immediately. result from the use of poor quality or nonrec-
ommended fuel may not be covered under
Fuel Requirements: warranty.
Fuel Type
This vehicle is certified to operate on unleaded Fuels Containing Oxygenates
gasoline only. Gasoline frequently contains oxygenates (alco-
Use clean, fresh unleaded gasoline with an Anti- hols and ethers) especially in areas of the U.S.A.
knock index equal to or higher than that shown in the
 GENERAL INFORMATION 65
j
and Canada which are required to sell such refor- NOTICE
mulated fuels as part of a strategy to reduce exhaust
Never use gasoline with an octane rat-
emissions.
ing lower than the minimum specified by
The types and volume of fuel oxygenates ap-
Kawasaki.
proved for use in unleaded gasoline by the U.S.
Never use “gasohol” with more than 10%
Environmental Protection Agency include a broad
ethanol, or more than 5% methanol. Gaso-
range of alcohols and ethers, but only two compo-
line containing methanol must also be
nents have seen any significant level of commercial
blended with cosolvents and corrosion
use.
inhibitors.
Gasoline/Alcohol Blends — Gasoline containing
Certain ingredients of gasoline may cause
up to 10% ethanol (alcohol produced form agricul-
paint fading or damage. Be extra careful
tural products such as corn), also known as “gaso-
not to spill gasoline or gasoline oxygenate
hol” is approved for use.
blends during refueling.
NOTICE When not operating your Kawasaki for 30
to 60 days, mix a fuel stabilizer (such as
Avoid using blends of unleaded gasoline and STA-BIL) with the gasoline in the fuel tank.
methanol (wood alcohol) whenever possible, Fuel stabilizer additives inhibit oxidation of
and never use “gasohol” containing more the fuel which minimizes gummy deposits.
than 5% methanol. Fuel system damage and Never store this product with “gasohol” in
performance problems may result. the fuel system. Before storage it is recom-
mended that you drain all fuel from the fuel
Gasoline/Ether Blends — The most common ether tank. See the “STORAGE” chapter in this
is methyl tertiary butyl ether (MTBE). You may use manual.
gasoline containing up to 15% MTBE.
NOTE
○Other oxygenates approved for use in unleaded
gasoline include TAME (up to 16.7%) and ETBE
(up to 17.2%). Fuel containing these oxygenates
can also be used in your Kawasaki.
 66 GENERAL INFORMATION
j
Glove Compartment Cupholders
A glove compartment is provided at the right side Cupholders are provided at the left and right sides
of the dashboard. Store only light items to avoid of the dashboard.
damage to the inside of the compartment. Do not
store items which must not get wet or dirty.

A. Cupholder

A. Glove Compartment
 GENERAL INFORMATION 67
j
Front Access Cover
• Pull the front access cover forward to disengage
the tabs from the slits of the front hood.

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 front of the front access cover up and open
the cover.
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
 68 GENERAL INFORMATION
j
Storage Box
The storage box is located under the front seat.
Remove the front seat and turn the knobs in direction
as shown to open the cover.

A. Front Access Cover

B. Knob

• Pull up the front ends of the access cover to make

sure the cover is locked securely.

WARNING
An open front access cover can distract or A. Knobs
B. Cover
impair visibility of the operator, causing loss
of vehicle control and potential serious in- The storage box is for storing only light-weight
jury or death. items in it to avoid damage to the inside of the stor-
Lock the front access cover securely before age box. Do not put items which must not get wet or
operating the vehicle. dirty in it.
Maximum Storage Box Load:
9 kg (20 lb)

Secure the cover with the knobs and install the

front seat when driving the vehicle.
 GENERAL INFORMATION 69
j
OFF Engine off. All electrical circuits off.
Ignition Switch All electrical equipment can be used.
ON
Hour meter works.
This is a three-position, key-operated switch. The
key can be removed from the switch only when it is Electric starter is engaged by holding
in the “OFF” position. ignition switch key in this position, only
START 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 ignition switch key to the
“START” position with the engine running, or
A. Ignition Switch damage to the starter can result.
B. “OFF” Position
C. “ON” Position NOTE
D. “START” Position
○The vehicle is equipped with a starter lockout
switch. This switch prevents the electric starter
from operating when the gear shift lever is in the
“H” (High), “L” (Low) or “R” (Reverse) position,
unless the brake is applied.
 70 GENERAL INFORMATION
j
In the event you lose your keys, you will need the
Keys key number to have a duplicate made. If you cannot
locate your key number, contact the dealer where
This UV comes with two keys. Use one for the you purchased your Kawasaki UV. It’s possible the
ignition switch and keep the other in a secure place dealer may have the number in its records. If the key
to use as a spare. A key number is stamped on number is lost completely, you will need to replace
the key itself. Record the key number in the space the ignition switch.
provided and store the number in a safe place. Contact your Kawasaki dealer to purchase addi-
tional spare keys either using your original key as a
master or using the key code on the tag or your key.
Store one key at home and keep another spare in
your wallet or riding gear, in case the original is lost.

A. Key
B. Key Number
Write your key number here.
 GENERAL INFORMATION 71
j
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 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
vehicle is moving or with the engine run-
ning above idling speed, or the transmission
could be damaged.

This vehicle is equipped with a sub-transmission

to allow maximum transmission efficiency. Use the
low gearing for maximum torque at low speeds, for
climbing hills, pulling a trailer, or keeping constant
low speeds. The high gearing raises the speed
 72 GENERAL INFORMATION
j
range for ordinary off-highway use. Stop the vehicle
before moving the gear shift lever. Selectable 2WD/4WD Shift Switch
NOTICE You can select “2WD” or “4WD” to suit various
Use of the high range for heavy loads, climb- driving conditions. The selectable 2WD/4WD shift
ing hills, and pulling a trailer can lead to pre- switch is located on the dashboard.
mature 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.

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.
 GENERAL INFORMATION 73
j
NOTICE
Shifting from “2WD” to “4WD” (or “4WD” to
“2WD”) when the vehicle is in motion could
cause drive train damage.

A. “2WD” Indicator Symbol

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

WARNING
The handling characteristics of this vehicle
differs between “2WD” and “4WD” accord-
ing 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 acci-
dent. Always stop the vehicle before chang-
ing from “2WD” to “4WD” and vice versa.
 74 GENERAL INFORMATION
j
Selectable DIFF-LOCK Shift Switch Belt Drive Transmission
You can select differential “LOCK” (locked-rear This vehicle is equipped with a belt-driven Contin-
axle) or “UNLOCK” (unlocked-rear axle) modes uously Variable Transmission (CVT). This automatic
to suit various driving conditions. The selectable drive system, although simple to operate, does re-
DIFF-LOCK shift switch is located on the dashboard. quire periodic inspection. Refer to the “MAINTE-
NANCE AND ADJUSTMENT” chapter.

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 indi-
cated by a light in the switch as a reminder. Refer
to the “Shifting the Differential” section in the “HOW
TO OPERATE” chapter.
 GENERAL INFORMATION 75
j
WARNING
Parking Brake Lever If the vehicle should move after it is parked,
it might be damaged or cause injury. Be sure
The parking brake lever is located at the left side of
to apply the parking brake before leaving the
the steering wheel. Pull the lever rearward to apply
vehicle.
the parking brake.
To release, push in and hold the knob on the end
of the lever and push the lever all the way forward.
Spring pressure helps return the lever to the re-
leased position.
Be sure to release the parking brake before driving
off. Failure to do so may result in poor performance
and premature wearing of the rear brakes and belt
converter system.

A. Parking Brake Lever

B. Knob
 76 GENERAL INFORMATION
j
NOTE
Doors ○Make sure that the all doors are properly closed
before starting the vehicle.
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 NOTICE
check that the latch is securely locked. If a door is The doors are not designed to bear weight.
damaged or does not close securely, contact an au- Never lean on or place excessive weight on
thorized Kawasaki dealer for repair or replacement. the doors or they will be damaged.

A. Door Handle
B. Door
C. Latch
 GENERAL INFORMATION 77
j
6-Persons Mode
Seats
There are front and rear seats on this vehicle. It
can be transformed from 3-persons to 6-persons by
unfolding the rear seat.
3-Persons Mode

A. Rear Seat

NOTE
○Converting the rear seat must be made in com-
bination with cargo bed conversion. Refer to the
“Converting Rear Seat and Cargo Bed” section in
A. Rear Seat (Stored Position) this chapter.
The front seat can be removed for vehicle mainte-
nance and adjustment.
Front Seat Removal
• Pull up the right and left ends of the front seat to
clear the projections.
• Remove the front seat.
 78 GENERAL INFORMATION
j

A. Front Seat A. Front Seat

B. Projections B. Projection (Both Sides)
C. Pull up C. Grommet (Both Sides)

Front Seat Installation

• Make sure that grommets are in position.
• Insert the projections of the front seat into the
grommets.
 GENERAL INFORMATION 79
j
WARNING
Seat Belts Not wearing a seat belt, or wearing one im-
properly can result in serious injury or death
The vehicle is equipped with retractable
in the event of an accident. Make certain
three-point seat belts for all occupants - opera-
the operator and all passengers always wear
tor and two passengers for the front seat and three
their seat belts properly.
passengers for the rear seat. Always wear the seat
belts when operating and riding in the vehicle.
WARNING
Operator and all passengers 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 se-
cure.

A. Seat Belt
B. Latch Plate
C. Buckle
 80 GENERAL INFORMATION
j
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. Seat Belt
B. Latch Plate
C. Buckle
D. Red Button
3. Put the lap portion of the belt low on your hips.
A. Lap Portion of Belt
Push down on the buckle end of the belt as you
B. Shoulder Belt
pull up on the shoulder part so the belt is snug
5. To unfasten the belt, press the red button in the
across your hips.
buckle.

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

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
 GENERAL INFORMATION 81
j
around both the occupant’s waist and shoulder. Un-
der rough driving situations the dual mode latch plate Throttle Pedal
will lock the seat belt in place.
To release the lock: The throttle pedal is the right pedal on the floor
• Move the slider in the direction of the arrow mark. board. Push the pedal down to increase engine
speed. Spring pressure returns the pedal to the rest
position when released. Always check that the throt-
tle 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. Slider
B. Arrow Mark

A. Throttle Pedal
 82 GENERAL INFORMATION
j
Trailer Hitch Bracket
This vehicle is equipped with a bracket for a trailer
hitch. Trailer towing equipment is not supplied with
this vehicle.
To avoid injury and property damage, observe the
following precautions:

WARNING
Improper towing of a loaded trailer could
cause an accident resulting in serious injury
or death.
• Never carry a passenger in a trailer.
A. Trailer Hitch Bracket
• 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 dis-
tance.
• 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 ve-
hicle and have an accident.
 GENERAL INFORMATION 83
j
Additional information that is specific to the winch
Winch (KAF820J) on this vehicle and you should follow is described
below.
This vehicle is equipped with a winch. The winch
Winch Switch
is located under the front guard.

A. Push here to “Spool Out”

A. Winch B. Push here to “Spool In”
B. Front Guard C. Winch Indicator
Every winching situation has the potential for per- D. Winch Switch
sonal injury. In order to minimize that risk, it is im-
portant that you carefully read the “BASIC GUIDE NOTE
TO WINCHING TECHNIQUES” that is supplied with ○Even if the engine is idling during winching, the
the vehicle, familiarize yourself with the operation of battery may drain faster than it is being charged.
your winch before using it, and be constantly safety Winch use places extra demand on the battery,
oriented. In the BASIC GUIDE, we will set forth causing it to drain faster. To prevent discharg-
many of the basic rules of safe winch operation. ing the battery to the point where it will no longer
However, your constant good judgment and consis- start the engine, keep the engine running during
tent focus on safety are of great importance because winching and winch cool time, and avoid perform-
every winching situation is different. ing more than 10 winch duty cycles in one outing.
 84 GENERAL INFORMATION
j
To maintain full battery performance, fully charge Connect the winch remote control switch as fol-
the battery before using your MULE the next day. lows.
○The winch indicator in the switch comes on during • Remove the cap from the winch remote control
winching. switch socket.

Winch Remote Control Switch

A. Winch Remote Control Switch Socket

A. Winch Remote Control Switch • Align the projection on the connector with the
groove on the socket and connect.
B. Winch Remote Control Switch Socket
C. Winch Switch
D. “IN” Position (Spool In)
E. “OUT” Position (Spool Out)
 GENERAL INFORMATION 85
j

A. Winch Remote Control Switch Connector A. Winch Remote Control Switch

B. Winch Remote Control Switch Socket B. Winch Remote Control Switch Socket
C. Projection C. Cap
D. Groove
After winch use, disconnect the winch remote con-
trol switch, store it in the glove compartment, and
install the cap of the winch remote control switch
socket to original position.
Safety Precautions

WARNING
To prevent serious injury or death, always
wind the winch rope on the bottom of the
winch drum. Never wind the winch rope over
the top of the drum, or the automatic load
holding brake will not function properly. If
the wire rope is winding off the top, you have
powered the winch “out” instead of “in.”
 86 GENERAL INFORMATION
j
Run Time Guidelines for the Winch
Run Dis- Cool
Load
Time tance Time
0 kN 14.2 m
2.5 min 12 min
(0 kgf, 0 lb) (46.5 ft)
2.2 kN 9.7 m
2.0 min 10 min
(230 kgf, 500 lb) (32.0 ft)
4.4 kN 6.4 m
1.5 min 10 min
(450 kgf, 1 000 lb) (21.0 ft)
6.7 kN 3.6 m
1.0 min 10 min
(680 kgf, 1 500 lb) (12.0 ft)
8.9 kN 2.3 m
A. Wrong 45 sec 10 min
(910 kgf, 2 000 lb) (7.5 ft)
B. Correct
11.1 kN 1.2 m
30 sec 10 min
How to Operate Winch (1 130 kgf, 2 500 lb) (4.0 ft)
This winch is an intermittent duty cycle device. It 13.3 kN 0.6 m
15 sec 10 min
must not be used with a duty cycle greater than 20%. (1 360 kgf, 3 000 lb) (2.0 ft)
Operation must not exceed the run time guidelines 15.6 kN 0.3 m
below. 10 sec 10 min
(1 590 kgf, 3 500 lb) (1.0 ft)
17.8 kN 0.1 m
5 sec 10 min
(1 810 kgf, 4 000 lb) (0.4 ft)
 GENERAL INFORMATION 87
j
Winch Maintenance
Inspect the winch before and after winching oper-
ation according to the maintenance table below. Re-
place any damaged parts before winching operation.
Before each After each Every 90
Check
use use days
Check fasteners and make sure they are tight and to proper
torque.
- Replace damaged fasteners.
• • •
Verify wiring to all components is correct and be certain that
all connections are tight. • •
Verify there is no exposed/bare wiring or terminals.
- Cover any exposures with terminal boots, heat shrink tubing or
electricians tape.
• •
Inspect rope for damage.
- Replace rope immediately if damaged. • • •
Keep winch, rope and switch control free from contaminants.
- Use a clean rag or towel to remove any dirt and debris. •
 88 BREAK-IN

BREAK-IN
j The first 20 hours or 200 km (120 mi) of vehicle NOTE
operation is designated as the break-in period. Do
not exceed 1/2 throttle during the break-in period. If
○Do not start moving or race the engine immedi-
ately after starting it, even if the engine is already
the vehicle is not used carefully during this period, warm.
you may end up with a "broken down" instead of
"broken in" vehicle.
○Do not race the engine while the transmission is
in neutral.
Break-in Period
Maximum Throttle ○It is important to perform the initial service after
Position the first 20 hours or 200 km (120 mi) of opera-
tion as described in this manual and the service
First 20 hours or 200 km manual for this vehicle. See the Periodic Main-
1/2 Throttle
(120 mi) tenance Chart in the “MAINTENANCE AND AD-
JUSTMENT” chapter.
 HOW TO OPERATE 89

HOW TO OPERATE

Daily Checks
Check the following items each day before operation. The time required is minimal, and habitual performance j
of these checks will help ensure safe, reliable operation.
If any irregularities are found during these checks, refer to the “MAINTENANCE AND ADJUSTMENT” chap-
ter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating
condition.

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

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

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

Engine Oil ........................................ Oil level between “F” and “L” holes on the dipstick (when engine is cold),
no leaks.
 90 HOW TO OPERATE
Tires ................................................. Air pressure (when cold):
Except for California Model (KAF820A/B/C/D):
Tire Load Cold Tire Pressure
Front Up to 733 kg (1 616 lb) 78.4 kPa (0.80 kgf/cm², 11.4 psi)
j Up to 590 kg (1 300 lb) 110 kPa (1.12 kgf/cm², 16.0 psi)
Rear 590  733 kg (1 300  1 616
130 kPa (1.33 kgf/cm², 18.9 psi)
lb)

California Model (KAF820A/B/C/D):

Tire Load Cold Tire Pressure
Front Up to 573 kg (1 263 lb) 78.4 kPa (0.80 kgf/cm², 11.4 psi)
Rear Up to 573 kg (1 263 lb) 110 kPa (1.12 kgf/cm², 16.0 psi)

Except for California Model (KAF820J):

Tire Load Cold Tire Pressure
Front Up to 714 kg (1 574 lb) 78.4 kPa (0.80 kgf/cm², 11.4 psi)
Up to 590 kg (1 300 lb) 110 kPa (1.12 kgf/cm², 16.0 psi)
Rear 590  714 kg (1 300  1 574
130 kPa (1.33 kgf/cm², 18.9 psi)
lb)

California Model (KAF820J):

Tire Load Cold Tire Pressure
Front Up to 556 kg (1 226 lb) 78.4 kPa (0.80 kgf/cm², 11.4 psi)
Rear Up to 556 kg (1 226 lb) 110 kPa (1.12 kgf/cm², 16.0 psi)
Check for cuts, cracks, damage, or excessive wear. Check for any
imbedded stones or other foreign particles in tread.
Front Final Gear Case ..................... No oil leaks.
 HOW TO OPERATE 91

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. Drain the oil and water in
the drain hose if necessary.
Screen at Belt Drive Transmission
(CVT) Air Duct .............................. Check and clean the screen for obstruction by insects, mud or foreign j
object.
Throttle ............................................ Throttle pedal free play 2  10 mm (0.08  0.39 in.). Throttle pedal
operates smoothly and returns to rest position when released.
Steering ........................................... Steering wheel free play 0  20 mm (0  0.79 in.). Action smooth without
excessive play, rough spots, or strange noises.
Brakes ............................................. Check for braking effectiveness (while test running). Brake pedal free
play 2  10 mm (0.08  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 parking
brake is applied with the ignition 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 release
button is pushed firmly.
Doors ............................................... Make sure there is no damage to the structure or loose bolts and all
doors are latched securely they are closed.
Winch (KAF820J) ............................ Check the bolts, nuts and fasteners for loose and/or missing.
Check the wire rope for kink, fray, or damage.
Check the hook and hook pin for wear, or damage.
Check the drum for crack, dent, or warp.
Check the clutch lever operates smoothly.
Check the winch switch and winch remote control switch operates
smoothly.
 92 HOW TO OPERATE
Check the cables and harnesses for damage, disconnection, or wrong
connection.

j
 HOW TO OPERATE 93

NOTE
Starting the Engine ○The vehicle is equipped with a starter lockout sys-
tem. This switch prevents the electric starter from
operating when the gear shift lever is in the “H”
DANGER (High) , “L” (Low) or “R” (Reverse) position, un-
Exhaust gas contains carbon monoxide, a less the brake is applied. j
colorless, odorless poisonous gas. Inhal-
ing carbon monoxide can cause serious
brain injury or death. DO NOT run the en-
gine in enclosed areas. Operate only in a
well-ventilated area.

• Close all doors.

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

• Make sure the parking brake is applied.

• Put the gear shift lever in the “N” (Neutral) position.
• Put the ignition switch key in the switch.
• tion totheactivate
Turn ignition switch key to the “START” posi-
the electric starter. Repeat until the
engine starts.

NOTICE
Do not operate the electric starter continu-
ously for more than 5 seconds, or the starter
may overheat and the battery power will drop
temporarily. Wait 15 seconds between each
operation of the starter to let it cool and for
battery power to recover.
 94 HOW TO OPERATE
the “MAINTENANCE AND ADJUSTMENT” chap-
Jump Starting ter.

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
j to start the engine.

DANGER
Battery acid generates hydrogen gas which
is flammable and explosive under certain
conditions. It is present within a battery at
all times, even in a discharged condition.
Keep all flames and sparks (cigarettes) away
from the battery. Wear eye protection when
working with a battery. In the event of bat-
tery acid contact with skin, eyes, or clothing, A. Battery Cover
wash the affected areas immediately with
water for at least 5 minutes. Seek medical • Lift the cargo bed and support it with the support-
ing rod. Refer to the “Cargo Bed” section in the
attention.
“GENERAL INFORMATION” chapter.

Connecting Jumper Cables • Connect a jumper cable from the positive (+) ter-
minal of the booster battery to the positive (+) ter-
• Make sure the ignition switch is turned off. minal of the vehicle battery.
• Remove the battery cover located at the right side
of the rear seat. Refer to the “Battery” section in
 HOW TO OPERATE 95

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. j
• Take care not to touch the positive and
negative cables together, and do not lean
over the battery when making this last con-
nection.
• Do not connect to a frozen battery. It could
explode.
• Do not reverse polarity by connecting pos-
itive (+) to negative (–), or a battery explo-
A. Vehicle Battery Positive (+) Terminal
B. From Booster Battery Positive (+) Terminal
sion and serious damage to the electrical
C. From Booster Battery Negative (–) Terminal system may occur.
D. Bracket Bolt

• Connect another jumper cable from the negative

• Follow the standard engine starting procedure.
(–) terminal of the booster battery to the bracket NOTICE
bolt on the engine.
Do not operate the starter continuously for
NOTICE more than 5 seconds, or the starter overheat
and the battery power will drop temporarily.
Do not connect the booster battery to the fol- Wait 15 seconds between each operation of
lowing portions as a ground. the starter to let it cool and for the battery to
• Battery negative (–) terminal recover power.
• Electrical components or leads
• Fuel line or fuel relative components
• After the engine starts, disconnect the jumper ca-
bles. Disconnect the negative (–) cable from the
vehicle first.
 96 HOW TO OPERATE

• Reinstall the battery cover. Refer to the “Battery”

section in the “MAINTENANCE AND ADJUST- Moving Off
MENT” chapter.
• Lower the cargo bed and secure it with the latches. • Make sure that all doors are properly closed.
Refer to the “Cargo Bed” section in the “GENERAL • Depress the brake pedal.
j
INFORMATION” chapter. • (Low) position.shift lever into the “H” (High) or “L”
Put the gear

• 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.
 HOW TO OPERATE 97

Braking Stopping the Engine

NOTE • Release the throttle pedal completely.

○When the throttle pedal is released completely and • Put

tion.
the gear shift lever into the “N” (Neutral) posi-
j
the engine speed drops near an idle, the vehicle
has no engine braking. This is caused by the ve- • Apply the parking brake to help prevent the vehicle
from rolling.
hicle’s automatic transmission which releases the
engine at very low speed to prevent it from stalling. • Turn the ignition switch key to the “OFF” position.
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 in-
crease braking distances. Failure to allow
for increased braking distance may result in
accident and injury. Always allow more dis-
tance to stop when carrying cargo or towing
a trailer.
 98 HOW TO OPERATE

Parking the Mule

WARNING
j 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 con-
tact with the muffler or exhaust pipe.

A. Parking Brake Lever

WARNING
The engine and exhaust system get ex- WARNING
tremely hot during normal operation and can
cause serious burns. If the vehicle should move after it is parked,
Never touch a hot engine, exhaust pipe, or it might be damaged or cause injury. Be sure
muffler during operation or after stopping to apply the parking brake before leaving the
the engine. vehicle.

• Stop the vehicle on a level surface. • Remove the ignition switch key to prevent unau-
thorized use.
NOTICE • When parking inside a garage or other structure,
be sure the structure is well ventilated and the ve-
Avoid parking on steeply inclined surfaces. hicle is not close to any source of flame or sparks.
This includes any appliance with a pilot light.
• When the engine has stopped, apply the parking
brake to help prevent the vehicle from rolling.
 HOW TO OPERATE 99

WARNING
Gasoline is extremely flammable and can be
Shifting Gears
explosive under certain conditions, creat-
ing the potential for serious burns. Do not • Stop the vehicle completely.
smoke. Make sure the area is well ventilated • Move the shift lever into the “H” (High) or “L” (Low)
position.
and free from any source of flame or sparks; j
this includes any appliance with a pilot light. • Ifmove
you intend to operate the vehicle in reverse,
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
 100 HOW TO OPERATE
NOTICE
Shifting to high or low range when the vehi-
2WD/4WD Shifting
cle is in motion could cause engine damage.
Do not shift from “H” (High) or “L” (Low) • Stop the vehicle completely.
to “R” (Reverse) and vice versa when the • Push the selectable 2WD/4WD shift switch to se-
lect the drive modes.
j vehicle is moving or with the engine run-
ning above idling speed, or the transmission
could be damaged.

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

WARNING
Shifting the transmission while the vehicle is A. Selectable 2WD/4WD Shift Switch
moving can cause abrupt changes in speed B. “2WD” Position
and direction resulting in loss of control C. “4WD” Position
and accident with severe personal injury or
death. NOTE
Do not shift the transmission while the vehi-
cle is moving. Stop the vehicle to shift the ○The “4WD” operating mode is indicated with the
“4WD” indicator symbol. Refer to the “Multifunc-
transmission.
tion Meter” section in the “GENERAL INFORMA-
TION” 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.
 HOW TO OPERATE 101

Drive off slowly to allow “4WD” to engage or

disengage. As it engages, the “4WD” indicator Shifting the Differential
symbol will appear.
○It is normal to hear a small clanking noise when • Stop the vehicle completely.
“4WD” engages or disengages while rolling on
hard surfaces, such as hard-packed dirt.
• Push the selectable DIFF-LOCK shift switch to
“LOCK” position.
j
WARNING
The handling characteristics of this vehicle
differs between “2WD” and “4WD” accord-
ing 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 acci-
dent. Always stop the vehicle before chang-
ing from “2WD” to “4WD” and vice versa.

NOTICE
Shifting from “2WD” to “4WD” (or “4WD” to A. Selectable DIFF-LOCK Shift Switch
“2WD”) when the vehicle is in motion could B. “LOCK” Position (Locked-Rear Axle Mode)
cause drive train damage. 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.
 102 HOW TO OPERATE

WARNING
Shifting to Locked-Axle Mode while turning
When Stuck
or before entering a turn can reduce steering
Release the throttle pedal immediately to protect
response, increasing the effort to turn. An
the drive belt and take the following actions to es-
unexpected change in direction can cause
cape from the stuck condition.
j the operator to lose control, resulting in an
accident and injury. Do not shift to Locked
-Axle Mode while turning or before entering • Change the gear shift lever to the “L” (LOW) posi-
tion, push the selectable DIFF-LOCK shift switch
a turn.
to “LOCK” position, and try to escape by slowly
revving up the engine. Refer to the “shifting the
NOTE Differential” section in this chapter.
○By pushing the shift switch to “LOCK” position, • If the above method is not successful, you can use
driving force to both wheels is equalized thereby a winch installed at the front of the vehicle (Winch
increasing traction. is an optional part.) or seek help from another
vehicle for towing (KAF820A/B/C/D).
Shifting to Differential (Unlocked-Rear Axle)
Mode
• If the above method is not successful, you can use
a winch at the front of the vehicle (see the “Winch”
• Stop the vehicle completely. section in the “GENERAL INFORMATION” chap-
• “UNLOCK”
Turn the selectable DIFF-LOCK shift switch to
position.
ter) or seek help from another vehicle for towing
(KAF820J).
If the indicator light in the DIFF-LOCK shift switch
does not go off, do one of the following procedures
to cancel the indicator light.
• Push the selectable DIFF-LOCK shift switch to the
“LOCK” position while stopping the vehicle.
• Turn the ignition switch to “OFF” position while
stopping the vehicle. Then turn on the ignition
switch.
If the indicator light in the DIFF-LOCK shift switch
does not go off, the electric shifting mechanism may
have a failure. Contact an authorized Kawasaki
dealer for inspection.
 HOW TO OPERATE 103

WARNING
Catalytic Converter The engine and exhaust system get ex-
tremely hot during normal operation and can
This vehicle is equipped with a catalytic converter
cause serious burns.
in the exhaust system. The converter reacts with
Never touch a hot engine, exhaust pipe, or
carbon monoxide, hydrocarbons and nitrogen ox-
ides to convert them into carbon dioxide, water, nitro-
muffler during operation or after stopping j
the engine.
gen and oxygen resulting in much cleaner exhaust
gases to be discharged into the atmosphere.
For proper operation of the catalytic converter, the • Use only unleaded gasoline. Never use leaded
gasoline. Leaded gasoline significantly reduces
following cautions must be observed.
the capability of the catalytic converter.
WARNING • Do not operate the vehicle with the engine or any
one cylinder misfiring. Under these conditions
Operating or parking the vehicle near unburned air/fuel mixture flowing out of engine
flammable materials can cause a fire, and excessively accelerates reaction in the converter
can result in property damage or severe allowing the converter to overheat and become
personal injury. damaged when the engine is hot, or reduces
Do not idle or park your vehicle in an converter performance when the engine is cold.
area where tall or dry vegetation, or other
flammable materials could come into con-
tact with the muffler or exhaust pipe.
 104 SAFE OPERATION

SAFE OPERATION
Safety is an attitude. Your common sense and
good judgement are your best defenses against ac- Unfamiliar Terrain
cident and injury in everything you do. Your safety
and the safety of others depends on you and your Before driving in a new area be sure to check
common sense. Use good judgement in the opera- for hidden obstacles or hazards. Keep your speed
tion of this or any other motor vehicle. down until you know the area well. You must know
j the terrain you intend to drive on and be familiar with
This vehicle is designed for an operator and two your machine and its handling characteristics. Use
passengers (for 3-persons mode) or an operator and existing trails and stay away from hazardous areas
five passengers (for 6-persons mode). Never carry such as steep, rocky slopes or swamps. Be cautious
persons in the cargo bed. Refer to the “LOADING when visibility is limited, as you may not be able to
INFORMATION” chapter before operating this vehi- see obstacles in your path.
cle.

Novice operators should practice braking and turn-

ing 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 sur-
face, 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 “LOAD-
ING INFORMATION” chapter.
 SAFE OPERATION 105

Driving in Reverse Driving in “4WD”

Start the engine following the procedure in the “4WD” gives greater traction when you are climb-
“Starting the Engine” section. Before shifting into ing steep inclines, or driving on bumpy, sandy or
reverse, stop the vehicle completely. Refer to the snowy surfaces. It also helps break loose, with the
“Gear Shift Lever” in the “GENERAL INFORMA- differential locked under certain circumstances, for
TION” chapter and “Shifting Gears” section in the example, when the vehicle is stuck in the mud. If
“HOW TO OPERATE” chapter. maximum torque is needed in these situations, shift
Turn around and look behind you before backing into the “L” (Low) position with the gear shift lever. j
up to be sure there are no obstacles or people in your Refer to the “Shifting Gears” section, “2WD/4WD
way. Gradually open the throttle and begin backing Shifting” and “Shifting the Differential” sections in the
up cautiously. “HOW TO OPERATE” chapter.
To stop while driving in reverse, close the throttle
and gradually apply the brake. Avoid sudden appli-
NOTE
cation of the brake. ○Do not drive in “4WD” on paved surfaces, because
it increases tire and drive train wear and makes the
NOTICE steering feel tight.
Do not operate the gear shift lever to change
Remember:
gears while driving the vehicle in reverse, or
the transmission may be damaged. •Use “4WD” on steep inclines or loose surfaces, or
when stuck in the mud, with the differential locked
if necessary.
Remember: •For maximum torque shift into low range.
•Look behind you before backing up. •Do not drive in “4WD” on paved surfaces.
•Open the throttle gradually.
•To stop, gradually apply the brake.
NOTE
○This vehicle is equipped with a reduced reverse
speed system. It limits the vehicle speed to 20
km/h (12 mph).
 106 SAFE OPERATION

Turning the Vehicle Hills

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

Remember:
•Slow down before entering the turn.
•Maintain an even speed through the turn.
 SAFE OPERATION 107

Climbing Hills
• 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.
Do not attempt to climb hills or steep inclines until • Don’t turn sideways to the hill.
you have mastered the controls and basic operating
maneuvers of this vehicle. Always go straight uphill
• Ifdown,
you get stuck on a hill, roll slowly straight back
using the brake, with the gear shift lever left
and, if the incline is steep and/or the surface is loose, in the “H” (High) or “L” (Low) position.
use “4WD” with the differential locked for greater
traction, and in low range for maximum torque.
NOTE
Avoid hills with slippery sides that will cause you ○When the throttle pedal is released completely and j
to lose traction. Do not climb hills where you cannot the engine speed drops near an idle, the vehicle
see far enough ahead. If you cannot see what is has no engine braking. This is caused by the ve-
on the other side of the crest of a hill, slow down hicle’s automatic transmission which releases the
until you can get a clear view. Don’t apply power engine at very low speed to prevent it from stalling.
suddenly while climbing, or the front wheels might Use the brakes to control the vehicle’s speed.
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.

Remember:
•Some hills are too steep. Use common sense.
 108 SAFE OPERATION
NOTE
Descending Hills ○When the throttle pedal is released completely and
the engine speed drops near an idle, the vehicle
Slow down or stop at the top of a hill so you can has no engine braking. This is caused by the ve-
pick a straight, safe path for descent to avoid any ob- hicle’s automatic transmission which releases the
stacles. Normally you should descend straight down engine at very low speed to prevent it from stalling.
a hill since driving at an angle could cause the vehi- Use the brakes to control the vehicle’s speed.
cle to lean to one side and possibly tip over. Proceed
slowly and cautiously. Apply the brake as necessary.
j Be careful if the surface is loose because the tires
are more likely to skid and braking effectiveness will
be reduced.
Turning while descending a slope must be done
very carefully and gradually to avoid tipping the ve-
hicle over.

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

Remember:
•Stop and look for obstacles before descending a
hill.
•Go straight downhill.
•Go slowly.
•If you must turn, do so carefully and gradually.
 SAFE OPERATION 109

Traversing Hillsides Sliding and Skidding

When driving across the side of a hill, reduce vehi- Obviously, on slippery or loose surfaces, special
cle speed and exercise extreme caution to prevent care is required. Sliding any vehicle may be haz-
tipping or loss of control. Avoid hills with slippery ardous because the wheels may suddenly regain
sides that will cause you to lose traction. Also avoid traction and cause the vehicle to tip or overturn.
traversing hillsides covered with rocks or other ob- Therefore, never drive “over your head” or when you
stacles which may cause you to lose your balance are unsure or unprepared for the surface.
or tip over. Often you can correct a skid by turning the wheels j
When driving on soft terrain, steer slightly uphill to in the direction of the skid. Do not apply heavy brak-
keep the vehicle on a straight line across the hillside. ing force or accelerate when skidding, since this may
If the vehicle begins to tip, steer downhill if possible cause further loss of control.
to regain control. Use caution and maintain low speeds to avoid un-
controlled skidding on areas covered with clay, mud,
ice, or snow. Use “4WD” and low range gearing effi-
ciently. These conditions are particularly hazardous
when descending a hill or making a turn. Remem-
ber 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.
 110 SAFE OPERATION

WARNING
Driving through Water Operating the vehicle in rivers or streams
where water is flowing quickly can cause the
Avoid driving through water whenever it is possi-
tires to lose traction and allow the vehicle
ble. When driving across shallow water, choose a
to be swept into the current. Never operate
location to enter and exit the water where the banks
the vehicle in fast-flowing water or in water
are not too steep or slippery. Check before entering
deeper than the bottom edge of the axle
for rocks, holes or other obstacles which may cause
caps.
you to overturn or become stuck or submerged.
j Observe the following rules for operating the vehi-
After prolonged exposure to water, the wheel bear-
cle in water.
ings may require lubrication or replacement.
Wash the vehicle in fresh water if it has been ex-
posed to salt water or operated in muddy conditions.

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

Remember:
A. Axle Cap •Avoid driving through water whenever possible.
•Don’t drive in deep and fast moving water.
•Dry out the brakes.
 SAFE OPERATION 111

Operator and Passenger Requirements

All operators of this vehicle should possess a valid
driver’s license.
The operator and passenger(s) must be able to
place both feet flat on the floorboards while seated
upright with their backs against the seatbacks when
firmly holding the steering wheel, handgrips or hand-
hold. j

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 front pas-
senger should hold onto the handgrips. The
rear passengers should hold the handhold
firmly with both hands.

Close all the doors. Wear the seat belts (for an

operator and passenger(s)). The doors, handgrips,
and handhold are not a substitute for the seat belts.

A. Front Center Handgrip

B. Front Right Handgrip
C. Rear Handhold
 112 SAFE OPERATION
This vehicle is designed for an operator and up to
five passengers.
Never carry persons in the cargo bed. Refer to the
“LOADING INFORMATION” chapter before operat-
ing this vehicle.

j
 MAINTENANCE AND ADJUSTMENT 113

MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor-
dance with the Periodic Maintenance Chart to keep the Mule in good running condition. The initial mainte-
nance is vitally important and must not be neglected.
If you are in doubt as to any adjustment or vehicle operation, please ask your authorized Kawasaki dealer to
check the Mule.
Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect mainte-
nance or improper adjustment done by the owner.
NOTE
○For KAF820J model, refer to the “Winch” section in the “GENERAL INFORMATION” chapter for winch main- j
tenance.

Periodic Maintenance Chart

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

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

FREQUENCY First Service Regular Service

After 50 Every Every Every
After 20
h, or 50 h, or 100 h, or 200 h, or
h, or 200 Every
1 000 1 000 2 000 km 4 000 km
km (120 year of
km (600 km (600 (1 200 (2 500
mile) of use
mile) of mile) of mile) of mile) of
use
OPERATION use use use use
ENGINE
○ Throttle pedal play - inspect • •
Fuel hose and connections - inspect D
j
Fuel hose - replace 5 years (D)
○ Idle speed - inspect D D
○ Spark plugs - clean and gap inspect D D
○ Air cleaner-clean and inspect * • •
○ Valve clearance - inspect * D D
Spark arrester - clean and inspect •
•
or every
6 months
Engine oil - change * • whichever
comes
first
 MAINTENANCE AND ADJUSTMENT 115

FREQUENCY First Service Regular Service

After 50 Every Every Every
After 20
h, or 50 h, or 100 h, or 200 h, or
h, or 200 Every
1 000 1 000 2 000 km 4 000 km
km (120 year of
km (600 km (600 (1 200 (2 500
mile) of use
mile) of mile) of mile) of mile) of
use
OPERATION use use use use

•
or ev-
ery year
Oil filter - replace * • whichever
j
comes
first
Front final gear case oil and transmission
case oil - change • •
Radiator - clean * • •
Radiator hoses and connections - check * D
Coolant - change * 2 years (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
Alternator/water pump belt - inspect* D D
Evaporative emission control system -
○ inspect* • •
 116 MAINTENANCE AND ADJUSTMENT

FREQUENCY First Service Regular Service

After 50 Every Every Every
After 20
h, or 50 h, or 100 h, or 200 h, or
h, or 200 Every
1 000 1 000 2 000 km 4 000 km
km (120 year of
km (600 km (600 (1 200 (2 500
mile) of use
mile) of mile) of mile) of mile) of
use
OPERATION use use use use
CHASSIS
Brake pad wear - inspect * D D

j
Brake light switch - inspect • •
Brake fluid - change 2 years (D)
Brake caliper piston seal and dust seal
2 years (D)
- 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 boots - inspect • •
Shock absorbers - inspect D
 MAINTENANCE AND ADJUSTMENT 117

FREQUENCY First Service Regular Service

After 50 Every Every Every
After 20
h, or 50 h, or 100 h, or 200 h, or
h, or 200 Every
1 000 1 000 2 000 km 4 000 km
km (120 year of
km (600 km (600 (1 200 (2 500
mile) of use
mile) of mile) of mile) of mile) of
use
OPERATION use use use use
Suspension arms - inspect D
Steering - inspect D D
Steering joint dust boots - inspect • • j
General lubrication - perform * D
Bolts, nuts, and fasteners tightness -
D D
inspect
Seat belts - inspect •
Cables - inspect D
Cargo bed latch - inspect •
 118 MAINTENANCE AND ADJUSTMENT

Engine Oil
• Ifutes
the vehicle has just been used, wait several min-
for all the oil to drain down.
• Remove
Park the vehicle on level ground.
In order for the engine to function properly, main- • Pull up thethedipstick
battery cover (see Battery Removal).
tain the engine oil at the proper level, and change the
oil and oil filter in accordance with the Periodic Main-
• it dry, and insert the out of the dipstick tube, wipe
dipstick till it bottoms into the
tenance Chart. Not only do dirt and metal particles tube securely.
collect in the oil, but the oil itself loses its lubricative
quality if used too long.

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

Oil Level Inspection

• Ifandtherunoil ithas just been changed, start the engine
for several minutes at idle speed. This A. Dipstick
fills the oil filter with oil. Stop the engine, then wait
several minutes until the oil settles. • Pull out the dipstick and check the oil level. The
oil level should be between the “F” (Full) and “L”
NOTICE (Low) holes on the dipstick.

Racing the engine before the oil reaches ev-

ery part can cause engine damage.
 MAINTENANCE AND ADJUSTMENT 119

A. Dipstick A. Oil Filler Cap

B. “F” (Full) Hole
C. “L” (Low) Hole • Place an oil pan beneath the engine.

• Reinsert the dipstick until it bottoms into the tube

• Remove the drain bolt.

securely.
• Ifusing
the oil level is too high, remove the excess oil,
a syringe or other suitable device.
• and add level
If the oil is too low, unscrew the oil filler cap
the correct amount of oil. Use the same
type and brand of oil that is already in the engine.
• Install the oil filler cap.
Oil and/or Oil Filter Change
• Lift the cargo bed and support it with the support-
ing rod.
• Warm
engine.
up the engine thoroughly and then stop the

• Remove the oil filler cap. A. Drain Bolt

 120 MAINTENANCE AND ADJUSTMENT

• Let the oil completely drain with the vehicle on

level ground.

WARNING
Engine oil is a toxic substance. Dispose of
used oil properly. Contact your local author-
ities for approved disposal methods or pos-
sible recycling.

• Ifscrews
the oil filter is to be replaced, remove the 4
and the cover under the rear seat.
j

A. Oil Filter

• Apply a thin film of oil to the gasket and tighten the

oil filter to the specified torque.

A. Screws
B. Cover

• Remove the oil filter cartridge and replace it with a

new one.

A. Gasket
 MAINTENANCE AND ADJUSTMENT 121

• Install the drain bolt with its gasket.

the specified torque.
Tighten it to *Kawasaki Performance Oils and Lubricants have
been specifically engineered for your vehicle. Con-
sistent use of these products meets or exceeds war-
NOTE ranty and service requirements and can help to ex-
○Replace any gaskets with new ones. tend the life of your Kawasaki.
Tightening Torque NOTE
Drain Bolt 50 N·m (5.1 kgf·m, 37 ft·lb) ○Do not add any chemical additives to the oil. Oils
fulfilling the above requirements are fully formu-
Oil Filter 20 N·m (2.0 kgf·m, 15 ft·lb) lated and provide adequate lubrication for the en-
gine.
• Fill the engine up to the “F” (Full) hole on the dip-
stick with high quality engine oil as specified in the Although 10W-40 engine oil is the recommended
j
table. oil for most conditions, the oil viscosity may need
• Start the engine and check for oil leakage. to be changed to accommodate atmospheric condi-
tions in your driving area.
Engine Oil
Type: Kawasaki Performance 4-Stroke
ATV/UTV Oil*
Kawasaki Performance 4-Stroke
Semi-Synthetic Oil*
Kawasaki Performance 4-Stroke
Full Synthetic Oil*
or other 4-stroke oils with API SG, SH,
SJ, SL, SM and JASO MA, MA1, MA2
rating
Viscosity: SAE 10W-40
Capacity: 2.1 L (2.2 US qt)
[when filter is not removed]

• Reinstall the removed parts as before.

• Run the engine for several minutes.
• Check the oil level.
 122 MAINTENANCE AND ADJUSTMENT

Front Final Gear Case Oil

(KAF820A/B/C/D)
In order for the differential, pinion, and ring gears
to function properly, check the oil level and change
the oil in accordance with the Periodic Maintenance
Chart.

WARNING
Vehicle operation with insufficient, deterio-
rated, or contaminated oil causes acceler-
j ated wear of the differential, pinion, and ring
gears and may result in seizure. Seizure can
lock the front wheels and skid the front tires, A. Front Final Gear Case
cousing loss of control. To prevent seizure, B. Oil Filler Cap
check the differential oil according to the pe-
riodic maintenance chart. NOTICE
Be careful not to allow any dirt or foreign ma-
Oil Level Inspection terials to enter the gear case.
• With the vehicle level front-to-rear and side-to
-side, remove the oil filler cap from the front final
gear case. • Check the oil level. The oil level should come to
the bottom of the filler opening. If it is low, add oil
through the oil filler opening as necessary.
 MAINTENANCE AND ADJUSTMENT 123

Oil Change
NOTE
○Before draining the oil, warm it up by running the
vehicle. Warm oil drains easily and picks up any
sediment.

• With the vehicle level, place an oil pan beneath the

gear case.
• Remove the oil filler cap and drain plug.
WARNING
Gear case oil is a toxic substance. Dispose j
of used oil properly. Contact your local au-
A. Front Final Gear Case thorities for approved disposal methods or
B. Filler Opening possible recycling.
C. Bottom of Filler Opening

• Install
torque.
the oil filler cap and tighten it to the specified WARNING
Oil on tires can make them slippery which
Tightening Torque can cause an accident and injury. When
Oil Filler Cap: 16 N·m (1.6 kgf·m, 12 ft·lb) draining or filling the gear case, be careful
that no oil gets on the tires or rims. Clean off
any oil that inadvertently gets on them with
NOTE soap and water.
○Use the same type and brand of oil that is already
in the gear case.
 124 MAINTENANCE AND ADJUSTMENT
Front Final Gear Case Oil
Capacity 0.43 L (0.45 US qt)
Type API “GL-5” Hypoid gear oil
Viscosity above 5°C (41°F) SAE 90
below 5°C (41°F) SAE 80

• Install
torque.
the oil filler cap and tighten it to the specified

Tightening Torque
Oil Filler Cap: 16 N·m (1.6 kgf·m, 12 ft·lb)
j

A. Drain Plug

• After the oil has completely drained, install the

drain plug with a new O-ring. Tighten it to the spec-
ified torque.
Tightening Torque
Drain Plug: 16 N·m (1.6 kgf·m, 12 ft·lb)

• Fill the gear case to the bottom thread of the filler

opening with a high quality oil as specified in the
table.
 MAINTENANCE AND ADJUSTMENT 125

Transmission Case Oil

In order for the transmission, differential, pinion,
and ring gears to function properly, check the oil level
and change the oil in accordance with the Periodic
Maintenance Chart.

WARNING
Vehicle operation with insufficient, deterio-
rated, or contaminated oil causes acceler-
ated wear of the transmission, differential,
pinion, and ring gears and may result in
j
seizure. Seizure can lock the rear wheels
and skid the rear tires, causing loss of A. Transmission Case
control. To prevebt seizure, check the trans- B. Oil Filler Cap
mission case oil according to the periodic
maintenance chart. NOTICE
Be careful not to allow any dirt or foreign ma-
Oil Level Inspection terials to enter the transmission case.
• Park the vehicle on level ground.
• Remove the oil filler cap and check the oil level
view from the slit of the rib. The oil level should
be between the high and low levels on the rib as
shown.
 126 MAINTENANCE AND ADJUSTMENT
Tightening Torque
Oil Filler Cap: 20 N·m (2.0 kgf·m, 15 ft·lb)

Oil Change
NOTE
○Before draining the oil, warm it up by running the
vehicle. Warm oil drains easily and picks up any
sediment.

• With the vehicle level, place an oil pan beneath the

transmission case.
j
• Remove the drain bolt.
A. Slit
B. Rib
C. High Level
D. Low Level

• Ifusing
the oil level is too high, remove the excess oil,
a syringe or other suitable device, through
the oil filler opening.
• If the oil level is too low, add the correct amount of
oil.
NOTE
○Use the same type and brand of oil that is already
in the transmission case.
○When adding oil, do not exceed the high level of A. Transmission Case
rib. B. Drain Bolt

• Install
torque.
the oil filler cap and tighten it to the specified
 MAINTENANCE AND ADJUSTMENT 127

WARNING Transmission Case Oil

The exhaust system can get extremely hot Capacity 2.0 L (2.1 US qt)
during normal operation and cause serious Type API “GL-5” Hypoid gear oil
burns. To avoid a serious burn, never touch
a hot muffler or exhaust pipe during oil drain- Viscosity above 5°C (41°F) SAE 90
ing. below 5°C (41°F) SAE 80

• Remove the oil filler cap. • Install

torque.
the oil filler cap and tighten it to the specified

WARNING Tightening Torque

Oil on tires can make them slippery which Oil Filler Cap: 20 N·m (2.0 kgf·m, 15 ft·lb)
can cause an accident and injury. When j
draining or filling the transmission case, be
careful that no oil gets on the tires or rims.
Clean off any oil that inadvertently gets on
them with soap and water.

• After the oil has completely drained, install the

drain bolt with a new gasket. Tighten it to the spec-
ified torque.
• Fill the transmission case to the high level on the
rib with a high quality oil as specified in the table.
Tightening Torque
Drain Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)
 128 MAINTENANCE AND ADJUSTMENT

Cooling System

WARNING
The cooling system is pressurized and can
get extremely hot during normal operation
and cause serious burns. To prevent burns,
do not touch the radiator when it is hot. Do
not attempt to open the radiator cap when hot
since steam and hot coolant can forcefully
erupt when the cap is even loosened slightly.
j
Radiator and Cooling Fan A. Screen
Check and clean the screen and radiator fins for B. Radiator
obstruction by insects or mud in accordance with
the Periodic Maintenance Chart. In dusty areas, the • Clean the screen, and radiator fins of any obstruc-
tions with a stream of low-pressure water.
radiator should be cleaned more frequently than the
recommended interval. • Ifit insects or mud can not be completely removed,
should be cleaned by an authorized Kawasaki
WARNING dealer.
To avoid injury, keep your hands and cloth- NOTICE
ing away from the fan blades at all times.
Using high-pressure water, as from a car
wash facility, could damage the radiator fins
and impair the radiator’s effectiveness.
Do not obstruct or deflect airflow through
the radiator by installing unauthorized ac-
cessories in front of the radiator or behind
the cooling fan. Interference with the ra-
diator airflow can lead to overheating and
consequent engine damage.
 MAINTENANCE AND ADJUSTMENT 129

Coolant
Coolant absorbs excessive heat from the engine
and transfers it to the air at the radiator. If the coolant
level becomes low, the engine overheats and may
suffer damage. Check the coolant level each day
before operating the vehicle, and replenish coolant
if the level is low. Change the coolant in accordance
with the Periodic Maintenance Chart.
NOTE
○A permanent type of antifreeze is installed in the
cooling system when shipped. It is colored green
and contains ethylene glycol. It is mixed at 50% j
with water and has a freezing point of –35°C
(–31°F). A. Reserve Tank
B. “F” (Full) Mark
Coolant Level Inspection C. “L” (Low) Mark
• Situate the vehicle on level ground. D. Cap
• Remove the front access cover. Refer to the
“Front Access Cover” section in the “GENERAL • Ifcapthefrom
amount of coolant is insufficient, unscrew the
the reserve tank and add coolant through
INFORMATION” chapter.
the filler opening to the “F” (Full) mark. Install the
• Check the coolant level through the coolant level
gauge on the reserve tank. The coolant level
cap.
should be between the “F” (Full) and “L” (Low) Recommended Coolant Solution
marks. Coolant Mixture Ratio:
NOTE Water 50%: Antifreeze 50% (1 : 1)
Recommended Antifreeze:
○Check the level when the engine is cold (room or Permanent type antifreeze (ethylene glycol
atmospheric temperature). plus corrosion and rust inhibitor chemicals for
aluminum engines and radiator).
Coolant Capacity
5.9 L (6.2 US qt)
 130 MAINTENANCE AND ADJUSTMENT
NOTE
○In an emergency you can add water alone to the Spark Plugs
coolant reserve tank, however it must be returned
to the correct mixture ratio by the addition of an- The standard spark plug is shown in the table. The
tifreeze concentrate as soon as possible. spark plug should be taken out periodically in ac-
cordance with the Periodic Maintenance Chart for
cleaning and inspection.
NOTICE Spark plug cleaning and inspection should be
If coolant must be added often, or the reserve done by an authorized Kawasaki dealer.
tank completely runs dry, there is probably
leakage in the system. Have the cooling sys-
tem inspected by your authorized Kawasaki
j dealer.

Coolant Change
Have the coolant changed by an authorized
Kawasaki dealer.

A. Gap

Standard Spark Plug

Plug TORCH 7026
0.9  1.1 mm
Plug Gap
(0.035  0.043 in.)
Tightening Torque 20 N·m (2.0 kgf·m, 15 ft·lb)
 MAINTENANCE AND ADJUSTMENT 131

Alternative Spark Plug

Plug NGK IFR6B11 Valve Clearance
1.0  1.1 mm Valve and valve seat wear decrease valve clear-
Plug Gap
(0.039 0.043 in.) ance, upsetting valve timing.
Tightening Torque 28 N·m (2.9 kgf·m, 21 ft·lb)
NOTICE
If valve clearance is left unadjusted, wear will
eventually cause the valves to remain partly
open; which lowers performance, burns the
valves and valve seats, and may cause seri-
ous engine damage. j
Valve clearance for each valve should be checked
and adjusted in accordance with the Periodic Main-
tenance Chart.
Inspection and adjustment should be done by an
authorized Kawasaki dealer.
Valve Clearance (Engine Cold)
Intake 0.13  0.23 mm (0.0051  0.0091 in.)
Exhaust 0.20  0.30 mm (0.0079  0.0118 in.)
 132 MAINTENANCE AND ADJUSTMENT
NOTE
Engine Air Cleaner ○If there is dust or mud around the battery and air
cleaner housing, clean them using compressed
A clogged engine air cleaner restricts the engine’s air.
air intake, increasing fuel consumption, reducing en-
gine power, and causing spark plug fouling. • Free the drain hose from the clamps.
• ing cap.the snaps and remove the air cleaner hous-
Pull up
WARNING
A clogged air cleaner may allow dirt and
dust to enter the fuel injection system and
the throttle may stick resulting in a haz-
j ardous operating condition. Clean the air
filter according to the periodic maintenance
chart; more often if the vehicle is used in
extremely dusty conditions.

NOTICE
A clogged air cleaner may allow dirt and dust
to enter the engine causing excessive wear
and possible engine damage.

The air filter element should be cleaned in ac- A. Drain Hose

B. Snaps
cordance with the Periodic Maintenance Chart. In
C. Cap
dusty areas, the element should be cleaned more
frequently than the recommended interval. • Pull the air cleaner element and adapter out of the
housing.
Element Removal
• Remove the battery cover (see Battery Removal). • Remove the element from the adapter.
• housing to keeplint-free
Push a clean, towel into the air cleaner
dirt or other foreign material from
entering.
 MAINTENANCE AND ADJUSTMENT 133

WARNING NOTE
If dirt or dust is allowed to pass through into ○Element installation is performed in the reverse
the fuel injection system, the throttle may order of removal.
stick or become inoperable resulting in a
hazardous operating condition. Element Cleaning
• Remove the element (see Element Removal).

NOTICE
• loosen dust.paper element by tapping it lightly to
Clean the

If dirt gets into the engine, excessive engine • Blow away the remaining dust by applying com-
pressed air from the inside to the outside (from the
wear and possible engine damage may oc-
clean side to the dirty side).
cur.
• Inspect the element material for damage. If any
part of the element is damaged, the element must
j
be replaced.
Element Installation
• Ifblow
there is dust and mud in the air cleaner housing,
out the inside of the air cleaner housing with
compressed air.
• Install the air filter element to the adapter.
• Install the element and adapter in the air cleaner
housing as shown.

A. Paper Element
B. Adapter
 134 MAINTENANCE AND ADJUSTMENT

A. Element A. Drain Hose

B. Adapter B. Plug
C. Tabs C. Battery
D. Air Cleaner Housing
• Ifthethere are any oil and water in the hose, remove
• Clamp the air cleaner housing cap securely. plug from the lower end of the drain hose and
• Install the drain hose to the clamps. drain the oil and water.
• Clean inside of the battery cover and install it (see
Battery Installation).
• Reinstall the plug to the drain hose.
Oil Draining
• Inspect the transparent drain hose located under
the air cleaner housing to see if any oil and water
have run down.
 MAINTENANCE AND ADJUSTMENT 135

Evaporative Emission Control System

(California Model)
This system routes fuel vapors from the fuel sys-
tem into the running engine or stores the vapors in
a canister when the engine is stopped. Although no
adjustments are required, a thorough visual inspec-
tion must be made at the intervals specified by the
“Periodic Maintenance Chart”.
Inspection
• Check that the hoses are securely connected. j
• hoses. any kinked, deteriorated, or damaged
Replace
A. Fuel Tank
B. Check Valve
C. Solenoid Valve
D. To Intake Manifold
E. Canister
F. Fuel Filter
G. To Injector
H. Fuel Pump
 136 MAINTENANCE AND ADJUSTMENT

Spark Arrester
This vehicle is equipped with a spark arrester ap-
proved for off-highway use by the U.S. Forest Ser-
vice. It must be properly maintained to ensure its
efficiency. Clean the spark arrester in accordance
with the Periodic Maintenance Chart.

WARNING
An incorrectly installed spark arrester can
emit sparks and cause a fire. Be sure the
j spark arrester and muffler are installed se-
curely.
A. Muffler
B. Spark Arrester Bolts
Spark Arrester Cleaning and Inspection C. Spark Arrester

WARNING • Remove the spark arrester and clean in a bath of

high flash-point solvent and if necessary use a fine
The muffler can become extremely hot dur- wire brush to gently remove any particles in the
ing normal operation and cause severe screen.
burns.
Since the engine must be running during this
procedure, wear heat-resistant gloves while
cleaning the spark arrester.
 MAINTENANCE AND ADJUSTMENT 137

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. Op-
erate only in a well-ventilated area.

• Stop the engine.

• Install the new gasket and paste it on the muffler
with grease before installing the spark arrester.
j

A. Spark Arrester

• Inspect the screen and replace it if it is damaged.

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

WARNING
Hot carbon particles are emitted when the
spark arrester is cleaned and can cause a
fire resulting in severe burns and damage.
Do not clean the spark arrester or run the
engine with the spark arrester disassembled
near combustible materials. A. Muffler
B. Gasket
• Raise and lower engine speed while tapping on
the muffler with a rubber mallet until carbon parti- • Install the spark arrester in place and tighten the
cles are purged from the muffler. bolts to the specified torque.
 138 MAINTENANCE AND ADJUSTMENT
Tightening Torque
Spark Arrester Throttle Pedal
13 N·m (1.3 kgf·m, 115 in·lb)
Mounting Bolts
If the throttle pedal has excessive play due to ei-
ther cable stretch or misadjustment, it will cause a
delay in throttle response, especially at low engine
speed. Also, the throttle may not open fully. If the
throttle pedal has no play, the throttle may be hard
to control, and the idle speed may be erratic. Check
the throttle pedal play periodically in accordance with
the Periodic Maintenance Chart.
j Throttle Pedal Play Inspection
• Apply the parking brake.
• Put the gear shift lever in the “N” (Neutral) position.
• Start the engine, and warm it up thoroughly.
• fore the engine
Measure the distance the throttle pedal moves be-
begins to pick up speed. Free play
should be 2  10 mm (0.08  0.39 in.). If the free
play is out of specification, have your authorized
Kawasaki dealer adjust the throttle pedal play.
 MAINTENANCE AND ADJUSTMENT 139

Idle Adjustment
Idle adjustment is controlled by the ECU (elec-
tronic control unit) and cannot be adjusted. If the
idle speed is unstable or out of specification, have
your authorized Kawasaki dealer inspect the fuel in-
jection system.
Specified Idle Speed 1 050 ±50 rpm

High Altitude Use

High altitude adjustment is not required as the j
ECU controls the air/fuel mixture automatically.
A. Throttle Pedal
B. 2  10 mm (0.08  0.39 in.)
 140 MAINTENANCE AND ADJUSTMENT

Fuel Hose Fuel Tank Vent

Fuel hose and connections should be checked and The fuel tank vent hoses must be routed as spec-
replaced periodically by an authorized Kawasaki ified.
dealer in accordance with the Periodic Maintenance The engine may stall or lose power if the fuel tank
Chart. vent is plugged or if the vent hose is pinched. Inspect
the vent hose before riding and whenever the engine
seems to lose power. If the fuel tank is full but the
engine feels as if it is running out of fuel, check the
vent and vent hose.
j

A. Fuel Tank Vent Hose

B. Check Valve
C. Fuel Tank
 MAINTENANCE AND ADJUSTMENT 141

IMPORTANT INFORMATION
Belt Drive Transmission (CVT) Neglect, abuse, or failure to maintain the trans-
mission can result in a severely worn or dam-
This vehicle is equipped with a belt-driven Contin-
aged drive belt locking up the transmission and
uously Variable Transmission (CVT). This automatic
wheels. Inspect the drive belt at least every 100
drive system, although simple to operate, does re-
hours of vehicle use or 2 000 km (1 200 miles)
quire periodic inspection since the drive belt wears
whichever comes first, since drive belt wear
with normal use.
with normal use. More frequent inspection is
Inspection should be done by an authorized
necessary if the vehicle is subjected to hard us-
Kawasaki dealer.
age such as pulling a trailer, operating in mud
or deep water, or in extremely dusty conditions.
If excessive belt slippage occurs, do not drive j
the vehicle until damaged components are re-
paired.

Causes of accelerated Belt Wear

Avoid these hard usage conditions to obtain maxi-
mum belt life and prevent accelerated belt wear and
deterioration.
• Operating the vehicle in high range while climbing
hills, carrying heavy loads, or pulling a trailer.
• Exceeding maximum vehicle load or trailer weight.
• Operating in mud or water deeper than recom-
mended.
A. Belt Drive Transmission (CVT)
• Operating in extremely dusty conditions.
Periodic Drive Belt Inspection Requirements • Continued operation with excessive belt slippage.
Drive belt wears with normal use. Inspection of • Failure to apply the brake controls while descend-
ing hills.
the drive belt is required at least every 100 hours
of vehicle use or 2 000 km (1 200 miles) whichever
comes first. More frequent inspection is necessary
if the vehicle is subjected to hard usage.
 142 MAINTENANCE AND ADJUSTMENT
Indications of Excessive Belt Slippage
Excessive slippage will accelerate belt wear and Brakes
lead to failure. Recognize these symptoms of ex-
cessive belt slippage. If excessive slippage occurs, The vehicle is equipped with hydraulically acti-
do not continue to drive the vehicle until all damaged vated disc brakes on all four wheels.
components are repaired.
Brake Pedal
• Smell of burning rubber.
• Visible white smoke. Brake Pedal Free Play Inspection
• Sluggish initial acceleration or loss of power. In accordance with the Periodic Maintenance
• Engine rpm is higher for the same vehicle speed. Chart, check the brake pedal free play.
• Engine vibration.
•Before the brake pedal free play inspection, check
j When Swamped that the brake pedal lever contacts with the stop-
If a large amount of water accidentally has entered per.
the CVT housing, it will cause drive belt slippage and
loss of power. If this occurs, consult an authorized
Kawasaki dealer.

A. Brake Pedal Lever

B. Stopper

• Depress the brake pedal lightly by hand.

 MAINTENANCE AND ADJUSTMENT 143

There should be 2  10 mm (0.08  0.39 in.)

• free of Fluid Requirement
play. Use heavy-duty brake fluid only from a fresh, un-
opened container marked DOT4.

WARNING
Over time, brake fluid can absorb moisture,
lowering its boiling point and reducing brake
effectiveness. Do not use fluid from a con-
tainer that has been left unsealed or that
has been open for a long time. Do not mix
two types and brands of fluid for use in the
brakes. Don’t leave the reservoir cap off for j
any length of time to avoid moisture con-
tamination of the fluid. Don’t add or change
brake fluid in the rain or during conditions
of blowing dust or debris.
A. Brake Pedal
B. 2  10 mm (0.08  0.39 in.)
NOTICE
• Ifthanthespecified
brake pedal has more or less free play
or the pedal action feels rough or Brake fluid quickly ruins painted surfaces.
“catchy,” have the brake system inspected imme- Wipe up any spilled fluid immediately.
diately by an authorized Kawasaki dealer.
Brake Fluid Fluid Level Inspection
In accordance with the Periodic Maintenance • With the vehicle on level ground, check through
the cover that the fluid level in the reservoir is be-
Chart, inspect the brake fluid level in the brake fluid
reservoir and change the brake fluid. The brake fluid tween the upper (marked MAX) and lower (marked
should also be changed if it becomes contaminated MIN) level lines.
with dirt or water.
 144 MAINTENANCE AND ADJUSTMENT

WARNING
Air in brake line can make the brake feel
mushy or soft. This may cause reduced
braking performance or brake failure and
result in an accident. If brake lever travel
is excessive or the brake feels mushy, have
an authorized Kawasaki dealer inspect it
immediately.

Fluid Change
Have the brake fluid changed by an authorized
j Kawasaki dealer.
Brake Disc and Brake Pad
A. Brake Fluid Reservoir
B. Upper Level Line (MAX) Disc and brake pad wear is automatically compen-
C. Lower Level Line (MIN) sated for and has no effect on the brake pedal ac-
tion. There are no parts that require adjustment on
• Ifcheck
the fluid level is lower than the lower level line,
for fluid leaks in the brake lines and fill the
the brake.
reservoir to the upper level line. WARNING
Air in brake line can make the brake feel
WARNING mushy or soft. This may cause reduced
Mixing two types and brands of fluid for use braking performance or brake failure and
in the brake lowers the brake fluid boiling result in an accident.
point and could reduce brake effectiveness. If brake lever travel is excessive or the brake
Change the fluid in the brake system com- feels mushy, have an authorized Kawasaki
pletely if the fluid level is low but the type and dealer inspect it immediately.
brand of the fluid already in the reservoir are
unknown.
Brake Wear Inspection
• Apply the brake forcefully for a few seconds and
check for fluid leakage around the fittings.
In accordance with the Periodic Maintenance
Chart, inspect the brakes for wear. For each disc
 MAINTENANCE AND ADJUSTMENT 145

brake caliper, if the thickness of either pad is less

than 1 mm (0.04 in.), replace both pads in the caliper Brake Light Switch
as a set. Pad wear inspection and pad replacement
should be done by an authorized Kawasaki dealer. When the brake pedal is depressed, the brake light
goes on. The brake light switch should be inspected
in accordance with the Periodic Maintenance Chart.
Inspection
• Turn the ignition switch to the “ON” position.
• go on aftertheabout
Depress brake pedal. The brake light should
10 mm (0.39 in.) of pedal travel.

A. Lining Thickness
B. 1 mm (0.04 in.)

Brake Hoses:
Brake hoses, pipes, and other components should
be checked and replaced periodically by an autho-
rized Kawasaki dealer in accordance with the Peri-
A. Brake Pedal
odic Maintenance Chart.
B. 10 mm (0.39 in.)

• Ifadjust
it does not, check the bulb and, if necessary,
the brake light switch.
 146 MAINTENANCE AND ADJUSTMENT
Adjustment
• Adjustment is best performed by an authorized
Kawasaki dealer since the brake light switch is
Parking Brake
hard to adjust. The parking brake helps hold the vehicle from
rolling while parked.
In accordance with the Periodic Maintenance
Chart, check the parking brake as follows.
Parking Brake Lever Inspection

A. Parking Brake Lever

• Pull the parking brake lever to the rear.

• should6 not
After to 14 clicks of lever travel, the vehicle
roll while parked.
• by an authorizedtheKawasaki
If it does, have parking brake cable adjusted
dealer.
Return Spring Inspection
• Visually check the return springs for damage.
 MAINTENANCE AND ADJUSTMENT 147

Steering Wheel
In accordance with the Periodic Maintenance
Chart, check the steering wheel for the specified
free play and smooth operation.
Free Play Inspection
• Park the vehicle on level ground.
• There should
Lightly turn the steering wheel left and right.
be 0  20 mm (0  0.79 in.) of free
• play.
• Iforthere is excessive free play or strange noises,
the steering feels rough or "catchy," have
j
the steering system checked by an authorized
A. Parking Brake Lever Return Springs
Kawasaki dealer.
• Ifbyitanis damaged, have it replaced with a new one
authorized Kawasaki dealer.

A. 0  20 mm (0  0.79 in.)
 148 MAINTENANCE AND ADJUSTMENT
Power Steering System (KAF820B/C/D/J)
Steering may become more difficult than usual for Wheels
the following reasons:
• The steering wheel was continuously turned or
held to the full turn stops with torque applied by
Rims
The rims are a drop-center, tubeless tire design.
driver. In this case the ECU works to protect the
Take care not to damage the sealing surfaces of the
system from overheating by stopping the power
tire or rim when removing or installing tires. Note that
assisting. Stop turning the steering wheel and wait
the rims, like automotive rims, are not symmetrical.
until the system temperature drops, and the power
All wheels must be installed so that the valve stems
steering recovers.
are on the outside of the vehicle.
• Fuses in the harness may have blown. There are
several reasons that the fuses may blow. Refer to Wheel Nuts
j the Fuse section in this chapter for details. Check for wheel nut tightness in accordance with
• Battery voltage has dropped. Voltage drop can
happen when the engine starts; inspect the battery
the Periodic Maintenance Chart.
voltage. Tightening Torque: 120 N·m (12.2 kgf·m, 88.5 ft·lb)
• Cable harness or connectors may have been
disconnected. Contact an authorized Kawasaki Tires
dealer for service. The front and rear tires are knobby tubeless tires.
NOTE When replacing tires, check the valve stems and
○If the steering becomes irregular or unusual for cores for damage. Take care not to damage the tire
sealing surfaces of the rims.
any reason other than above, have an authorized
Kawasaki dealer check the steering and relevant
components immediately. In some cases the
power steering’s neutral position can be affected
by an accident or bump.
 MAINTENANCE AND ADJUSTMENT 149

Standard Tire (Tubeless) Tire Air Pressure (when cold)

Make, Type: Except for California Model (KAF820J):
DURO Up to 714 kg (1 574 78.4 kPa (0.80
Front
Front FRONTIER DI2037 lb) Load kgf/cm², 11.4 psi)
Size: Up to 590 kg (1 300 110 kPa (1.12
26 × 9.00R12 4PR Tubeless lb) Load kgf/cm², 16.0 psi)
Make, Type: Rear
590  714 kg (1 300 130 kPa (1.33
DURO  1 574 lb) Load kgf/cm², 18.9 psi)
Rear FRONTIER DI2037
Size:
26 × 11.00R12 4PR Tubeless Tire Air Pressure (when cold)
California Model (KAF820J): j
Tire Air Pressure (when cold) Up to 556 kg (1 226 78.4 kPa (0.80
Front
Except for California Model (KAF820A/B/C/D): lb) Load kgf/cm², 11.4 psi)
Up to 733 kg (1 616 78.4 kPa (0.80 Up to 556 kg (1 226 110 kPa (1.12
Front Rear
lb) Load kgf/cm², 11.4 psi) lb) Load kgf/cm², 16.0 psi)
Up to 590 kg (1 300 110 kPa (1.12
lb) Load kgf/cm², 16.0 psi) NOTE
Rear
590  733 kg (1 300 130 kPa (1.33 ○Tires are an important part of the suspension of
 1 616 lb) Load kgf/cm², 18.9 psi) the vehicle. Tire construction characteristics and
tire inflation pressure can greatly influence vehicle
handling. Kawasaki recommends that you always
Tire Air Pressure (when cold) replace tires with standard replacement tires as
California Model (KAF820A/B/C/D): shown above. It is also very important to have
Up to 573 kg (1 263 78.4 kPa (0.80 tires of the same type and size on all axles, and
Front
lb) Load kgf/cm², 11.4 psi) at the same inflation pressure, on each axle.
Up to 573 kg (1 263 110 kPa (1.12 ○Installation of non-standard tires, or use of differ-
Rear ent tires on one axle, can change or impair the
lb) Load kgf/cm², 16.0 psi)
handling of the vehicle.
○Installation of tubeless tires on rims requires com-
pressed air and is normally recommended as a
 150 MAINTENANCE AND ADJUSTMENT
dealer service operation. Nevertheless, a tube WARNING
can be inserted into the tire by the operator as an
Operating with unequally or improperly pres-
emergency repair.
surized tires can adversely affect steering or
handling. Inflate both front tires to the same
Maximum Tire Air Pressure for Seating Beads pressure and both rear tires to the same
250 kPa pressure.
Front and Rear
(2.5 kgf/cm², 36 psi)
Tire Wear, Damage
Payload and Tire Pressure As tire tread wears down, tires become more sus-
Failure to maintain proper inflation pressures or ceptible to puncture and failure.
j
observe payload limits for your tires can change or
impair handling and performance of the vehicle. The
• In accordance with the Periodic Maintenance
Chart, measure the depth of the tread with a
maximum vehicle load as follows. depth gauge, and replace any tire that has worn
KAF820A/B/C/D down to the minimum allowable tread depth.
Except for California Model 733 kg (1 616 lb)
California Model 573 kg (1 263 lb)

KAF820J
Except for California Model 714 kg (1 574 lb)
California Model 556 kg (1 226 lb)

Use a tire pressure gauge to accurately set tire

pressure.

A. Tire Depth Gauge

Minimum Tread Depth: 4 mm (0.16 in.)

 MAINTENANCE AND ADJUSTMENT 151

• Visually inspect the tire for cracks and cuts, replac-

ing the tire in case of bad damage. Swelling or Joint Boots
high spots indicate internal damage, requiring tire
replacement. In accordance with the Periodic Maintenance
• Remove any imbedded stones or other foreign
particles from the tread.
Chart, inspect the joint boots on the front axles, tie
rod ends, steering knuckles, and rear axle shafts for
cracks, holes, damage or deterioration. If there is
any one of them, have the joint boot replaced by an
authorized Kawasaki dealer.

A. Steering Knuckle
B. Tie Rod
C. Front Axle
D. Joint Boots
 152 MAINTENANCE AND ADJUSTMENT

Suspension

Shock Absorber Spring Force Adjustment

The spring adjusting sleeves on the shock ab-
sorbers have 5 positions so that the springs can be
adjusted for different riding and loading conditions.
On the California model, the rear shock absorbers
are not adjustable.

A. Rear Axle
B. Joint Boots

A. Rear Shock Absorber (Except for California

Model)
B. Adjusting Sleeve
C. Rear Shock Absorber (California Model)
 MAINTENANCE AND ADJUSTMENT 153

Spring Action (Front Shock Absorber)

Up to 573 kg (1263 lb) Load (California Model of
KAF820A/B/C/D)
Up to 556 kg (1226 lb) Load (California Model of
KAF820J)
Posi- Spring Sur-
Setting Load Speed
tion Force face
1 Weak Soft Light Good Low
2 (STD) ↑ ↑ ↑ ↑ ↑
3 | | | | |
4 ↓ ↓ ↓ ↓ ↓ j
5 Strong Hard Heavy Bad High
A. Adjusting Sleeve (Turn with a hook wrench)
If the spring action feels too soft or too stiff, have Spring Action (Front Shock Absorber)
the sleeves adjusted by an authorized Kawasaki 590  733 kg (1 300  1 616 lb) Load
dealer in accordance with the following table. (KAF820A/B/C/D (Except for California
• Turn the adjusting sleeves on the shock absorbers
to the desired position.
Model))
Posi- Spring Sur-
Setting Load Speed
tion Force face
1 Weak Soft Light Good Low
2 (STD) ↑ ↑ ↑ ↑ ↑
3 | | | | |
4 ↓ ↓ ↓ ↓ ↓
5 Strong Hard Heavy Bad High
 154 MAINTENANCE AND ADJUSTMENT
Spring Action (Front Shock Absorber) Spring Action (Rear Shock Absorber)
590  714 kg (1 300  1 574 lb) Load (KAF820J 590  733 kg (1 300  1 616 lb) Load
(Except for California Model)) (KAF820A/B/C/D (Except for California
Posi- Spring Sur- Model))
Setting Load Speed
tion Force face Posi- Spring Sur-
Setting Load Speed
1 Weak Soft Light Good Low tion Force face

2 (STD) ↑ ↑ ↑ ↑ ↑ 1 Weak Soft Light Good Low

2 ↑ ↑ ↑ ↑ ↑
3 | | | | |
4 ↓ ↓ ↓ ↓ ↓ 3 | | | | |

5 4 ↓ ↓ ↓ ↓ ↓
j Strong Hard Heavy Bad High
5 (STD) Strong Hard Heavy Bad High
Spring Action (Rear Shock Absorber) Up to 590
kg (1 300 lb) Load (Except for California Model) Spring Action (Rear Shock Absorber)
Posi- Spring Sur- 590  714 kg (1 300  1 574 lb) Load (KAF820J
Setting Load Speed (Except for California Model))
tion Force face
1 Weak Soft Light Good Low Posi- Spring Sur-
Setting Load Speed
tion Force face
2 (STD) ↑ ↑ ↑ ↑ ↑
1 Weak Soft Light Good Low
3 | | | | |
2 ↑ ↑ ↑ ↑ ↑
4 ↓ ↓ ↓ ↓ ↓
3 | | | | |
5 Strong Hard Heavy Bad High
4 ↓ ↓ ↓ ↓ ↓
5 (STD) Strong Hard Heavy Bad High
 MAINTENANCE AND ADJUSTMENT 155

WARNING
Improper shock absorber adjustment can
Seat Belts
cause poor handling and loss of stability,
In accordance with the Periodic Maintenance
which could lead to an accident.
Chart, check that each seat belt functions properly.
Always adjust the shock absorbers on the
Push the latch plate into the buckle until it clicks.
left and right side to the same setting.
The latch plate must slide smoothly into the buckle.
The click sound indicates it is securely latched. Pull
the belt vigorously to make sure the retractor locks
the seat belt.

A. Seat Belt
B. Buckle
C. Red Button
Push the red button in the buckle to make sure the
latch plate is released freely and the belt is wound
into the retractor freely. Also check the belt web-
bing for wear, cuts or damage. If any irregularities
 156 MAINTENANCE AND ADJUSTMENT
are found, have the seat belt system checked or re-
placed by an authorized Kawasaki dealer. Cargo Bed Latches
Depending on the cargo loading and/or passenger
riding conditions, latch lever compression needs to
be adjusted.
Release the latch lever bolts and adjust the posi-
tion of the latch assembly so that the latch lever will
be secured without rattling and tighten the bolts.

A. Retractor
B. Seat Belt
C. Latch Plate

A. Latch Assembly
B. Latch Lever
C. Latch Lever Bolts

NOTE
○Adjustment should be made for both sides.
 MAINTENANCE AND ADJUSTMENT 157

Headlight Beam Battery

The headlight beams can be adjusted vertically. The battery is located under the right end of the
• Remove the front access cover. Refer to the
“Front Access Cover” section in the “GENERAL
rear seat.

INFORMATION” chapter. DANGER

• Turn the adjusting screw on each headlight rim in
or out to adjust the headlight vertically.
Battery contains sulfuric acid and produces
hydrogen gas. Sulfuric acid can cause burns
and hydrogen gas can cause an explosion.
Read and heed the battery safety label.
j
Battery Removal
• Push the locking tab to clear the hook.
• Unlatch the latch as shown (right side).

A. Adjusting Screws
B. Headlight
C. LED Sub Headlight (KAF820C/D/J)
 158 MAINTENANCE AND ADJUSTMENT

• Unlatch the latch (left side).

A. Battery Cover
B. Latch
C. Locking Tab A. Battery Cover
1. Push the locking tab. B. Latch
2.
3.
Pull
Slide • Clear the hooks upward on the battery cover.
4. Open
 MAINTENANCE AND ADJUSTMENT 159

A. Hooks A. Battery Cover

B. Battery Cover B. Tabs
1. Slide
2. Pull NOTE
• Clear the tabs on the battery cover, and remove ○If there is dust or mud around the battery and air
the battery cover right ward. cleaner housing, clean them using compressed
air.

• Remove the screws and washers.

 160 MAINTENANCE AND ADJUSTMENT

A. Screws and Washers A. Band

B. Battery Holder Nut
• For KAF820J model, remove the air cleaner hous-
ing cap and element (see Element Removal).
C. Bolt
D. Collar
• Remove the battery holder nut. E. Battery Holder
• Remove the shaft and collar. F. Negative (–) Cable
• Disconnect thebattery
Remove the holder as shown. G. Red Cap
• minal. negative (–) cable from the (–) ter- H. Positive (+) Cable
1. Lift
2. Pull
• Slide the red cap.
• minal. the positive (+) cable from the (+) ter-
Disconnect
• Take the battery out.
• Clean the battery using a solution of baking soda
and water. Be sure that the lead connections are
NOTE
clean.
○There is no need to separate the smaller cables • Perform a visual inspection. Inspect for defective
clamped with the positive (+) cable. or cracked case and cover, and loose or damaged
terminal posts or cables. Replace battery and/or
cables immediately if any damage is found.
 MAINTENANCE AND ADJUSTMENT 161

Battery Installation NOTE

• Check that the rubber dampers on the battery ○If you install the breather hoses to the battery, do
holder and the floor board are properly in place. not use any lubricants.
• Put the battery in place on the rubber damper. ○Do not be choked the breather hoses.
• Connect the three positive (+) cables to the (+)
terminal, and then connect the negative (–) cable
to the (–) terminal.
• Put a light coat of grease on the terminals to pre-
vent corrosion.
• Cover the positive (+) terminal with the red cap.

WARNING j
Loose battery cables can create sparks
which can cause a fire or explosion resulting
in injury or death. Make sure the battery
terminal bolts are tightened securely and the
cap is installed over the positive (+) terminal.

• Install the battery holder, collar and bolt.

• Run the the
Tighten battery holder nut securely. A. Left Breather Hose
B. Clamp
• into the floorboad
left breather hose into the clamp, and run
until the blue painted mark po-
C. Blue Painted Mark
D. Right Breather Hose
sition is level with the floorboad. E. Collar
• Run the right breather hose into the hole of the
floorboad.
F. White Painted Mark
G. Band
• Tie the collar and right breather hose at the white
painted mark on the breather hose with a band.
H. Slits

• Be sure that the slit of each breather hose faces • Be sure that the breather hose ends are 20 mm
(0.8 in.) from bottom surface of floorboad.
up.
 162 MAINTENANCE AND ADJUSTMENT

A. Breather Hose Ends A. Battery Cover

B. 20 mm (0.8 in.) B. Hooks
C. Slots
• Tighten the screws with washers securely.
• Insert the hooks of the battery cover into the slots
as shown.
• Insert the tabs into the slots as shown.
 MAINTENANCE AND ADJUSTMENT 163

A. Battery Cover A. Battery Cover

B. Tabs B. Tabs
C. Slots C. Slots

• Insert the tabs into the slots as shown. • Lock the latch as shown (right side).
 164 MAINTENANCE AND ADJUSTMENT
Battery Characteristics
The battery installed in this vehicle is a sealed
type, and the sealing strip should not be removed
at any time after the specified electrolyte has been
installed in the battery for initial service. It is not nec-
essary to check the battery electrolyte level or add
distilled water.
However, in order to maximize battery life and en-
sure that it will provide the power needed to start
your vehicle you must properly maintain the battery’s
charge. When used regularly, the charging system
in your vehicle helps keep the battery fully charged.
j If your vehicle is only used occasionally or for short
periods of time, the battery is more likely to dis-
A. Latch charge.
B. Battery Cover Due to their internal composition, batteries contin-
1. Close ually self discharge. The discharge rate depends
2. Pull on the type of battery and ambient temperature. As
3. Push temperatures rise, so does the discharge rate. Ev-
• Lock the latch (left side). ery 15°C (59°F) doubles the rate.
Electrical accessories, such as digital clocks and
WARNING computer memory, also draw current from the bat-
tery even when the key is switched off. Combine
Loose battery cables can create sparks such “key-off” draws with hot temperature, and a
which can cause a fire or explosion resulting battery can go from fully charged to completely dis-
in injury or death. charged in a matter of days.
Make sure the battery terminal screws are
tightened securely and the covers are in-
stalled over the terminals.
 MAINTENANCE AND ADJUSTMENT 165

Self-discharge Sulfation occurs when the battery is left in a dis-

charged condition for an extended time. Sulfate is a
Approx. Number of Days From
normal by product of the chemical reactions within a
100% Charged to 100% discharged
Temperature battery. But when continuous discharge allows the
Lead-Antimony Lead-Calcium sulfate to crystallize in the cells, the battery plates
Battery Battery become permanently damaged and will not hold a
40°C (104°F) 100 Days 300 Days charge. Battery failure due to sulfation is not war-
rantable.
25°C (77°F) 200 Days 600 Days
Battery Maintenance
0°C (32°F) 550 Days 950 Days It is the owner’s responsibility to keep the battery
fully charged. Failure to do so can lead to battery
Current Drain failure and leave you stranded. j
Days from 100% Days from 100% If you are riding your vehicle infrequently, inspect
Discharg- the battery voltage weekly using a voltmeter. If
Charged to 50% Charged to 100%
ing Ampere it drops below 12.6 volts, the battery should be
Discharged Discharged
charged using an appropriate charger (check with
7 mA 60 Days 119 Days your kawasaki dealer or visit by kawasaki.com). If
10 mA 42 Days 83 Days you will not be using your vehicle for longer than
two weeks, the battery should be charged using an
15 mA 28 Days 56 Days appropriate charger. Do not use an automotive-type
20 mA 21 Days 42 Days quick charger that may overcharge the battery and
damage it.
30 mA 14 Days 28 Days
NOTE
In extremely cold weather the fluid in an inade-
quately charged battery can easily freeze, which
○Leaving the battery connected causes the electri-
cal components to make the battery discharged,
can crack the case and buckle the plates. A fully resulting the over discharge of the battery. In this
charged battery can withstand sub-freezing temper- case, the repair or replacement of the battery is
atures with no damage. not included in the warranty. If you do not drive for
Battery Sulfation four weeks or more, disconnect the battery from
A common cause of battery failure is sulfation. the vehicle.
 166 MAINTENANCE AND ADJUSTMENT
Kawasaki-recommended chargers are: Make East Penn Manufacturing
Battery Mate 150-9
Type 426RMF
OptiMate 4
Yuasa MB-2040/2060
Christie C10122S NOTE
If the above chargers are not available, use equiv- ○If you charge the sealed battery, never fail to ob-
alent one. serve the instructions shown on the label on the
For more details, ask your Kawasaki dealer. battery and charger.
Battery Charging
•Remove the battery from the vehicle (see Battery
Removal).
WARNING
Battery posts, terminals and related acces-
j •Attach the leads from the charger and charge the
battery at a rate (amperage × hours) that is indi- sories contain lead and lead compounds,
cated on the battery. If it is not possible to read chemicals known to the State of California to
the rate, charge the battery at an amperage that cause cancer and reproductive harm. Wash
is about 1/10th of the battery capacity. hands after handling.
•The charger will keep the battery fully charged un-
til you are ready to reinstall the battery in the vehi-
cle (see Battery Installation).

NOTICE
Never remove the sealing strip, or the battery
can be damaged.
Do not install a conventional battery in this
vehicle, or the electrical system cannot work
properly.
 MAINTENANCE AND ADJUSTMENT 167

Fuse
• Pull the cover forward to clear the projections, and
remove the cover.

Fuses are arranged in the fuse boxes located in

the front access cover. The main power fuses are
located under the rear seat. If the electrical systems
do not function, inspect the fuses. Before replacing a
fuse, check the wiring harness and electrical equip-
ment for bare wires or other possible causes for the
blown fuse.
NOTICE
j
Do not use a fuse of a higher capacity than
the specified fuse rating, or damage to the
electrical system could result. Refer to the
Fuse Location label on the other side fuse
case lid. A. Cover
B. Projections
C. Pull Forward
Fuse
• Remove the front access cover. Refer to “Front
Access Cover” section in the “GENERAL INFOR-
MATION” chapter.
 168 MAINTENANCE AND ADJUSTMENT

A. Fuse Boxes A. Fuses

B. ECU Fuse Box B. Main Fuse
C. ECU Fuse
Open the fuse box lids and check the fuse element. D. Spare Fuses
If it is blown out, replace the fuse.
 MAINTENANCE AND ADJUSTMENT 169

Main Power Fuse

• Remove the battery cover (see Battery Removal).

A. Fuse Box
Open the fuse box lid and check the fuse element.
A. Battery Cover If it is blown out, replace the fuse.
 170 MAINTENANCE AND ADJUSTMENT
Before replacing a fuse, check the wiring harness
and electrical equipment for bare wires or other pos-
sible causes for blown fuse.
Power Steering System Fuse (KAF820B/C/D/J)
There is 40 A fuse for the power steering system
in the front access cover.

A. Fuse Box Lid

B. Main Power Fuses

A. 40 A Fuse
B. Hook

A. Spare Fuse
 MAINTENANCE AND ADJUSTMENT 171

Breaker
The breaker for the radiator fan is located in the
front access cover. The reset operation is unneces-
sary because the fan circuit returns normally by the
fan breaker function.

A. Spare Fuse
If the fuse is blown, steering becomes heavy. Re-
place the blown fuse with a fuse of the same specific
amperage and type. If a replaced fuse blows again,
there can be trouble with the ECU or harness/con-
nectors. Contact an authorized Kawasaki dealer for
inspection.
• You can check the 40 A fuse if it is blown at the
top of the fuse. When replacing the fuse, release
A. Breaker

the hook of fuse.

WARNING
The electrical system can produce painful
electrical shocks. When replacing the 40 A
fuse, first remove the cables from the battery
terminals to avoid electric shock.
 172 MAINTENANCE AND ADJUSTMENT

General Lubrication Cleaning

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

• Be sure the engine and exhaust are cool before

washing.
 MAINTENANCE AND ADJUSTMENT 173

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

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

and household cleaning products such as ammo- NOTICE

nia-based window cleaners. They will damage Using high-pressure water, as from a car
or deteriorate painted parts, plastic parts, rubber wash facility, could damage the radiator fins
parts and other synthetic parts including covers and impair the radiator’s effectiveness. Do
and LED headlight lens. not obstruct or deflect airflow through the
• Avoid applying degreaser to seals, brake pads,
and tires.
radiator by installing unauthorized acces-
sories in front of the radiator or behind the
• Gasoline, brake fluid, and coolant will damage the
finish of painted and plastic surfaces: wash them
cooling fan. Interference with the radiator j
airflow can lead to overheating and conse-
off immediately. quent engine damage.
• Avoid wire brushes, steel wool, and all other abra-
sive pads or brushes.
• Take care when washing the headlight lens and
other plastic parts as they can easily be scratched.
Matte Paint Parts
• When washing the vehicle, always use a mild neu-
tral detergent and water, or cleaners for matte
NOTE paint.
○After riding in an area where the roads are salted • The matte paint effect may be lost when the paint
or near the ocean, immediately wash your vehicle is excessively rubbed.
with cold water. Do not use warm water as it ac-
celerates the chemical reaction of the salt. After
• If any doubt, consult an authorized Kawasaki
dealer.
drying, apply a corrosion protection spray on all
metal and chrome surfaces to prevent corrosion. Plastic Parts
○Condensation may form on the inside of the head- After washing, use a soft cloth to gently dry plastic
parts. When dry, treat the headlight lens and other
light lens after riding in the rain, washing the ve-
hicle or humid weather. To remove the moisture, nonpainted plastic parts with an approved plastic
start the engine and turn on the headlight. Gradu- cleaner/polisher product.
ally the condensation on the inside of the lens will
clear off.
 174 MAINTENANCE AND ADJUSTMENT
NOTICE The sidewalls of tires and other rubber compo-
nents should be treated with a rubber protectant to
Plastic parts may deteriorate and break if
help prolong their useful life.
they come in contact with chemical sub-
stances or household cleaning products Where to be Careful
such as gasoline, brake fluid, window clean- Avoid spraying water with any great force near the
ers, thread-locking agents, or other harsh following places.
chemicals. If a plastic part comes in contact
• Disc brake master cylinder and caliper.
with any harsh chemical substance, wash it
off immediately with water and a mild neu- • Under the cargo bed - if water gets into the ignition
coils or into the spark plug caps, it can ground out
tral detergent, and then inspect for damage. the spark. When this happens the vehicle will not
Avoid using abrasive pads or brushes to operate properly and the affected parts must be
j clean plastic parts, as they will damage the wiped dry.
part’s finish.
• Power Steering System - if water gets into the ac-
tuator or is sprayed over the ECU, they may cause
Chrome and Aluminum malfunction.
Chrome and uncoated aluminum parts can be • Winch - if water gets into the motor, it may be dam-
aged.
treated with a chrome/aluminum polish. Coated
aluminum should be washed with a mild neutral de-
tergent and finished with a spray polish. Aluminum NOTICE
wheels, both painted and unpainted can be cleaned Coin operated, high pressure spray wash-
with special non-acid based wheel spray cleaners. ers are not recommended. Water may be
Leather, Vinyl, and Rubber forced into bearings and other components
If your vehicle has leather accessories, special causing eventual failure from rust and cor-
care must be taken. Use a leather cleaner/treatment rosion. Some soaps are highly alkaline and
to clean and care for leather accessories. Washing may leave a residue or cause spotting.
leather parts with detergent and water will damage
them, shortening their life. NOTE
Vinyl parts should be washed with the rest of the
vehicle, then treated with a vinyl treatment.
○(For KAF820D/J) Abrasive cleanser or high pres-
sure washer will damage the surface finish on the
bodywork.
 MAINTENANCE AND ADJUSTMENT 175

Washing Your Vehicle

Bolt and Nut Tightening
•Before washing, precautions must be taken to
keep water off the following parts.
Muffler rear opening - cover with a plastic bag. In accordance with the Periodic Maintenance
Ignition switch - cover the keyhole with tape. Chart, have the tightness of the bolts, nuts, and fas-
teners checked by an authorized Kawasaki dealer.
•Rinse your vehicle with cold water from a garden
hose to remove any loose dirt.
•Mix a mild neutral detergent (designed for motor-
cycles or automobiles) and water in a bucket. Use
a soft cloth or sponge to wash your vehicle.
•After washing, rinse your vehicle thoroughly with
clean water to remove any residue (residue from
the detergent can damage parts of your vehicle).
j
•Remove the plastic bag and tape.
•Use a soft cloth to dry your vehicle. As you dry,
inspect your vehicle for chips and scratches. Do
not let the water air dry as this can damage the
painted surfaces.
•Carefully ride your vehicle at a slow speed and
apply the brakes several times. This helps dry
the brakes and restores them to normal operating
performance.
 176 TRANSPORTING AND STORAGE

TRANSPORTING AND STORAGE

Transporting the Vehicle

• Stop the engine and remove the ignition switch
key to prevent loss during transport.
• Fasten the vehicle to the transporter with a heavy
-duty strap or rope using tie down points on front
Note the following points
[A] and rear [B] of the vehicle. Do not attach tie
NOTICE straps or ropes to the A-arms, other suspension
parts, or drive shafts. Straps must be directed
• To avoid damage and the wind adversely
affecting the vehicle, transport it in an en-
downwards and outwards from the vehicle.
Front Tie Down Points
closed truck or trailer.
• If an enclosed transporter is not available,
remove the plastic hard top and position
the vehicle facing forward.
j
• Never tow the vehicle or use a car type
dolly with the front or rear wheels on the
dolly as this could damage the differential
and/or transmission.

• Secure the fuel tank cap.

• Make sure that the cargo bed is latched and the
tail gate is closed.
• Before loading the vehicle on the transporter, se-
lect a firm level surface.
• Secure loading ramps to the transporter when
loading and unloading. A. Tie down points on the front of vehicle

• Always
ing.
position the vehicle level when transport-

• Set the parking brake.

 TRANSPORTING AND STORAGE 177

Rear Tie Down Points

Storage

Preparation for Storage:

• Clean the entire vehicle thoroughly.
• Run the engine for about five minutes to warm the
oil, shut it off and drain the engine oil.

WARNING
Engine oil is a toxic substance. Dispose of
used oil properly. Contact your local author-
ities for approved disposal methods or pos-
sible recycling.

B. Tie down points on rear of vehicle • Put in fresh engine oil. j

• Empty the fuel from the fuel tank.
• Equip the transporter with all the necessary lights
and signs required by local, state, provincial, or WARNING
federal laws. Gasoline is extremely flammable and can
be explosive under certain conditions and
cause severe burns. Do not smoke. Turn
the ignition switch off. Make sure the area
is well ventilated and free from any source
of flame or sparks, including any appliance
with a pilot light.

WARNING
Gasoline is a toxic substance. Dispose of
fuel properly. Contact your local authorities
for approved disposal methods.
 178 TRANSPORTING AND STORAGE
NOTE • Remove the battery, and store it where it will not
○As an alternative to draining the fuel system, a fuel be exposed to direct sunlight, moisture, or freezing
temperatures. During storage it should be given a
stabilizer, such as STA-BIL, may be used. Follow
the manufacturer’s instructions for use. slow charge (one ampere or less) about once a
month.
WARNING NOTICE
Fuel stabilizers may contain poisonous sub- Keep the battery well charged during cold
stances. Heed the manufacturer’s warnings weather so that the electrolyte does not
for use. freeze and crack open the battery. The more
discharged a battery becomes, the more
• Remove the spark plugs and spray fogging oil di-
rectly into each cylinder. Turn the engine over sev-
easily it freezes.
Never remove the sealing strip, or the battery
eral times with the ignition switch key to coat the
can be damaged.
cylinder walls. Install the spark plugs.
j
WARNING • Tie a plastic bag over the exhaust pipe to prevent
moisture or small animals from entering.
An air/oil mist may be forcibly ejected from
the spark plug holes and could get into your
• For KAF820J model, turn the clutch lever on the
winch to the “ENGAGE” position.
eyes. Do not lean over the engine when per-
forming this procedure. If you do get oil in
• Put a cover over the vehicle to keep dust and dirt
from collecting on it.
your eyes, wash them immediately with lib-
eral amounts of clean, fresh water and con- Removal from Storage:
sult a physician as soon as possible.
DANGER
• Put boards under the front and rear wheels to keep
dampness away from the tire rubber.
Exhaust gas contains carbon monoxide, a
colorless, odorless poisonous gas. Inhal-
• Spray oil on all unpainted metal surfaces to pre-
vent rusting. Avoid getting oil on rubber parts or in
ing carbon monoxide can cause serious
brain injury or death. DO NOT run the en-
the brakes. gine in enclosed areas. Operate only in a
• Lubricate all the cables as indicated in the General
Lubrication section in the “MAINTENANCE AND
well-ventilated area.

ADJUSTMENT” chapter. • Remove the plastic bags from the exhaust pipe.
 TRANSPORTING AND STORAGE 179

• Clean the terminals of the battery, charge the bat-

tery if necessary, and install it in the vehicle.
• Lubricate as indicated in the “General Lubrication”
section in the “MAINTENANCE AND ADJUST-
• Make sure the spark plugs are tight. MENT” chapter.
• Fill the fuel tank with fuel.
• Check all the points listed in the “Daily Checks”
section in the “HOW TO OPERATE” chapter.

j
 180 TROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE
Starter Motor Won’t Turn • Cooling fan breaker functioned
• Fuse failed (be sure to check for cause of failure) • Engine oil level too low
• Battery cables do not make good electrical contact
with battery terminals No Power
• Battery discharged •Engine overheated

Engine Cranks, But Won’t Start

•Too much idling or low speed running (not
enough air flow)
•No fuel in tank •Overloaded
•Water in fuel •Wrong spark plug
•Air filter clogged or intake blocked •Radiator clogged
•Engine flooded •Coolant level too low
•Fuel tank vent clogged •Coolant deteriorated
•Spark plug wire not on spark plug •Cooling fan breaker functioned
•Valve Clearance incorrect •Engine oil level too low
•Spark plug dirty •Compression leakage
j •Valve clearance insufficient
Engine Stops •Air filter clogged or intake blocked
•No fuel in tank •Spark plug dirty or worm
•Water in fuel •Engine oil incorrect
•Air filter clogged or intake blocked •Water in fuel
•Fuel tank vent clogged •Drive belt slipping
•Engine overheated •Water in belt drive torque converter housing
•
Too much idling or low speed running (not
enough air flow) Power Steering Won’t Work (KAF820B/C/D/J)
•
Overloaded •ECU functioned to prevent overheating.
•
Wrong spark plug •Fuse failed
•
Radiator clogged •Battery discharged
•
Coolant level too low •Cable harness/connectors disconnected
•
Coolant deteriorated
 TROUBLESHOOTING GUIDE 181

Selectable 2WD/4WD or DIFF-LOCK Systems • Motor rotating but low power and/or low speed
Malfunction • Overloaddischarged
Battery
•Actuators failed • Motor overheated
•ECU failed • rotating but drum not rotating
•Battery disconnected • Motor
Winch Won’t Work (KAF820J) •Winch
Clutch unlocked
•Motor not rotating • Winchto ropereverse rotation
• Winch switch or winch remote control switch off •Motor overheated
spooled reversely
• Fuse failed • Continuous winchandoperation
smoke has occurred
• Battery discharged • Overload without cool time
• Cables/harness connectors disconnected •
•Motor rotating only on one side
• Winch switch or winch remote control switch
failed

j
182 YOUR WARRANTY/OWNER SATISFACTION

YOUR WARRANTY/OWNER SATISFACTION

Welcome to the Kawasaki family!

Congratulations on buying your Kawasaki vehicle. You’ve chosen a great, high-quality product with state-of-the
-art features and built to Kawasaki’s high standards. Your satisfaction is important to your authorized Kawasaki
dealer and to Kawasaki Motors Corp., U.S.A. Here is some important information regarding your vehicle’s lim-
ited warranty.

Frequently Asked Questions

What is a Limited Warranty?

The most important thing to know about your warranty is that it protects you from manufacturing defects in
material or workmanship during the warranty period. You can find the warranty period in the Kawasaki Limited
Warranty Certificate your Kawasaki dealer provided to you at the time of sale. The warranty does not cover the
cost of regularly-scheduled maintenance. The warranty also does not apply to the normal wear of items such
as tires, brake pads, transmission drive belts, chains, sprockets, etc.

What is the Kawasaki Protection Plus?

Much of the warranty coverage offered by the limited warranty can be extended by purchasing the Kawasaki
Protection Plus (KPP). See your Kawasaki dealer or go to Kawasaki.com for more information if you don’t
already have the KPP.

What Am I Responsible For?

You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner’s
manual.

You are responsible for notifying your dealer immediately if there is a problem, and you, as the owner, will need
to authorize the dealer to inspect the unit.
 YOUR WARRANTY/OWNER SATISFACTION 183

You will be responsible for paying for routine maintenance, including the first scheduled service. You can have
the required servicing done by your Kawasaki dealer (recommended) or an equally-qualified service facility.
You can also do your own maintenance work if you have the proper tools, service references, and mechanical
skills. However, if a failure is found to be caused by improper servicing, it would not be covered by the limited
warranty.

You may purchase a Kawasaki Service Manual and any necessary special tools directly from your Kawasaki
dealer.

You will be responsible for paying for repairs needed because of an accident, to replace worn parts such as
tires, chains, brakes, and for repairs needed because of a lack of maintenance, misuse or racing.

Whether you do it yourself or take your vehicle to a Kawasaki dealer, be sure to record your service in the
Maintenance Record section of this Owner’s Manual. Keep all receipts for the service and/or items necessary
to perform the maintenance so that in the event of a failure you can document the service history.

What Are The Dealership’s Responsibilities?

Your Kawasaki dealer offers a wide range of services, parts, accessories, and information on your product and
on Kawasaki.

Each dealer is independently owned and operated and is responsible for the dealership’s operations, its repair,
warranty, and service work, and its personnel.

Your dealer is responsible for completing the set up and pre-delivery service of your new Kawasaki vehicle. The
dealership should also explain its operation, maintenance, and warranty provisions so you understand them at
the time of purchase or at any other time you have questions.

The dealership is responsible for inspecting your Kawasaki vehicle if there is a failure, investigating the cause
of the problem, and getting any needed authorization from Kawasaki if the repair is one that will be covered by
the limited warranty. The dealership will also file all necessary paperwork. The dealership is responsible for
correctly completing any necessary repairs, whether they are covered by the limited warranty or not.
184 YOUR WARRANTY/OWNER SATISFACTION

How Do I Get Warranty Service?

If there is a problem with your vehicle within the limited warranty period, you will need to schedule a service
appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and diag-
nosis. You can go to any Kawasaki dealer for warranty repairs. Your Kawasaki dealer will inspect your vehicle
and give you the results of the inspection. The dealer will perform the repairs at no cost to you if it is determined
that the problem is covered by the warranty.

Kawasaki will work with your dealer to resolve any warranty issues. No authorization for warranty work can be
given until your vehicle has been inspected by a Kawasaki dealer.

What if I am not Satisfied With My Warranty Service?

If you aren’t satisfied with your dealership’s repair work or operations, it is best to discuss the situation with the
appropriate dealership manager. If you have already done this, then contact the dealership’s owner or general
manager to request a review of the issue.

If you are unable to resolve a problem after consulting with the dealership management and need further as-
sistance, contact Kawasaki Motors Corp., U.S.A. at the address below. Please be certain to provide the model,
vehicle identification number (VIN), mileage or hours of use, accessories, dates that events occurred and what
action has been taken by both you and your dealer. Include the name and address of the dealership. To
assist us in resolving your inquiry, please include copies of related receipts and any other pertinent informa-
tion including the name of the dealership personnel with whom you have been working. Upon receipt of your
correspondence, Kawasaki Motors Corp., U.S.A. will contact the dealership and work with it in resolving your
problem.
 YOUR WARRANTY/OWNER SATISFACTION 185

Want to Contact Kawasaki?

This owner’s manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should
either be able to answer any other questions you might have immediately or be able to find the answer for you.

Please send your correspondence to:.

Consumer Services
Kawasaki Motors Corp., U.S.A.
P.O. Box 25252
Santa Ana, CA 92799-5252
(949) 460-5688
186 ENVIRONMENTAL PROTECTION

ENVIRONMENTAL PROTECTION
Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors
through education and fostering responsible enjoyment of public lands. When using your Kawasaki Utility Ve-
hicle (UV), please follow these Tread Lightly! guidelines:

Tread Lightly!
Travel responsibly on designated roads and trails or in permitted areas.
Respect the rights of others including private property owners and all recreational trail users, campers and
others to allow them to enjoy their recreational activities undisturbed.

Educate yourself by obtaining travel maps and regulations from public agencies, planning for your trip, taking
recreation skills classes, and knowing how to use and operate your equipment safely.

Avoid sensitive areas such as meadows, lakeshores, wetlands and streams, unless on designated routes.
This protects wildlife habitat and sensitive soils from damage.

D o your part by leaving the area better than you found it, properly disposing of waste, minimizing the use of
fire, avoiding the spread of invasive species, restoring degraded areas, and joining a local enthusiast organi-
zation.

Properly discard used batteries, tires, engine oil, other vehicle components, or the entire vehicle that you
might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency
for their proper disposal procedure.
 MAINTENANCE RECORD 187

MAINTENANCE RECORD
Owner Name...................................................................................................................................

Address ..........................................................................................................................................

Phone Number ...............................................................................................................................

Engine Number ..............................................................................................................................

Vehicle Number..............................................................................................................................

Key Code ........................................................................................................................................

Selling Dealer Name ......................................................................................................................

Address ..........................................................................................................................................

Phone Number ...............................................................................................................................

Warranty Start Date .......................................................................................................................

Note: Keep this information and a spare key in a secure location.

Date Traveled Distance Maintenance Performed Dealer Name Dealer Address

188 MAINTENANCE RECORD

Date Traveled Distance Maintenance Performed Dealer Name Dealer Address

 MAINTENANCE RECORD 189

Date Traveled Distance Maintenance Performed Dealer Name Dealer Address

190 MAINTENANCE RECORD

Date Traveled Distance Maintenance Performed Dealer Name Dealer Address

 MAINTENANCE RECORD 191

Date Traveled Distance Maintenance Performed Dealer Name Dealer Address