Quick Reference Guide

This Quick Reference Guide will assist you in

finding the information youre looking for.

A Table of Contents is included after the

Foreword.

GENERAL INFORMATION

HOW TO OPERATE

SAFE OPERATION

MAINTENANCE AND ADJUSTMENT

STORAGE

TROUBLESHOOTING GUIDE

Whenever you see the symbols shown below,

heed their instructions! Always follow safe operating and maintenance practices.

WARNING
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal
injury, or loss of life.

CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly
observed, could result in damage to or destruction of equipment.

NOTE

This note symbol indicates points of particular in-

terest for more efficient and convenient operation.

MULE610 4 4............KAF400A/KAF400C
MULE600......................KAF400B

NOTE

The KAF400C is identical to the KAF400A in every aspect: controls, features, and specifications
except for the camouflage surface treatment.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) and evaporative emission (3) control systems in compliance with applicable regulations of
the United States Environmental Protections Agency and California Air Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases
are led to the breather chamber through the crankcase. Then, it is led to the intake manifold.
Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase,
and then returned back to the bottom of the crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine family is engine modifications that consist of
a catalytic converter in the muffler (California model only), a modified carburetor and ignition system having
optimum ignition timing characteristics.
The carburetor 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 thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the
atmosphere.
3-1. Evaporative Emission Control System (Other than California model)
The evaporative emission control system for this vehicle consists of low permeation fuel hoses.
3-2. Evaporative Emission Control System (California model only)
The evaporative emission control system for this vehicle consists of low permeation fuel hoses and fuel tank.
Also, vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel
vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped.
High Altitude Performance Adjustment Information
To improve the EMISSION CONTROL PERFORMANCE of vehicles operated at high altitude, Kawasaki recommends the following modification.

NOTE

When properly performed, these specified modifications only are not considered to be emissions system
tampering and vehicle performance is generally unchanged as a result.

Installation Instructions:
High altitude adjustment requires replacement of certain carburetor components and belt drive torque converter components. Installation of these optional parts may be performed by an authorized Kawasaki dealer,
or the consumer, following repair recommendations specified in the appropriate Kawasaki Service Manual.
Maintenance and Warranty
Proper maintenance is necessary to ensure that your vehicle will continue to have low emission levels. This
Owners 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 Owners Manual at your own expense.
You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have provided 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 verification 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.

Among those acts presumed to constitute tampering are

Do not tamper with the original emission related parts:
Carburetor and internal parts
Spark plug
Magneto or electronic battery ignition system
Fuel filter
Air cleaner element

the acts listed below:

hoses
Fuel
Fuel
tank
Muffler and carbon canister (California model only)

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 Kawasakis engineering expertise and a tradition of manufacturing high-quality consumer products.
Please read this Owners Manual carefully before starting your new Mule so that you will be thoroughly
familiar with the proper operation of your vehicles controls, its features, capabilities, and limitations.
To ensure a long, troublefree 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 maintenance information. Those who plan to do their own work should, of course, be competent mechanics and
possess the special tools described in the Service Manual.
Keep this Owners Manual aboard your Mule at all times so that you can refer to it whenever you need information.
This manual should be considered a permanent part of the Mule and should remain with the Mule when it is
sold.
All rights reserved. No part of this publication may be reproduced without our prior written permission.
This publication includes the latest information available at the time of printing. However, there may be minor
differences 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.

Consumer Products & Machinery Company
2008 Kawasaki Heavy Industries, Ltd.

Apr. 2008. (1). (M)

TABLE OF CONTENTS
BASIC SAFE DRIVING....................................
SPECIFICATIONS............................................
SERIAL NUMBER LOCATIONS......................
LOCATION OF PARTS ....................................
LOCATION OF LABELS..................................
LOADING INFORMATION...............................
GENERAL INFORMATION..............................
Lighting/Electrical Accessory Connector .......
Brake Pedal...................................................
Cargo Bed .....................................................
Choke Knob...................................................
Engine Oil Temperature Warning Light
(KAF400 A/C) .............................................
Fuel Tank.......................................................
Fuel Gauge....................................................
Glove Compartment ......................................
Front Cargo Compartment ............................
Ignition Switch ...............................................
Hour Meter ....................................................
Light Switch ...................................................
Shift Levers ...................................................
Gear Shift Lever .........................................
2WD-4WD Shift Lever (KAF400A/C)..........
Differential Shift Lever ................................
Parking Brake Lever......................................
Parking Brake Warning Light.........................
Seat ...............................................................
Seat Belts ......................................................
Throttle Pedal ................................................
Trailer Hitch Bracket (Accessory) ..................
Winch Installation ..........................................

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27
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39
41
41
42
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46
46
48
49
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HOW TO OPERATE.........................................
Daily Safety Checks ......................................
Starting the Engine ........................................
Throttle-linked choke system......................
Jump Starting ................................................
Moving Off .....................................................
Braking ..........................................................
Stopping the Engine ......................................
Parking the Mule ...........................................
Hi-Lo Shifting (KAF400A/C) ..........................
Reversing Gears ...........................................
2WD-4WD Shifting (KAF400A/C) ..................
Shifting the Differential ..................................
SAFE OPERATION..........................................
Unfamiliar Terrain ..........................................
Driving in Reverse .........................................
Driving in 4WD (KAF400A/C)......................
Turning the Vehicle........................................
Hills................................................................
Climbing Hills.................................................
Descending Hills............................................
Traversing Hillsides .......................................
Sliding and Skidding......................................
Driving through Water....................................
MAINTENANCE AND ADJUSTMENT.............
Periodic Maintenance Chart ..........................
Engine Oil......................................................
Front Final Gear Case Oil (KAF400A/C) .......
Transmission Case Oil ..................................
Cooling Fan ...................................................
Spark Plug.....................................................

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62
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67
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69
69
73
77
79
82
83

Valve Clearance ............................................

Engine Air Cleaner ........................................
Spark Arrester ...............................................
Throttle Pedal ................................................
Choke Knob...................................................
Carburetor .....................................................
Fuel System ..................................................
Fuel Filter ...................................................
Evaporative Emission Control System
(California model only) ............................
Belt Drive Torque Converter ..........................
Belt Drive Torque Converter Air Cleaner .......
Brakes ...........................................................
Brake Pedal................................................
Brake Light Switch.........................................
Parking Brake Lever......................................
Steering Wheel..............................................
Wheels ..........................................................
Rims ...........................................................
Wheel Nuts.................................................
Tires ...........................................................
Joint Boots.....................................................
Suspension....................................................
Seat Belts ......................................................
Headlight Beam .............................................
Battery ...........................................................
Fuse ..............................................................
General Lubrication .......................................
Cleaning ........................................................
Bolt and Nut Tightening .................................
STORAGE........................................................
TROUBLESHOOTING GUIDE.........................
OWNER SATISFACTION.................................
ENVIRONMENTAL PROTECTION..................

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125

MAINTENANCE RECORD .............................. 126