Kawasaki KAF400A, KAF400B, KAF950F, KAF950G Owner's Manual
Tangazo
Tangazo
Utility Vehicle
Owner's Manual
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ENGLISH
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Quick Reference Guide
This Quick Reference Guide will assist you in finding the information you're looking for.
GENERAL INFORMATION
HOW TO OPERATE
SAFE OPERATION
MAINTENANCE AND ADJUSTMENT
STORAGE
TROUBLESHOOTING GUIDE
A Table of Contents is included after the Foreword.
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Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to personal injury.
NOTE
○
This note symbol indicates points of particular interest for more efficient and convenient operation.
NOTE
○
This general OM contains following models.
Please refer to where applicable to your MULE.
KAF400A ................ MULE610 4 × 4
KAF400B ................ MULE600
KAF950F ................
MULE4010 DIESEL 4 × 4
KAF950G ................
MULE4010 TRANS 4 × 4
DIESEL
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FOREWORD
Congratulations on your purchase of a new Kawasaki Mule. It is the result of Kawasaki's engineering expertise 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 maintenance information. Those who plan to do their own work should, of course, be competent mechanics and possess the special tools described in the Service Manual.
Keep this Owner's Manual aboard your Mule at all times so that you can refer to it whenever you need information.
This manual should be considered a permanent part of the Mule and should remain with the Mule when it is sold.
All rights reserved. No part of this publication may be reproduced without our prior written permission.
This General Owner's Manual offers only the standard descriptions from various models so some descriptions shown may not apply to your particular model. For detailed information of your Mule (Mule handling, maintenance, service and technical data) refer to the Engine Owner's Manual. If not available, consult an authorized
Kawasaki dealer.
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
© 2009 Kawasaki Heavy Industries, Ltd.
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TABLE OF CONTENTS
BASIC SAFE DRIVING ......................................
SPECIFICATIONS ..............................................
DECLARATION OF CONFORMITY ...................
SERIAL NUMBER LOCATIONS ........................
LOCATION OF PARTS .......................................
LOCATION OF LABELS ....................................
LOADING INFORMATION .................................
GENERAL INFORMATION ................................
Cold Weather Information ................................
Lighting/Electrical Accessory Connector .........
Brake Pedal ......................................................
Cargo Bed ........................................................
Choke Knob ......................................................
Glow Plug Light ................................................
Coolant Temperature Warning Light ................
Fuel Tank ..........................................................
Fuel Requirements: .......................................
Fuel Gauge .......................................................
Glove Compartment .........................................
Air Filter Restriction Gauge ..............................
Front Cargo Compartment ...............................
Horn Button ......................................................
Ignition Switch ..................................................
Main Switch ......................................................
Hour Meter ........................................................
Light Switch ......................................................
Speedometer ....................................................
Oil Pressure Warning Light ..............................
Engine Oil Temperature Warning Light ............
Shift Levers ......................................................
Gear Shift Lever ............................................
2WD-4WD Shift Lever (KAF400A &
KAF950) .....................................................
Differential Shift Lever ...................................
Reverse Light ...................................................
Parking Brake Lever .........................................
Parking Brake Warning Light ............................
Seat ..................................................................
Seat Belts .........................................................
Steering Wheel .................................................
Power Steering Warning Light ..........................
Throttle Pedal ...................................................
Trailer Hitch Bracket .........................................
Winch Installation .............................................
HOW TO OPERATE ...........................................
Daily Safety Checks .........................................
Starting the Engine ...........................................
Cold Weather Starting ......................................
Starting After Fuel System Service ..................
Jump Starting ...................................................
Moving Off ........................................................
Braking .............................................................
Stopping the Engine .........................................
Parking the Mule ..............................................
Hi-Lo Shifting ....................................................
Reversing Gears ..............................................
2WD-4WD Shifting ...........................................
Shifting the Differential .....................................
Shifting to Locked-Axle Mode .......................
Converting Rear Seat and Cargo Bed .............
Raising & Lowering the Cargo Bed ..................
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Raising the cargo bed (Shortened Condition)
: ....................................................................
Raising the cargo bed (Extended Condition): 101
SAFE OPERATION .............................................
Unfamiliar Terrain ..............................................
Driving in Reverse .............................................
Driving in "4WD" ................................................
Turning the Vehicle ............................................
Hills ....................................................................
Climbing Hills .....................................................
Descending Hills ...............................................
Traversing Hillsides ...........................................
Sliding and Skidding ..........................................
Driving through Water .......................................
NOISE AND VIBRATION CONTROL INFORMA-
TION ..................................................................
Control Information ............................................
MAINTENANCE AND ADJUSTMENT ................
Periodic Maintenance Chart ..............................
Engine Oil ..........................................................
Front Final Gear Case Oil .................................
Transmission Case Oil ......................................
Cooling Fan .......................................................
Cooling System .................................................
Radiator and Cooling Fan ..............................
Coolant ...........................................................
Spark Plugs .......................................................
Valve Clearance ................................................
Engine Air Cleaner ............................................
Spark Arrester ...................................................
Throttle Pedal ....................................................
Choke Knob .......................................................
Carburetor .........................................................
Fuel System ......................................................
Fuel Filter ...........................................................
Injection Pump ...................................................
Fuel Tank Vent ...................................................
Belt Drive Torque Converter ..............................
Belt Drive Torque Converter Air Cleaner ...........
Brakes ...............................................................
Brake Pedal ....................................................
Brake Shoe Linings ........................................
Brake Fluid .....................................................
Brake Light Switch .............................................
Parking Brake Lever ..........................................
Steering Wheel ..................................................
Power Steering System (for KAF950) ............
Cargo Bed Latches ............................................
Wheels ..............................................................
Rims ...............................................................
Wheel Nuts .....................................................
Tires ................................................................
Joint Boots .........................................................
Suspension ........................................................
Seat Belts ..........................................................
Headlight Beam .................................................
Battery ...............................................................
Battery Characteristics ...................................
Fuse ...................................................................
Power Steering System ..................................
Breaker ..............................................................
General Lubrication ...........................................
Cleaning ............................................................
Bolt and Nut Tightening .....................................
STORAGE ............................................................
TROUBLESHOOTING GUIDE ............................
ENVIRONMENTAL PROTECTION .....................
MAINTENANCE RECORD ..................................
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10 BASIC SAFE DRIVING
Knowing and following these rules for safe operation will increase your satisfaction with your new Kawasaki vehicle.
Perform the Daily Safety Checks
Refer to the Daily Safety Checks section for a list of items to check each day before use. Habitual performance of these checks will help to insure safer, more reliable usage. Be sure that any irregularities found during these checks are corrected before operating the vehicle.
Drive Carefully and with Good Judgement
We want you to be satisfied with your new Kawasaki vehicle, so drive carefully, safely, and exercise good judgement. Practice basic maneuvers so you can drive confidently and safely.
Read the Owner's Manual
Read and understand this Owner's Manual. This is especially important for inexperienced drivers.
Refer to this Owner's Manual if you have any questions.
Off-Highway Use Only
This vehicle is not an all-terrain vehicle; it is designed and equipped to be a multiuse utility vehicle for off-highway use only. Operation on paved surfaces is not recommended.
BASIC SAFE DRIVING
Operator's Capacity
All operators should possess a valid driver's license. Children may not have the skills and judgement necessary to operate this vehicle safely.
Never Drink and Drive
Alcohol and drugs impair your judgement and slow your reactions. Even drugs prescribed by a physician can be dangerous. Check with your doctor.
Dress Properly
As appropriate to operating conditions wear an approved helmet, eye protection, and protective clothing. Proper clothing can make driving more comfortable and reduce the severity of injury in the event of an accident.
Wearing Seat Belt
Both the operator and passenger should wear the seat belts whenever the vehicle is operated. This will reduce the severity of injury in case of a sudden stop or collision.
Also, to reduce chance of injury, always keep arms and legs inside the cab frame while the vehicle is in motion.
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Before Starting the Engine
Three "musts" before starting the engine are:
1. Apply the parking brake,
2. Put the gear shift lever in the "N" (neutral) position,
3. Check the throttle pedal for proper operation. It should return to its rest position when released.
Use the Parking Brake
Always apply the parking brake before getting out of your vehicle.
Obey Local Laws
Know and obey all laws and regulations governing the use of off-highway vehicles in your area. Respect private property. Always try to preserve nature and the environment.
Refueling
Before refueling the vehicle, shut the engine off and make sure the area is well ventilated and free of any source of flame or sparks. Gasoline (for
KAF400) and diesel fuel (for KAF950) are very flammable.
Tire Air Pressure
Tire inflation and type can affect the vehicle's handling characteristics. Check the tire pressure frequently. Use only the recommended tires for replacement.
BASIC SAFE DRIVING 11
Cab Frame
The cab frame is an approved Roll Over protection Structure as defined within the Machinery Directive.
If the cab frame becomes damaged, it will no longer meet the requirements of the Machinery Directive.
Therefore, it must not be repaired and should be replaced by an authorized Kawasaki Dealer.
12 SPECIFICATIONS
PERFORMANCE
Maximum Torque
Minimum Turning Radius
Differential Mode:
DIMENSIONS
Overall Length
Overall Width
Overall Height
Wheelbase
Track:
Ground Clearance
Curb Mass
Cargo Bed (L × W × H)
ENGINE
Type
Displacement
Bore x Stroke
Compression Ratio
Starting System
Cylinder Numbering Method
Firing Order
Front
Rear
SPECIFICATIONS
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Carburetor (for KAF400)
Ignition System ( do. )
Ignition Timing ( do. )
Spark Plug ( do. )
Injection Pump (for KAF950)
Lubrication System
Engine Oil Type:
Capacity:
Coolant Capacity
DRIVE TRAIN
Driving Type
Transmission Type
Primary Reduction Ratio
Final Reduction Ratio
Overall Drive Ratio: Forward
Reverse
Forward Transmission Gear Ratio:
Reverse
Front Final Gear Case Oil (for KAF950)
Front Final Gear Case Oil Capacity ( do. )
Transmission Case Oil
Transmission Case Oil Capacity
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SPECIFICATIONS 13
14 SPECIFICATIONS
FRAME
Type
Steering (for KAF950)
Castor
Trail
Tire Size:
Fuel Tank Capacity
ELECTRICAL EQUIPMENT
Battery
Headlight
Front & Rear
Tail/Brake Light
Reverse Light
LOAD CAPACITY
Maximum Vehicle Load
(Including occupants and cargo)
Maximum Cargo Bed Load
Specifications subject to change without notice.
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SPECIFICATIONS 15
16 DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
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DECLARATION OF CONFORMITY 17
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18 SERIAL NUMBER LOCATIONS
SERIAL NUMBER LOCATIONS
The engine and frame serial numbers are used to register the vehicle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the event of theft, the investigating authorities will require both numbers as well as the model type and any peculiar features of your machine that can help them identify it.
Frame No.
A. Frame Number (for KAF400)
B. Seat (Raised Position)
A. Frame Number (for KAF950)
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SERIAL NUMBER LOCATIONS 19
Engine No.
A. Engine Number (for KAF400)
A. Engine Number (for KAF950)
20 LOCATION OF PARTS
(for KAF400)
1. Headlights
2. Cab Frame
3. Front Cargo Hood
4. Front Cargo Compartment
5. Steering Wheel
6. Seat
7. Set Belts
8. Cargo Bed
9. Grille (Front Bumper)
10. Air Cleaner Intake
11. Parking Brake
12. Air Cleaner (Carburetor)
13. Battery
14. Suspensions
15. Carburetor
16. Latch
17. Tail Gate
LOCATION OF PARTS
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18. Handgrip
19. Air Cleaner (Belt Drive Torque Converter)
20. Belt Drive Torque Converter
21. Latch
22. Dashboard
23. Tail/Brake Light
24. Muffler
25. Fuel Tank
26. Fuel Tank Cap
27. Fuel Gauge
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LOCATION OF PARTS 21
22 LOCATION OF PARTS
28. Differential Shift Lever
29. Choke Knob
30. Horn Button
31. Engine Oil Temperature
Warning Light
32. Paring Brake Warning Light
33. Hour Meter
34. Gear Shift Lever
35. Front Cargo Latch
36. 2WD-4WD Shift Lever (KA-
F400A)
37. Ignition Switch
38. Accessory Connector
39. Glove Compartment
40. Brake fluid Level
41. Brake Light Switch
42. Light Switch
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LOCATION OF PARTS 23
(for KAF950F)
1. Headlights
2. Cab Frame
3. Front Cargo Hood
4. Front Cargo Compartment
5. Steering Wheel
6. Seat
7. Seat Belts
8. Front Bumper
9. Radiator
10. Parking Brake
11. Battery
12. Latch
13. Air Cleaner (Belt Drive Torque
Converter)
14. Belt Drive Torque Converter
15. Handgrip
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24 LOCATION OF PARTS
16. Air Cleaner (Engine)
17. Screen
18. Tail Gate
19. Cargo Bed
20. Dashboard
21. Coolant Reserve Tank
22. Tail/Brake Lights
23. Trailer Hitch Bracket
24. Muffler (Spark Arrester)
25. Fuel Tank
26. Fuel Tank Cap
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LOCATION OF PARTS 25
27. Left Glove Compartment
28. Light Switch
29. Front Cargo Hood Knob
30. Oil Pressure Warning Light
31. Coolant Temperature Warning Light
32. Speedometer
33. Parking Brake Warning Light
34. Glow Plug Light
35. Power Steering Warning Light
36. Hour Meter
37. Main Switch
38. Power Outlet
39. Bottle Holder
40. Right Glove Compartment
41. 2WD-4WD Shift Lever
42. Gear Shift Lever
43. Throttle Pedal
44. Brake Pedal
45. Horn Button
46. Differential Shift Lever
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26 LOCATION OF PARTS
(For KAF950G Four-person mode)
1. Headlights
2. Cab Frame
3. Front Cargo Hood
4. Front Cargo Compartment
5. Steering Wheel
6. Front Seat
7. Rear Seat
8. Seat Belts
9. Cargo Bed
10. Front Bumper
11. Radiator
12. Parking Brake
13. Battery
14. Latch
15. Air Cleaner (Belt Drive Torque
Converter)
16. Belt Drive Torque Converter
17. Handgrip
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LOCATION OF PARTS 27
(Two-person mode)
18. Screen
19. Latch Handle
20. Tail Gate
21. Dashboard
22. Tail/Brake Lights
23. Muffler (Spark Arrester)
24. Trailer Hitch Bracket
25. Fuel Tank
26. Fuel Tank Cap
27. Fuel Gauge
28. Rear Seat (folded)
29. Air Cleaner
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28 LOCATION OF PARTS
30. Left Glove Compartment
31. Light Switch
32. Front Cargo Hood Knob
33. Oil Pressure Warning Light
34. Coolant Temperature Warning
Light
35. Speedometer
36. Parking Brake Warning Light
37. Glow Plug Light
38. Power Steering Warning Light
39. Hour Meter
40. Main Switch
41. Power Outlet
42. Bottle Holder
43. Right Glove Compartment
44. 2WD-4WD Shift Lever
45. Gear Shift Lever
46. Throttle Pedal
47. Brake Pedal
48. Horn Button
49. Differential Shift Lever
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LOCATION OF LABELS
Some labels are not applicable to all models, and their location may also vary depending on models.
Please note that illustrations of models and labels used here are for representation purposes only.
For information specific to your model, refer to the
English Owner's Manual or contact an authorized
Kawasaki dealer or the distributor.
NOTE
○
Labels and their locations listed hereafter are for
KAF950 for example use only. See your own OM in English for relevant information.
All warning labels which are on your Mule are repeated here. Read them and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your Mule. Therefore, it is very important that all warning labels be on your Mule in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct position.
NOTE
○
The sample warning labels in this section have part numbers to help you and your dealer obtain the correct replacement.
LOCATION OF LABELS 29
30 LOCATION OF LABELS
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1. Warning (Off-Highway Utility Vehicle)
2. Notice (Shifting)
3. Warning (Front Cargo Hood)
4. Notice (Downhill Speed)
5. Warning (General)
6. Specification
7. Specification (CE mark)
8. Warning (Owner's Manual)
9. Cab Frame Information
10. Important Information (Tires/Max. Load)
11. Warning (Pinching)
12. Warning (Cargo Bed)
19. Danger (Radiator)
20. Warning (Passenger's in Cargo Bed)
21. Information (Front Hood)
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LOCATION OF LABELS 31
13. Warning (Refueling)
14. Warning (Towing Bracket)
15. Warning (Hot Surfaces)
16. Notice (Engine Oil Fill)
17. Notice (Engine Oil Level)
18. Important Engine Information
32 LOCATION OF LABELS
(1) (3)
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(2) (4)
(5)
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LOCATION OF LABELS 33
34 LOCATION OF LABELS
(6)
(7)
(8)
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(9)
(10)
(11)
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LOCATION OF LABELS 35
(12)
36 LOCATION OF LABELS
(14)
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(13)
(15)
(16)
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LOCATION OF LABELS 37
(17)
38 LOCATION OF LABELS
(18)
(19) (20)
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(21)
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LOCATION OF LABELS 39
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40 LOADING INFORMATION
LOADING INFORMATION
WARNING
Incorrect loading, improper installation or use of accessories, or modification of your vehicle may result in an unsafe operating condition. Before you operate it, make sure that the vehicle is not overloaded and that you have followed these instructions.
With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. In some cases, improper installation or use of accessories, or vehicle modifications, will void the utility vehicle warranty. In selecting and using accessories, and in loading the vehicle, you are personally responsible for your own safety and the safety of other persons involved.
NOTE
○
Kawasaki Parts and Accessories have been specially designed for use on Kawasaki utility vehicles. We strongly recommend that all parts and accessories you add to your vehicle be genuine
Kawasaki components.
Because any vehicle is sensitive to increases in weight and changes in weight distribution, you must take care in carrying cargo. The following general guidelines have been prepared to help you make your determinations.
•
Reduce speed when carrying cargo. Braking distance is increased. Use extreme caution when climbing and descending hills, and traversing slopes. Carrying cargo and pulling a trailer can make the vehicle difficult to steer and may affect vehicle handling in an unpredictable manner.
•
Do not operate this vehicle faster than 16 km/h when pulling a trailer.
•
All cargo should be carried as low as possible to reduce the effect on the vehicle's center of gravity.
Cargo weight should be equally distributed from side to side. This helps maintain stability by centralizing weight. Avoid carrying cargo that extends beyond the rear of the vehicle. Do not carry cargo
• on top of the cab frame.
Do not carry more than kg in the cargo bed.
•
Cargo should be securely anchored. Make sure the cargo will not move around while the vehicle is moving. Recheck cargo security as often as possible (while the vehicle is stopped) and adjust as necessary.
NOTICE
The front body work and fenders are not designed to carry cargo or to support your weight. They may break.
•
Always subtract trailer tongue weight from the
Maximum Load capacity. Refer to the "Trailer
Hitch Bracket" section in the "General Information" chapter.
Maximum Load
Weight of operator, passenger, and cargo must not exceed kg
NOTE
○
Maximum Load and cargo weight for your Mule are show in your English OM titled “ LOADING IN-
FORMATION
” chapter. Refer to the relevant page and copy the data value into the space provided in this page.
•
This vehicle is not designed to carry passengers in the cargo bed. Installing additional passenger seating or carrying passengers in the cargo bed can cause changes in vehicle handling.
WARNING
Passengers riding in the cargo bed can be tossed about or even thrown out causing serious injury or death. Do not install seating or carry passengers in the cargo bed.
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LOADING INFORMATION 41
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42 GENERAL INFORMATION
GENERAL INFORMATION
Cold Weather Information
(for KAF950 only)
Fuel
For most year - round service, number 2-D diesel fuel meeting ASTM specification D-975 will provide good performance.
At temperatures below
−
7°C (20°F), number 2-D grade diesel fuel thickens enough to clog the fuel filter. This is usually caused by naturally-occurring paraffin in diesel fuel turning to wax as it gets colder.
If the engine starts but stalls after a short time and will not restart, the fuel filter may be clogged. For best results in cold weather use climatized number
2-D diesel fuel or dilute the number 2-D diesel fuel with 50% number 1-D diesel fuel. This will provide better protection from fuel gelling or wax plugging the fuel filters.
When using the vehicle at temperatures below
−
20°C (
−
4°F), consult your dealer about the best fuel to use.
WARNING
Starting fluids such as ether are explosive and may cause severe injury. Do not use starting fluids containing ether in the air intake system.
NOTE
○
Do not add gasoline, gasohol, alcohol, or aftermarket cetane improver additives to diesel fuel.
Damage to the fuel injection system may result.
Engine Oil
Use only oils conforming to API Service CF or CF-
4. Use the proper SAE viscosity grade of engine oil for the expected ambient temperature range as indicated in the following chart.
STARTING TEMPERATURE RANGE ANTICI-
PATED BEFORE NEXT OIL CHANGE
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Lighting/Electrical Accessory Connector
(for KAF950)
The lighting 12 volt connector is located on the dashboard.
An auxiliary light may be connected to this connector.
GENERAL INFORMATION 43
Optional items such as wiper and so on may be connected to those connectors.
A. Connector
Other connectors for electrical accessories are located under the left side dashboard.
A. Connectors
(for KAF400)
The lighting/electrical accessory 12 volt connector is located on the dashboard.
An auxiliary light or an accessory may be connected to this connector.
44 GENERAL INFORMATION
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Brake Pedal
The brake pedal is the left pedal on the foot board.
Depress the pedal to slow or stop the vehicle.
A. Accessory Connector
B. Ignition Switch
NOTICE
Do not connect a light or load of more than watts to these connectors, or the battery may become discharged very rapidly.
NOTE
○
Allowable watt of your Mule is shown in your English OM, titled “ Lighting/Electrical Accessory Connector
” section of
“
GENERAL INFORMATION
” chapter. Refer to the relevant page and copy the data value into the space provided in this page.
A. Brake Pedal
Cargo Bed
For loading and unloading, the tail gate of the cargo bed can be opened. Raise the latch handles at each end of the tail gate and slide both latches towards the center of the vehicle. The tail gate can now be lowered. The gate is held level to the cargo bed floor with wire loops.
(for KAF400)
A. Wire Loop
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GENERAL INFORMATION 45
A. Tail Gate
B. Latch
46 GENERAL INFORMATION
Close the tail gate by sliding both latches toward the center of the vehicle. Push the handles down to make sure the latches stay securely closed.
The cargo bed may be tilted by releasing the latches on each side, and then lifting the bed with the handgrips. Support the bed in the tilted position with the rod.
A. Supporting Rod
A. Latch
B. Handgrip
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(for KAF400)
A. Latch
B. Handgrip
C. Fuel Tank Cap
NOTE
○
Raise the seat first before releasing the latch.
NOTICE
Do not carry more than the maximum load stated here in the cargo bed.
Maximum Load: kg ( lb)
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GENERAL INFORMATION 47
WARNING
Overloading or improper use of the cargo bed can cause changes in handling which can lead to an accident. Follow guidelines provided in the
“
LOADING INFORMATION
” chapter.
Passengers riding in the cargo bed can be tossed about or even thrown out causing serious injury or death. Do not install seating or carry passengers in the cargo bed.
Driving with the cargo bed tilted may be hazardous. Always lower and latch the bed before driving. Be careful not to catch any part of your body, such as hands or arms, between the bed and cab frame or vehicle frame when lifting and lowering the bed.
NOTE
○
Maximum load for the cargo bed of your Mule is shown in your English OM titled
“
Cargo Bed
” section of “ GENERAL INFORMATION ” chapter. Refer to the relevant page and copy the data value into the space provided in this page.
(for KAF950G)
Maximum Load:
Short Bed mode: 318 kg (700 lb)
Long Bed mode: 499 kg (1 100 lb)
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48 GENERAL INFORMATION
Cargo Bed Conversion
Cargo bed can be converted in combination with passenger capacity, and it can be converted between a short or long bed by moving the rear seat and the screen. See the HOW TO OPERATE chapter for the converting operations.
Shortened Cargo Bed
Extended Cargo Bed
Raising the cargo bed
The cargo bed can be raised for engine maintenance or servicing. Release the latches on both sides and raise it with the handgrips. Support the bed in the tilted position with the rod. The raising & lowering procedures are different with the rider's seats being set for 2 persons or 4 persons. See the
HOW TO OPERATE chapter for the handling.
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Choke Knob
(for KAF400)
The choke knob located on the dashboard, to the left of the steering shaft, provides a rich mixture for cold starting.
Pull the choke knob all the way out until it stops and hold it to start the engine. Warm the engine up using the choke and throttle until the idle speed is stable, and then release the choke knob.
Refer to the "Starting the Engine" section in the
"How to Operate" chapter for detailed information.
GENERAL INFORMATION 49
NOTE
○
If the choke is left on (pulled out) after the engine has warmed up, spark plug fouling and poor fuel economy may result.
A. Choke Knob
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50 GENERAL INFORMATION
Glow Plug Light
(for KAF950)
The glow plug light goes on for 5 seconds when the main key is turned to the ON position. The light also goes on whenever the key is in the "start" position. The light goes off after the glow heats fully. If it does not go on or go off, have the glow plug and related system checked by an authorized Kawasaki dealer.
Refer to the "Starting the Engine" section in the
"How to Operate" chapter for detailed information.
Coolant Temperature Warning Light
(for KAF950)
The coolant temperature warning light (TEMP) comes on whenever the coolant temperature rises too high while the vehicle is in operation. If it stays on, stop the engine and check the coolant level in the reserve tank after the engine cools down.
Refer to the “ Cooling System ” section in the
“
Maintenance and Adjustment
” chapter.
Also check the breaker of the radiator fan and, if it has functioned, reset the breaker. Be sure to check that the radiator fan is free from mud and other obstacles. See Breaker section of MAINTENANCE
AND ADJUSTMENT chapter.
A. Glow Plug Light
A. Coolant Temperature Warning Light
Black plate (51,1)
NOTE
○
When you touch the cooling fan, be sure to disconnect the ( – ) cable of the battery, since the cooling fan can turn automatically even with the ignition switch off.
NOTICE
Do not let the engine continue running with a warning light on. Prolonged engine operation can result in engine damage from overheating.
GENERAL INFORMATION 51
Fuel Tank
(for KAF400)
The fuel tank is mounted under the right end of the seat. The gasoline octane rating listed is recommended. Avoid filling the tank in the rain or where heavy dust is blowing, so that the fuel does not get contaminated.
A. Fuel Tank
B. Filling Cap
Black plate (52,1)
52 GENERAL INFORMATION
WARNING
Diesel fuel is extremely flammable and can be explosive under certain conditions. Turn the ignition key to “ OFF ” . Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Never fill the tank completely to the top. As the fuel expands in a warm tank, it may overflow through the vents in the tank cap. After refueling, make sure the fuel tank cap is closed securely. If diesel fuel is spilled on the fuel tank, wipe it off immediately.
Fuel Requirements:
Fuel Type
Use only unleaded gasoline with an octane rating equal to or higher then that shown in the table.
Octane Rating Method Minimum Rating
Research Octane Number (RON)
91
NOTICE
Use of leaded gasoline is illegal in some countries, states of territories.
Check local regulations before using leaded gasoline.
Octane Rating
The octane rating of a gasoline is a measure of its resistance to detonation or "knocking." The term commonly used to describe a gasoline's octane rating is the Research Octane Number (RON). Always use a gasoline with an octane rating equal to, or higher than, RON 91.
NOTE
○
If "knocking" or "pinging" occurs, use a different brand of gasoline or higher octane rating.
NOTICE
Do not use alcohol or "gasohol" in this vehicle. It has not been tested and certified for use with such fuels. Damage to the vehicle may result from the use of improper fuel.
(for KAF950)
The fuel tank is mounted under the right side of the cargo bed. Use clean, fresh diesel fuel (ASTM
D975) for good performance of this vehicle. Avoid refilling the tank in the rain or where heavy dust is blowing, so that the fuel does not get contaminated.
NOTICE
Fuel that is contaminated by water or dirt can cause severe damage to the fuel system.
A. Fuel Tank
WARNING
Diesel fuel is extremely flammable and can be explosive under certain conditions. Turn the main switch key to the OFF position. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
Never fill the tank completely to the top. If the tank is filled completely to the top, heat may cause the fuel to expand and overflow though the vents in the tank cap.
After refueling, make sure the tank cap is closed securely.
If diesel fuel is spilled on the fuel tank, wipe it off immediately.
Black plate (53,1)
GENERAL INFORMATION 53
Fuel Requirements:
Fuel Type
The use of quality fuel from reputable supplier, specially formulated for vehicle use, is recommended to maintain performance and life from the engine.
In all cases, diesel fuel of minimum cetane number 40 (ASTM D975) should be used. When operating in cold weather or high altitude above 1 500 m
(5 000 ft), diesel fuel of greater cetane number is recommended.
If available in your area, a high cetane "premium" diesel fuel may offer improved cold-starting and warm-up performance.
NOTICE
Do not use gasoline, gasohol or any other fuel, except diesel fuel. Improper fuel can cause severe fuel injection system and engine damage.
Lower Sulfur
Sulfur content is recommended at less than
0.05%.
To avoid engine corrosion, and engine oil contamination, do not use fuel with more than 0.5% sulfur content.
Black plate (54,1)
54 GENERAL INFORMATION
Fuel Gauge
The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank.
When the red indicator needle comes near the "E"
(Empty) mark, refuel at the earliest opportunity.
Glove Compartment
(for KAF950)
A glove compartment is provided at the each end of the dashboard. Store only light items to avoid damage to the inside of the compartments. Do not store anything which must not get wet or dirty.
Release the plug in the bottom of the left and right glove compartments to remove any water that may have entered.
A. Fuel Gauge
A. Left Glove Compartment
A. Right Glove Compartment
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GENERAL INFORMATION 55
Air Filter Restriction Gauge
(for KAF950)
The air filter restriction gauge is on right side under the seat. It shows whether the air cleaner is clogged. The air cleaner element should be cleaned if the restriction gauge window band changes from yellow to red. After servicing the air cleaner element, the restriction gauge should be reset by pushing the button at the end of the gauge.
A. Air Filter Restriction Gauge
Black plate (56,1)
56 GENERAL INFORMATION
Front Cargo Compartment
The front cargo compartment is located under the front cargo hood. Store only light-weight items in it to avoid damage to the inside of the compartment.
Do not put items which must not get wet or dirty in it.
A. Front Cargo Compartment
Hood Opening
Pull the latch release knob and raise the hood until it stops.
A. Latch Release Knob
NOTE
○
When the hood is hard to open, pull and lift up the front hood center portion with pulling the knob to open the hood.
•
Hood Closing
Close the hood until it locks.
•
After the hood is closed, push the two parts of the hood to ensure the hood is latched.
Black plate (57,1)
GENERAL INFORMATION 57
Horn Button
(for KAF950)
A car-type horn button is provided on the center of the steering wheel. Push the horn button to sound the horn.
A. Push here.
B. Latches
WARNING
An open front cargo hood can distract or impair visibility of the operator, causing loss of vehicle control and potential serious injury or death.
Latch the hood securely before operating the vehicle.
A. Horn Button
Black plate (58,1)
58 GENERAL INFORMATION
Ignition Switch
This is a three-position, key-operated switch. The key can be removed from the switch only when it is in the "OFF" position.
(for KAF400)
A. Ignition Switch
B. "OFF" position
C. "ON" position
D. "START" position
E. Accessary Connector
OFF
ON
START
Engine off. All electrical circuits off.
All electrical equipment can be used.
Hour meter works.
Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is in "N" (neutral) position. 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 for the battery to recover power.
Do not turn the ignition switch key to the
"START" position with the engine running, or damage to the starter can result.
NOTE
○
The vehicle is equipped with a starter lockout switch. This switch prevents the electric starter from operating when the gear shift lever is in the
“
H
”
(High) and
“
L
”
(Low) for KAF400A or
“
F
”
(Forward) for KAF400B or “ R ” (Reverse) position.
Blank keys are available at your Kawasaki dealer.
Ask your dealer to make any additional spare keys you need, using your original key as a master.
Write your key number here.
Black plate (59,1)
GENERAL INFORMATION 59
Main Switch
(for KAF950)
This is a three-position, key-operated switch. The key can be removed from the switch only when it is in the "OFF" position.
A. Main Switch
B. "OFF" position
C. "ON" position
D. "START" position
E. Hour Meter
Black plate (60,1)
60 GENERAL INFORMATION
OFF
ON
START
Engine off. All electrical circuits off.
All electrical equipment can be used.
Hour meter works.
Electric starter is engaged by holding main switch key in this position, only when gear shift lever is in "N" (neutral) position. Upon release, key will return to "ON" position.
NOTICE
Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power.
Do not turn the main switch key to the
"START" position with the engine running, or damage to the starter can result.
NOTE
○
The vehicle is equipped with a starter lockout 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.
Blank keys are available at your Kawasaki dealer.
Ask your dealer to make any additional spare keys you need, using your original key as a master.
Hour Meter
The hour meter shows the total hours that the vehicle has been operated. This meter cannot be reset.
NOTE
○
The data is maintained even if the battery is disconnected.
○
When the figures come to 99999, they turn back to 00000 for KAF400 or 9999.9 to 0.0 for KAF950 and start counting upward again when the ignition switch is turned on or while the vehicle is operated.
(for KAF400)
A. Hour Meter
(for KAF950)
A. Hour Meter
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GENERAL INFORMATION 61
Light Switch
Turn on the headlights and taillights by pushing the light switch in, with the ignition switch key in the
"ON" position.
The lights go off when the switch is pushed out.
Black plate (62,1)
62 GENERAL INFORMATION
Speedometer
(for KAF950)
The speedometer shows the speed of the vehicle.
In the speedometer face is the odometer. The odometer shows the total distance that the vehicle has been driven.
Oil Pressure Warning Light
(for KAF950)
The oil pressure warning light goes on whenever the oil pressure is dangerously low or the main key is in the ON position with the engine not running, and goes off when the engine oil pressure is high enough.
NOTICE
If the engine oil gets extremely low or if the oil pump does not function properly, or oil passages are clogged, or otherwise do not function properly, the oil pressure warning light will light. If this light stays on when the engine speed is running slightly above the idle speed, stop the engine immediately and find the cause.
A. Speedometer
B. Odometer
A. Oil Pressure Warning Light
Black plate (63,1)
GENERAL INFORMATION 63
Engine Oil Temperature Warning Light
(for KAF400A only)
The oil temperature warning light comes on whenever the engine oil temperature rises too high while the vehicle is in operation. If it stays on, stop the engine and check the engine oil level after the engine cools down.
Refer to the “ Engine Oil ” section in the “ Maintenance and Adjustment
” chapter.
A. Engine Oil Temperature Warning Light
NOTICE
Do not let the engine continue running with a warning light on. Prolonged engine operation can result in engine damage from overheating.
Black plate (64,1)
64 GENERAL INFORMATION
Shift Levers
This vehicle is equipped with three different shift levers: the gear shift lever, the 2WD-4WD shift lever
(KAF400A & KAF950) and the differential shift lever.
Gear Shift Lever
The gear shift lever is located on the dashboard, to the right of the steering shaft. The gear shift lever has four (KAF400A & KAF950) or three (KAF400B) positions: “ H ” (High) and “ L ” (Low) for KAF400A and
KAF950 only or
“
F
”
(Forward) for KAF400B,
“
N
”
(Neutral), and “ R ” (Reverse).
Model
KAF400A
KAF950
KAF400B
Gear Position
"H" (High), "L" (Low), "N" (Neutral), "R"
(Reverse)
"F" (Forward),
“
N" (Neutral), "R" (Reverse)
Make certain that the vehicle is completely stopped and the engine is idling before shifting from
“ H ” (High) or “ L ” (Low) for KAF400A and KAF950 only or “ F ” (Forward) for KAF400B to “ R ” (Reverse) or vice versa. Move the gear shift lever up or down as indicated on the label next to the shift lever.
Refer to the "Reversing Gears" section in the
"How to Operate" chapter.
(for KAF950)
A. Gear Shift Lever
B. "H" (High) Position
C. "L" (Low) Position
D. "N" (Neutral) Position
E. "R" (Reverse) Position
(for KAF400)
A. Gear Shift Lever
B.
“
R
”
(Reverse) Position
C.
“
N
”
(Neutral) Position
D.
“
H
”
(High) Position
E.
“
L
”
(Low) Position (KAF400A & KAF950 only) or
“
F
”
(Forward) Position (KAF400B only)
NOTICE
Do not shift from
“
H
”
(High) or
“
L
”
(Low) to
“ R ” (Reverse) and vice versa for KAF400A or
“
F
”
(Forward) to
“
R
”
(Reverse) and vice versa for KAF400B when the vehicle is moving or with the engine running above idling speed, or the transmission could be damaged.
Black plate (65,1)
GENERAL INFORMATION 65
The KAF400A & KAF950 are 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 for agricultural use.
The high gearing raises the speed range for ordinary off-highway use. Stop the vehicle before moving the Hi-Lo shift lever.
NOTICE
Use of the high range for heavy loads, climbing hills, and pulling a trailer can lead to premature wear of the torque converter belt and pulleys. Use low range for these conditions.
Refer to the "Hi-Lo Shifting" section in the "How to
Operate" chapter.
2WD-4WD Shift Lever (KAF400A & KAF950)
This vehicle can be operated either in "2WD" or
"4WD".
The 2WD-4WD shift lever is located on the dashboard, to the right of the steering shaft. Move the
2WD-4WD shift lever up or down on the label to the left of the lever.
Refer to the "2WD-4WD Shifting" section in the
"How to Operate" chapter.
Black plate (66,1)
66 GENERAL INFORMATION
A. 2WD-4WD Shift Lever
B. Stopper
C. "2WD" Position
D. "4WD" Position
Differential Shift Lever
This vehicle is equipped with a dual-mode rear differential. The differential shift lever is located on the dashboard, to the left of the steering shaft. Move the shift lever up or down as indicated on the label next to the shift lever.
Refer to the "Shifting the Differential" section in the "How to Operate" chapter.
A. Differential Shift Lever
B. Stopper
C. Differential (Unlocked-Axle) Mode Position (UN-
LOCK)
D. Locked-Axle Mode Position (LOCK)
Black plate (67,1)
Reverse Light
A reverse light is provided under the cargo bed.
When the gear shift lever is shifted to "R" (reverse) position, the reverse light will be lit.
GENERAL INFORMATION 67
Parking Brake Lever
The parking brake lever is located at the left side of the seat. Pull the lever up and to the rear to apply the parking brake.
To release, push in and hold the knob on the end of the lever and push the lever all the way down.
Spring pressure helps return the lever to the released 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.
(for KAF950)
A. Reverse Light
A. Parking Brake Lever
B. Knob
68 GENERAL INFORMATION
(for KAF400)
A. Parking Brake Lever
WARNING
If the vehicle should move after it is parked, it might be damaged or cause injury. Be sure to apply the parking brake before leaving the vehicle.
Black plate (68,1)
Parking Brake Warning Light
(for KAF400 & 950)
The parking brake warning light goes on when the parking brake is applied with the ignition switch in the "ON" position.
NOTE
○
This light shows only that the parking brake is on.
It does not show the degree of parking brake application.
(for KAF950)
A. Parking Brake Warning Light
(for KAF400)
A. Parking Brake Warning Light
Black plate (69,1)
GENERAL INFORMATION 69
Seat
The seat can be raised for vehicle maintenance and adjustment.
•
Pull up on the rear edge of the seat.
A. Seat (Raised Position)
70 GENERAL INFORMATION
(for KAF950G)
There are front and rear seats on this vehicle. It can be transformed from 2-passenger to 4-passenger by unfolding the rear seat.
2-passenger mode
4-passenger mode
Black plate (70,1)
NOTE
○
Converting the rear seat must be made in combination with cargo bed conversion. See the conversion of Rear Seat section in the HOW TO
OPERATE chapter.
Black plate (71,1)
Seat Belts
(for KAF400 & KAF950F)
The vehicle is equipped with lap-style seat belts both for the operator and passenger. Always wear the seat belts when operating and riding in the vehicle.
GENERAL INFORMATION 71
To wear the seat belt properly, follow this procedure:
1. Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted.
2. Push the latch plate into the buckle until it clicks.
3. Adjust the seat belt for a SNUG FIT.
A. Seat Belt
B. Latch Plate
C. Buckle
WARNING
Seat belts reduce injury. Always wear your seat belt. The lap-style seat belt may not provide adequate protection for small children.
Special care is recommended when carrying a child passenger.
A. Buckle
B. Latch Plate
72 GENERAL INFORMATION
To tighten the belt, pull on the end of the belt coming from the latch plate. To loosen the belt, pull the latch plate at a right angle to the belt.
WARNING
Too much belt slack could reduce its protection effectiveness in an accident. Always adjust the belt to a SNUG FIT.
To unfasten the belt, press the red button in the buckle.
A. Red Button
Black plate (72,1)
Black plate (73,1)
(for KAF950G)
The vehicle is equipped with retractable lap-style seat belts for all occupants - operator and passenger for the front seat and two passengers for the rear seat. Always wear the seat belts when operating and riding in the vehicle
GENERAL INFORMATION 73
To wear the seat belt properly, follow this procedure:
1. Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted.
2. Push the latch plate into the buckle until it clicks.
3. Verify the belt retracts to a SNUG FIT.
WARNING
Too much seat belt slack could reduce its protection effectiveness in an accident. Always verify that the belt is at a SNUG FIT.
To unfasten the belt, press the red button in the buckle.
A. Seat Belt
B. Buckle
C. Red Button
WARNING
Seat belts reduce injury. Always wear your seat belt. The lap-style seat belt may not provide adequate protection for small children.
Special care is recommended when carrying a child passenger.
Black plate (74,1)
74 GENERAL INFORMATION
Steering Wheel
(for KAF950)
The steering wheel position can be adjusted to suit the operator. Refer to the "Steering Wheel" section in the "Maintenance and Adjustment" chapter.
This vehicle is equipped with an electrical power steering system. The system does not require regular maintenance by users. Do not tamper with the electronic control unit (ECU) or loosen the fittings of steering actuator, or the neutral position setting of the steering will be adversely affected and will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer.
If the steering becomes more difficult than usual or you experience other steering problems, refer to the
“
Steering Wheel
” section in the
“
MAINTE-
NANCE AND ADJUSTMENT
” chapter.
NOTE
○
The power steering system functions only when engine is running.
○
If you install wireless equipment on board, contact an authorized dealer. Installing such equipment improperly may affect the ECU.
Power Steering Warning Light
(for KAF950)
The power steering warning light will momentarily illuminate when the main switch is first turned to the
”
ON
” position, then goes off in one second if the system is in order. If the warning light illuminates any other time, it indicates the ECU or actuator has malfunctioned, or the wiring harness has become disconnected. Stop driving immediately and see an authorized Kawasaki dealer to have the system checked.
A. Power Steering Warning Light
Black plate (75,1)
NOTE
○
If the warning light does not go on when the main switch is “ ON ” , there may be a problem with the light itself. See a dealer for inspection.
GENERAL INFORMATION 75
Throttle Pedal
The throttle pedal is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine.
In addition, there must be adequate throttle pedal play and stop position. Refer to the "Maintenance and Adjustment" chapter for the throttle pedal adjustment procedure.
A. Throttle Pedal
Black plate (76,1)
76 GENERAL INFORMATION
Trailer Hitch Bracket
This vehicle is equipped with a bracket for a trailer hitch. (Optional for KAF400) Trailer towing equipment is not supplied with this vehicle.
To avoid injury and property damage, observe the following precautions:
WARNING
Improper towing of a loaded trailer could cause an accident resulting in serious injury or death. Never carry a passenger in a trailer.
Never load more than kg tongue weight on the towing bracket. Do not operate the vehicle faster than km/h when towing. Remember that towing a trailer increases braking distance. Do not tow more than kg trailer weight (trailer plus cargo weight). Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other location or you may lose control of the vehicle and have an accident.
A. Trailer Hitch Bracket (Optional for KAF400)
NOTE
○
Maximum load for the cargo bed of your Mule is show in your English OM titled
“
Cargo Bed
” section of “ GENERAL INFORMATION ” chapter. Refer to the relevant page and copy the data value into the space provided in this page.
Winch Installation
(for KAF950) Installing procedure for a winch
1. Remove the front bumper cover screws, and front bumper cover.
A. Front Bumper Cover
B. Screws
2. Remove the front bumper and side plate to gain access by releasing bolts and screws.
A. Front Bumper
B. Bolts
C. Winch Bracket
Black plate (77,1)
GENERAL INFORMATION 77
78 GENERAL INFORMATION
Black plate (78,1)
3. You can see the bracket attached to a crossmember.
A. Side Plate
B. Screws
A. Winch Bracket
4. Follow a manual to be supplied by the winch maker for installing the winch and other accessory as necessary.
5. After installing the winch, be sure to re-install the bumper and bumper cover.
(for KAF400)
Black plate (79,1)
GENERAL INFORMATION 79
A. Winch Bracket
Black plate (80,1)
80 HOW TO OPERATE
HOW TO OPERATE
Daily Safety Checks
Check the following items each day before operation. The time required is minimal, and habitual performance of these checks will help ensure safe, reliable operation.
If any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating condition.
WARNING
Failure to perform these checks before operation may result in serious damage or an accident. Always perform daily safety checks before operation.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas.
Inhaling carbon monoxide can cause serious brain injury or death.
Do not run the engine in enclosed areas. Operate only in a well-ventilated area.
Fuel ...................................................
Enough fuel in tank, no leaks.
Engine oil ..........................................
Oil level between H and L lines (when engine is cold), no leaks.
Air Cleaner (for KAF950) ..................
Check the restriction gauge for the red band in the window.
Tires ..................................................
Air pressure (when cold):
Front
Rear kPa ( kPa ( kgf/cm²) kgf/cm²)
Check for cuts, cracks, damage, or excessive wear.Check for any imbedded stones or other foreign particles in tread.
Black plate (81,1)
HOW TO OPERATE 81
Front Final Gear Case and Transmission Case (for KAF400A & 950) ....
No oil leaks.
Coolant (for KAF950) ........................
Coolant level between level lines (when engine is cold), no leaks.
Throttle ..............................................
Throttle pedal free play ~ mm.Throttle pedal operates smoothly and returns to rest position when released.
Steering ............................................
Steering wheel free play ~ mm.Action smooth without excessive play, rough spots, or strange noises.
Brakes ...............................................
Check for braking effectiveness (while test running).Brake pedal free play ~ mm.Brake fluid level between level lines, no leaks.Parking brake lever travel: ~ clicks.
Electrical Equipment .........................
All lights and horn work. Check for dirt on or damage to lights.
Battery ..............................................
Electrolyte level between level lines in each cell.
Engine Cooling Fan Screen ..............
Check for mud and other debris.
NOTE
○
Information for the various values shown here such as tire pressures, free plays are described in your English
OM, titled “ Daily Safety Checks ” section of “ HOW TO OPERATE ” chapter. Refer to the relevant page and copy those data values into the spaces provided in this page.
Black plate (82,1)
82 HOW TO OPERATE
Starting the Engine
(for KAF400)
Throttle-linked choke system
This vehicle is equipped with the choke that controls the throttle operation without pressing the throttle pedal when starting the engine.
Mechanism of the System
○
By pulling the choke knob out, the choke valve in the carburetor starts to close.
○
By further pulling the knob over the stepping response, throttle valve linked to the choke starts to open slightly. (You can feel this move by increased resistance of the choke knob.)
A. Full Choke Stroke
B. Ordinary Choke Stroke
C. Throttle-linked Choke Stroke
Using this choke system, start the engine with the following procedure.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas.
Operate only in a wellventilated area.
•
Wear the seat belts (both operator and passenger).
•
Apply the parking brake.
•
Put the gear shift lever in the
“
N
”
(Neutral) position.
•
Put the ignition key in the switch.
NOTE
○
When engine is cold and air temperature is below
20°C (68°F), pull the choke knob all the way out and keep holding the knob so that the throttlelinked choke system functions. Release the choke knob when the engine has started and push in the choke knob after the engine starts to warm up.
○
When engine is warm or air temperature is 20°C
(68°F) or higher, do not use the choke. Push down the throttle pedal slightly. If the engine is hard to start, use the choke for a short time only.
•
Turn the key in the ignition switch to the start position to activate the electric starter. Repeat until engine starts.
Black plate (83,1)
NOTICE
Do not operate the electric starter continuously for more than 5 seconds, or the starter may overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and for the battery power to recover.
NOTE
○
If the engine is flooded, make sure the choke knob is all the way in. Then crank the engine over with the throttle fully open (throttle pedal fully depressed) until the engine starts.
○
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; KAF400A only) or “ R ” (Reverse) position.
○
If the brake pedal is depressed, it is possible to start in any position.
•
Gradually return the choke knob to the
“
OFF
” position a little at a time as necessary to keep the engine running properly during warm-up.
NOTE
○
If you drive the vehicle before the engine is warmed up, return the choke to the “ OFF ” position as soon as you start moving.
HOW TO OPERATE 83
(for KAF950)
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas.
Operate only in a wellventilated area.
•
Wear the seat belts (both operator and passenger).
•
Apply the parking brake.
•
Shift the gear shift lever in the N (neutral) position.
•
Put the main key in the main switch at the OFF position.
•
Turn the main switch key to the ON position. The glow plug system is designed so that the glow plug light goes on at that time, and turns off after 5 seconds.
•
After the glow plug light turns off, turn the main key to the START position to activate the electric starter leaving the throttle open part away (pressing lightly on the throttle pedal). Repeat until the engine starts.
Black plate (84,1)
84 HOW TO OPERATE
NOTICE
Do not operate the electric starter continuously for more than 5 seconds, or the starter may overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power.
NOTE
○
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) and
“
L
”
(Low) for KAF400A and
KAF950 only or “ F ” (Forward ) for KAF400B or “ R ”
(Reverse) position.
○
When the key is turned to the START position, the glow plug light goes on again, and after the key returns to the ON position, the glow plug light remains lit for about 20 seconds.
•
When the engine starts, release the main switch key, which will return to the ON position.
•
Run the engine at slow idle until the engine idles smoothly (approximately 2 ~ 3 minutes). Avoid unnecessary idling; instead, stop the engine.
NOTICE
Do not operate the engine at full throttle or under load until engine has warmed up or engine damage could occur.
Cold Weather Starting
(for KAF950)
When parking your vehicle overnight, leaving it inside a garage, even if not heated, will make morning starting much easier. Changing to a lighter grade engine oil also makes starting easier under these conditions (consistent with recommended quality and viscosity).
If the ambient temperature is -10°C or lower, use this special starting procedure.
•
Turn the main switch to the ON position, lighting the glow plug light.
•
When the glow plug light turns OFF, turn OFF the main switch, then turn it back ON again.
•
Repeat this 2 or 3 times to thoroughly preheat the combustion chambers.
•
Finally, crank the engine to start it.
Starting After Fuel System Service
(for KAF950)
Air bleeding of the fuel system may be required before engine starting if air was introduced into the fuel system during maintenance. (Fuel filter draining/replacement, repairs, etc.)
To bleed out the air: •
Loosen the air vent plug on top of the fuel filter. (It has a 10 mm wrench head. It is not necessary to remove the air vent plug.)
•
Repeatedly depress the priming pump button on top of the fuel filter bracket until fuel flows from loosened air vent plug.
•
Tighten the air vent plug bolt using a 10 mm
• wrench.
•
Wipe up any spilled diesel fuel.
Follow normal starting procedures.
A. Fuel Filter
B. Air Vent Plug
C. Priming Pump
Black plate (85,1)
HOW TO OPERATE 85
Black plate (86,1)
86 HOW TO OPERATE
Jump Starting
If your vehicle battery is "run down," it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine.
DANGER
Battery acid generates hydrogen gas which is flammable and explosive under certain conditions. It is present within a battery at all times, even in a discharged condition. Keep all flames and sparks (cigarettes) away from the battery. Wear eye protection glasses when working with a battery. In the event of battery acid contact with skin, eyes, or clothing, wash the affected areas immediately with water for at least five minutes. Seek medical attention.
Connecting Jumper Cables
•
Make sure the ignition switch is turned to "OFF"
(for KAF400) or the main switch for KAF950.
•
Remove the battery cap for KAF950.
(for KAF950)
A. Battery
B. Cap Cover
•
Connect a jumper cable from the positive (+) terminal of the booster battery to the positive (+) terminal of the vehicle battery.
(for KAF400)
Black plate (87,1)
HOW TO OPERATE 87
A. Vehicle Battery Positive (+) Terminal
B. From Booster Battery Positive (+) Terminal
C. Unpainted Metal Surface
D. From Booster Battery Negative (
–
) Terminal
A. Battery
B. Vehicle Battery Positive (+) Terminal
C. From Booster Battery Positive (+) Terminal
D. Unpainted Metal Surface
E. From Booster Battery Negative (
–
) Terminal
•
Connect another jumper cable from the negative
(
–
) terminal of the booster battery to an unpainted metal surface on your vehicle. Do not use the negative (
–
) terminal of the battery.
Black plate (88,1)
88 HOW TO OPERATE
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 carburetor or battery. Take care not to touch the positive and negative cables together, and do not lean over the battery when making this last connection. Do not connect to a frozen battery. It could explode.
Do not reverse polarity by connecting positive (+) to negative ( – ), or a battery explosion and serious damage to the electrical system may occur.
•
Follow the standard engine starting procedure.
NOTICE
Do not operate the starter continuously for more than 5 seconds, or the starter overheat and the battery power will drop temporarily.
Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power.
•
After the engine starts, disconnect the jumper cables. Disconnect the negative ( – ) cable from the vehicle first.
•
Reinstall the battery cap for KAF950.
Moving Off
•
•
Depress the brake pedal.
Put the gear shift lever into the "H" (High) or "L"
(Low KAF400A & KAF950) position or “ F ” (For-
• ward) position for KAF400B.
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.
Black plate (89,1)
Braking
NOTE
○
When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking. This is caused by the vehicle's automatic transmission which releases the engine at very low speed to prevent it from stalling. Employ the brakes to control the vehicle's
• speed.
•
Release the throttle pedal completely.
Press on the brake pedal evenly and firmly.
WARNING
Carrying cargo or towing a trailer will increase braking distances. Failure to allow for increased braking distance may result in accident and injury. Always allow more distance to stop when carrying cargo or towing a trailer.
HOW TO OPERATE 89
Stopping the Engine
•
Release the throttle pedal completely.
•
Put the gear shift lever into the "N" (Neutral) position.
•
Apply the parking brake to help prevent the vehicle from rolling.
•
Turn the ignition switch key to the "OFF" position.
Black plate (90,1)
90 HOW TO OPERATE
Parking the Mule
•
Stop the vehicle on a level surface.
NOTICE
Avoid parking on steeply inclined surfaces.
•
When the engine has stopped, apply the parking brake to help prevent the vehicle from rolling.
(for KAF950)
(for KAF400)
A. Parking Brake Lever
A. Parking Brake Lever
WARNING
If the vehicle should move after it is parked, it might be damaged or cause injury. Be sure to apply the parking brake before leaving the vehicle.
•
Remove the ignition switch key to prevent unauthorized use (or main switch for KAF950).
•
When parking inside a garage or other structure, be sure the structure is well ventilated and the vehicle is not close to any source of flame or sparks.
This includes any appliance with a pilot light.
(for KAF400)
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch “ OFF ” . Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Never fill the tank completely to the top. If the tank is filled completely to the top, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.
(for KAF950)
WARNING
Diesel fuel is flammable and can ignite under certain conditions.
•
Hi-Lo Shifting
(for KAF400A & 950)
Shifting to Low Range
Black plate (91,1)
HOW TO OPERATE 91
Stop the vehicle completely.
•
For easy Hi-Lo shifting, put the gear shift lever in neutral.
•
Move the shift lever "L" (Low) position.
A. Gear Shift Lever
B. "H" (High) Position
C. "L" (Low) Position
D. "N" (Neutral) Position
E. "R" (Reverse) Position
•
Shifting to High Range
Stop the vehicle completely.
•
Put the gear shift lever in neutral.
•
Move the shift lever "H" (High) position.
Black plate (92,1)
92 HOW TO OPERATE
NOTE
○
Before shifting make certain that the vehicle is completely stopped. The Hi-Lo shift lever cannot be shifted when the vehicle is in motion.
(for KAF950)
NOTICE
Exceeding maximum downhill speed can cause transmission belt slippage, and excessive belt wear, damage or failure.
DO NOT EXCEED MAXIMUM DOWNHILL
SPEED:
Low range – 19 km/h
High range – 40 km/h
Reversing Gears
•
Release the throttle pedal, and stop the vehicle.
•
When you want to operate the vehicle in reverse, stop the vehicle completely, allowing the engine to slow to idling speed, and move the gear shift lever to the "R" (Reverse) position.
NOTICE
Do not shift from
“
H
”
(High) or
“
L
”
(Low) to
“ R ” (Reverse) and vice versa for KAF400A &
KAF950 only or
“
F
”
(Forward) to
“
R
”
(Reverse) and vice versa for KAF400B when the vehicle is moving or with the engine running above idling speed, or the transmission could be damaged.
2WD-4WD Shifting
(KAF400A & 950)
•
Pull the stopper under the 2WD-4WD shift lever knob and while holding it against the knob, move the shift lever to the all way down "4WD".
•
To shift back into "2WD" position, pull and hold the stopper, then move the shift lever all the way up "2WD".
NOTE
○
When the shift lever is moved from "2WD" to
"4WD", the transmission shifts immediately. When the shift lever is moved from "4WD" to "2WD", the transmission may not shift all the way into "2WD" until the vehicle has rolled a short distance.
A. 2WD-4WD Shift Lever
B. Stopper
C. "2WD" Position
D. "4WD" Position
Black plate (93,1)
HOW TO OPERATE 93
Black plate (94,1)
94 HOW TO OPERATE
Shifting the Differential
NOTE
○
Do not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph).
Shifting to Locked-Axle Mode
•
Pull the stopper under the differential shift lever knob and while holding it against the knob, move the shift lever all the way down (LOCK).
Shifting to Differential (Unlocked-Axle) Model
•
Pull and hold the stopper, then move the shift lever all the way up (UN-LOCK).
NOTE
○
When the shift lever is moved, the differential may not immediately lock or unlock until the vehicle has rolled a short distance.
A. Differential Shift Lever
B. Stopper
C. Differential (Unlocked-Axle) Mode Position (UN-
LOCK)
D. Locked-Axle Mode Position (LOCK)
Black plate (95,1)
Converting Rear Seat and Cargo Bed
(for KAF950G)
This vehicle can be converted to accommodate more passengers and less cargo or fewer passengers and more cargo.
WARNING
If passengers ride in the cargo bed, they could be tossed about or thrown from the vehicle, causing serious injury or death. Never carry passengers in the cargo bed. Tilting the cargo bed when it is loaded may cause the vehicle to tip over backwards, causing serious injury or death. Never tilt the cargo bed when it is loaded. Driving with the cargo bed tilted may be hazardous. Always lower and latch the bed before driving.
The seats and the cargo bed can be converted in the following way.
HOW TO OPERATE 95
From 4-person to 2-person
1. Pull the rear seat stopper pin on the left side.
A. Stopper pin
B. Rear Seat
96 HOW TO OPERATE
2. Push the rear seat back forward.
3. Release the latches on both sides.
Black plate (96,1)
4. Push the rear seat assembly forward into the stored position.
A. Latch
B. Rear Seat Back (lowered position)
A. Rear Seat (Stored position)
B. Front Seat Back
Black plate (97,1)
5. Swing open the cargo bed side plates and fasten the latches on the both sides.
HOW TO OPERATE 97
6. Slide the stopper pins towards inside at the bottom of the removable screen.
A. Cargo Bed Side Plates
B. Latch
A. Stopper Pin
B. Screen
98 HOW TO OPERATE
7. Pull and remove the screen from the sockets, move forward and insert into the sockets at the end of the side plates.
A. Screen
B. Sockets
8. Latch the stopper pins at the bottom of the screen.
From 2-person to 4-person Mode
•
Reverse the procedure for 4-person to 2-person mode conversion.
NOTE
○
When folding the cargo bed end side plates, be sure to insert the end projections into the counterparts on the screen.
A. Projections
B. Cargo Bed Side Plate (folded)
Black plate (98,1)
Raising & Lowering the Cargo Bed
(for KAF950G)
WARNING
Reduced clearance between cargo bed and cab frame can cause hand injury. Do not hold cab frame in the location of the label when raising or lowering the cargo bed.
Raising the cargo bed (Shortened Condition) :
1. Pull the rear seat stopper pin on the left side.
Black plate (99,1)
HOW TO OPERATE 99
2. Push the rear seat back forward.
3. Release the latches on both sides.
A. Latch
B. Rear Seat Back (lowered position)
A. Stopper pin
B. Rear Seat
Black plate (100,1)
100 HOW TO OPERATE
4. Push the rear seat assembly forward into the stored position.
5. Holding the hand grip and cargo bed top, raise the cargo bed.
A. Rear Seat (Stored position)
B. Front Seat Back
A. Handgrip
B. Hold here.
Black plate (101,1)
6. Support the bed in the tilted position with the supporting rod.
HOW TO OPERATE 101
Raising the cargo bed (Extended Condition):
1. Release the side latches.
A. Supporting Rod
B. Cargo Bed (Raised Position )
NOTE
○
To lower the cargo bed, follow the reverse procedure for raising. Be sure to restore the seat as before and put the latches on. Never drive the Mule without putting the latches to the cargo bed.
A. Latch
B. Rear Seat (Stored position)
2. Holding the handgrip and cargo bed on the top edge, raise the cargo bed.
3. Support the bed in the tilted position with the supporting rod.
NOTE
○
To lower the cargo bed, follow the reverse procedure for raising. Be sure to attach the latches to the cargo bed.
102 HOW TO OPERATE
WARNING
The cargo bed becomes heavier in the extended mode. Pay attention when raising or lowering the cargo bed not to injure your hand.
Black plate (102,1)
Black plate (103,1)
SAFE OPERATION 103
SAFE OPERATION
Safety is an attitude. Your common sense and good judgement are your best defenses against accident and injury in everything you do. Your safety and the safety of others depends on you and your common sense. Use good judgement in the operation of this or any other motor vehicle.
(for KAF400 & 950F)
This vehicle is designed for an operator and one passenger only. Never carry persons in the cargo bed. Refer to the "Loading Information" chapter before operating this vehicle.
(for KAF950G)
This vehicle is designed for an operator and one passenger (for 2-person mode) or an operator and three passengers (for 4-person mode). Never carry persons in the cargo bed. Refer to the “ Loading Information
” chapter before operating this vehicle.
Novice operators should practice braking and turning in an open, off-highway area away from other vehicles and persons. The terrain should be flat and free of obstacles, with either a loose or hard dirt surface, but not a mixture of both.
WARNING
Incorrect loading, improper installation or use of accessories, or modification of your vehicle may result in an unsafe operating condition. Before operation, make sure that the vehicle is not overloaded and that you have followed the instructions in the "LOADING IN-
FORMATION" chapter.
Black plate (104,1)
104 SAFE OPERATION
Unfamiliar Terrain
Before driving in a new area be sure to check for hidden obstacles or hazards. Keep your speed down until you know the area well. You must know the terrain you intend to drive on and be familiar with your machine and its handling characteristics. Use existing trails and stay away from hazardous areas such as steep, rocky slopes or swamps. Be cautious when visibility is limited, as you may not be able to see obstacles in your path.
Driving in Reverse
Start the engine following the procedure in the
"Starting the Engine" section. Before shifting into reverse, stop the vehicle completely. Refer to the Gear
Shift Lever in the "Shift Levers" section and "Reversing Gears" section.
Turn around and look behind you before backing up to be sure there are no obstacles or people in your way. Gradually open the throttle and begin backing up cautiously.
To stop while driving in reverse, close the throttle and gradually apply the brake. Avoid sudden application of the brake.
NOTICE
Do not operate the gear shift lever to change gears while driving the vehicle in reverse, or the transmission may be damaged.
Remember:
○
Look behind you before backing up.
Open the throttle gradually.
To stop, gradually apply the brake.
Black plate (105,1)
Driving in "4WD"
(for KAF400A & 950)
"4WD" gives greater traction when you are climbing steep inclines, or driving on bumpy, sandy or snowy surfaces. It also helps break loose, with the differential locked under certain circumstances, for example, when the vehicle is stuck in the mud. If maximum torque is needed in these situations, shift into the low position with the shift lever. Refer to the
"Shift Levers" section and "2WD-4WD Shifting,"
"Shifting the Differential," and "Hi-Lo Shifting" sections.
NOTE
○
Do not drive in "4WD" on paved surfaces, because it increases tire and drive train wear and makes the steering feel tight.
Remember:
○
Use "4WD" on steep inclines or loose surfaces, or when stuck in the mud, with the differential locked
○ if necessary.
For maximum torque shift into low range.
Do not drive in "4WD" on paved surfaces.
SAFE OPERATION 105
Turning the Vehicle
The vehicle will turn in a smaller radius with the differential unlocked (in differential mode). In this mode, the rear wheels can turn at different speeds allowing the vehicle to turn tighter and more smoothly. Even in this mode, however, avoid sharp turns to keep the vehicle from tipping. Reduce vehicle speed before entering the turn and use the throttle to maintain an even speed through the turn.
WARNING
In the differential mode, if either rear wheel leaves the ground it will spin freely, and the wheel on the ground will transmit very little power. When a spinning wheel touches the ground, it may grab abruptly, causing the operator to lose control. Do not make sharp turns, even in the differential mode, in order to avoid loss of control or tipping.
Remember:
○
Slow down before entering the turn.
Maintain an even speed through the turn.
Black plate (106,1)
106 SAFE OPERATION
Hills
As with any motor vehicle, loading of the vehicle, and the surface and steepness of the hill are among the critical considerations in climbing, descending or traversing hills. Use extreme caution on hills. Keep in mind that loading changes a vehicle's center of gravity and that the higher the center of gravity, the more likely the vehicle is to tip on uneven surfaces.
Slippery, loose, or bumpy surfaces on hills are especially hazardous. Some hills are just too steep to climb. Always use common sense and practice good judgement.
Climbing Hills
Do not attempt to climb hills or steep inclines until you have mastered the controls and basic operating maneuvers of this vehicle. Always go straight uphill and, if the incline is steep and/or the surface is loose, use "4WD" (for KAF400A & KAF950) with the differential locked for greater traction, and in low range for maximum torque.
Avoid hills with slippery sides that will cause you to lose traction. Do not climb hills where you cannot see far enough ahead. If you cannot see what is on the other side of the crest of a hill, slow down until you can get a clear view. Don't apply power suddenly while climbing, or the front wheels might rise off the ground. If the vehicle does not have enough power to reach the top of the hill and stalls, allow the vehicle to roll slowly straight back down the hill controlling its descent with the brakes. Leave the gear shift lever in the
“
H
”
(High) and
“
L
”
(Low) position for KAF400A and KAF950 only or “ F ” (Forward) position for KAF400B 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.
Black plate (107,1)
○
Never ride past your limit of visibility. If you can't see what is on the other side of the crest of a hill,
○ slow down until you can get a clear view.
Don't turn sideways to the hill.
○
If you get stuck on a hill, roll slowly straight back down, using the brake, with the gear shift lever left in the “ H ” (High) and “ L ” (Low) position for KA-
F400A and KAF950 only or
“
F
”
(Forward) position for KAF400B.
NOTE
○
When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking. This is caused by the vehicle's automatic transmission which releases the engine at very low speed to prevent it from stalling. Use the brakes to control the vehicle's speed.
SAFE OPERATION 107
Descending Hills
Slow down or stop at the top of a hill so you can pick a straight, safe path for descent to avoid any obstacles. Normally you should descend straight down a hill since driving at an angle could cause the vehicle to lean to one side and possibly tip over.
Proceed slowly and cautiously. Apply the brake as necessary. Be careful if the surface is loose because the tires are more likely to skid and braking effectiveness will be reduced.
Turning while descending a slope must be done very carefully and gradually to avoid tipping the vehicle over.
WARNING
Riding sideways across a hill may cause the vehicle to overturn, causing severe injury or death. Do not turn sideways to the hill.
Remember:
○
Stop and look for obstacles before descending a
○ hill.
Go straight downhill.
Go slowly.
If you must turn, do so carefully and gradually.
NOTE
○
When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking. This is caused by the
Black plate (108,1)
108 SAFE OPERATION vehicle's automatic transmission which releases the engine at very low speed to prevent it from stalling. Use the brakes to control the vehicle's speed.
(for KAF950)
NOTICE
Exceeding maximum downhill speed can cause transmission belt slippage, and excessive belt wear, damage or failure.
DO NOT EXCEED MAXIMUM DOWNHILL
SPEED:
Low range - 19 km/h
High range - 40 km/h
Traversing Hillsides
When driving across the side of a hill, reduce vehicle speed and exercise extreme caution to prevent tipping or loss of control. Avoid hills with slippery sides that will cause you to lose traction. Also avoid traversing hillsides covered with rocks or other obstacles which may cause you to lose your balance or tip over.
When driving on soft terrain, steer slightly uphill to keep the vehicle on a straight line across the hillside.
If the vehicle begins to tip, steer downhill if possible to regain control.
Black plate (109,1)
Sliding and Skidding
Obviously, on slippery or loose surfaces, special care is required. Sliding any vehicle may be hazardous because the wheels may suddenly regain traction and cause the vehicle to tip or overturn.
Therefore, never drive "beyond your abilities" or when you are unsure or unprepared for the surface.
Often you can correct a skid by turning the wheels in the direction of the skid. Do not apply heavy braking force or accelerate when skidding, since this may cause further loss of control.
Use caution and maintain low speeds to avoid uncontrolled skidding on areas covered with clay, mud, ice, or snow. Use "4WD" and low range gearing efficiently (for KAF400A & KAF950). These conditions are particularly hazardous when descending a hill or making a turn. Remember that this vehicle is not for use on public streets, roads, or highways.
Remember:
○
Be especially careful on very slippery surfaces.
Don't drive on public streets, roads, or highways.
SAFE OPERATION 109
Driving through Water
Avoid driving through water whenever it is possible. When driving across shallow water, choose a location to enter and exit the water where the banks are not too steep or slippery. Check before entering for rocks, holes or other obstacles which may cause you to overturn or become stuck or submerged.
Observe the following rules for operating the vehicle in water.
A. Axle Cap
110 SAFE OPERATION
WARNING
Operating the vehicle in rivers or streams where water is flowing quickly can cause the tires to lose traction and allow the vehicle to be swept into the current. Never operate the vehicle in fast-flowing water or in water deeper than the bottom edge of the axle caps.
After prolonged exposure to water, the wheel bearings may require relubrication or replacement.
Wash the vehicle in fresh water if it has been exposed to salt water or operated in muddy conditions.
WARNING
Wet brakes provide greatly reduced efficiency and could lead to an accident and injury. After operation in water, always apply the brakes long enough for friction to dry the linings. Also, the brake that gets wet may wear out faster. Check for brake wear more frequently if the vehicle is used in water.
Remember:
○
Avoid driving through water whenever possible.
Don't drive in deep and fast moving water.
Dry out the brakes.
Black plate (110,1)
Black plate (111,1)
NOISE AND VIBRATION CONTROL INFORMATION 111
NOISE AND VIBRATION CONTROL INFORMATION
Control Information
Noise Level
Acceleration
Driver's Ear
Vibration Level
Steering Wheel
Seat
Seat Back dB (A) dB (A) m/S² m/S² m/S²
NOTE
○
Noise and vibration levels of your MULE are shown in your English OM, titled
“
NOISE AND VI-
BRATION CONTROL INFORMATION ” . Refer to the relevant page and copy those data values into the space provided in this page.
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.
Black plate (112,1)
112 MAINTENANCE AND ADJUSTMENT
MAINTENANCE AND ADJUSTMENT
The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the Mule in good running condition.
The initial maintenance is vitally important and must not be neglected.
If you are in doubt as to any adjustment or vehicle operation, please ask your authorized kawasaki dealer to check the Mule.
Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect maintenance or improper adjustment done by the owner.
Black plate (113,1)
MAINTENANCE AND ADJUSTMENT 113
Periodic Maintenance Chart
(for KAF400)
In addition to the following items, always perform the Daily Safety Checks listed in the HOW TO OPERATE chapter.
•
= Clean, adjust, lubricate, replace parts as necessary.
D = Service to be performed by an authorized Kawasaki Dealer.
* = Service more frequently when operated in mud, dust, or other harsh riding conditions.
FREQUENCY
First Service Regular Service Whenever comes first
OPERATION
Every
After 50 hrs. or
1 000 km of use
Every 250 hrs.
or 5 000 km of use
Every 500 hrs.
or 10 000 km of use
ENGINE
Converter belt - check*
Converter driven pulley shoe - check*
Converter air cleaner element - clean*
Converter dust or water - drain*
Fuel filter - change*
Fuel system cleanliness - check*
Air cleaner element - clean*
Spark plug - clean and gap
Valve clearance - check
Engine oil - change* 1 year
•
•
•
D
D
•
•
•
•
D
D
•
•
•
Black plate (114,1)
114 MAINTENANCE AND ADJUSTMENT
OPERATION
Oil filter - replace*
Throttle pedal play - check
Idle speed - adjust
Spark arrester - clean
Fuel hose - replace
Fuel hoses and connections- check
CHASSIS
Steering - check
Steering and axle shaft joint dust boots check
Brake pedal play - check*
Parking brake lever - check
Brake hose and pipe - check
Brake fluid level - check
Brake wear - check*
Tire wear - check*
Brake light switch - check
Battery - check*
Whenever comes first
Every
D
•
D
•
•
•
•
•
FREQUENCY
First Service Regular Service
After 50 hrs. or
1 000 km of use
Every 250 hrs.
or 5 000 km of use
•
•
• •
•
4 years (D)
D D
Every 500 hrs.
or 10 000 km of use
•
•
•
D
•
•
•
D
•
D
•
•
Black plate (115,1)
OPERATION
Seat belt - check
General lubrication - perform*
Bolts, nuts, and fasteners tightness check
Wheel nuts tightness - check
Front final gear case oil and transmission case oil - change*
Brake fluid - change
Brake master cylinder cup and dust seal
- replace
Brake wheel cylinder assembly -replace
Brake hose - replace
Whenever comes first
Every
1 year
MAINTENANCE AND ADJUSTMENT 115
FREQUENCY
First Service Regular Service
After 50 hrs. or
1 000 km of use
Every 250 hrs.
or 5 000 km of use
D
•
Every 500 hrs.
or 10 000 km of use
•
•
D
2 years (D)
D
•
2 years (D)
•
2 years (D)
4 years (D)
Black plate (116,1)
116 MAINTENANCE AND ADJUSTMENT
(for KAF950)
In addition to the following items, always perform the Daily Safety Checks listed in the HOW TO OPERATE chapter.
•
= Clean, adjust, lubricate, replace parts as necessary.
D = Service to be performed by an authorized Kawasaki Dealer.
* = Service more frequently when operated in mud, dust, or other harsh riding conditions.
OPERATION
Whenever comes first
Every
FREQUENCY
First Service
After 50 hrs. or 1
000 km of use
Regular Service
Every 100 hrs. or 2
000 km of use
Every 250 hrs. or 5
000 km of use
Every 500 hrs. or 10
000 km of use
Every
800 hrs. or
16 000 km of use
ENGINE
Converter belt - check*
Converter drive belt deflection
-inspect*
Converter driven pulley shoe check*
Converter air cleaner element clean*
Valve clearance - check
Engine oil - change*
Oil filter - replace
Throttle pedal play - check
Idle speed - adjust
1 year
•
•
•
•
•
•
D
D
•
•
•
D
D
•
Black plate (117,1)
OPERATION
Fuel hose - replace
Fuel filter element - change*
Fuel filter water - drain*
Fuel hoses and connections check *
Spark arrester - clean
Radiator - clean*
Radiator hoses and connections - check*
Coolant - change
Cooling fan belt - check
CHASSIS
Steering - check
Steering joint dust boots check
Brake pedal play - check*
Brake fluid level - check
Parking brake lever - check
Whenever comes first
Every
1 year
2 years (D)
MAINTENANCE AND ADJUSTMENT 117
FREQUENCY
First Service
After 50 hrs. or 1
000 km of use
•
D
D
Regular Service
Every 100 hrs. or 2
000 km of use
Every 250 hrs. or 5
000 km of use
Every 500 hrs. or 10
000 km of use
Every
800 hrs. or
16 000 km of use
4 years (D)
•
•
D
•
•
D
•
•
•
•
D
D
D
•
•
•
•
Black plate (118,1)
118 MAINTENANCE AND ADJUSTMENT
OPERATION
Brake hose and pipe - check
Brake wear - check*
Tire wear - check*
Battery - check
Brake light switch - check
Seat belt - check
General lubrication - perform*
Bolts, nuts, and fasteners tightness - check
Wheel nuts tightness - check
Front final gear case oil and transmission case oil - change*
Brake fluid - change
Brake master cylinder cup and dust seal - replace
Brake wheel cylinder assembly
- replace
Brake hose - replace
Whenever comes first
Every
1 year
FREQUENCY
First Service
After 50 hrs. or 1
000 km of use
D
•
•
Regular Service
Every 100 hrs. or 2
000 km of use
Every 250 hrs. or 5
000 km of use
Every 500 hrs. or 10
000 km of use
Every
800 hrs. or
16 000 km of use
D
•
•
D
•
D
•
D
•
•
D
•
•
2 years (D)
2 years (D)
2 years (D)
4 years (D)
Black plate (119,1)
Engine Oil
In order for the engine to function properly, maintain the engine oil at the proper level, and change the oil and oil filter in accordance with the Periodic
Maintenance Chart. Not only do dirt and metal particles collect in the oil, but the oil itself loses its lubricative quality if used too long.
WARNING
Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart in the owner
’ s manual.
Oil Level Inspection
•
If the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes until the oil settles.
NOTICE
Racing the engine before the oil reaches every part can cause engine damage.
•
If the vehicle has just been used, wait several minutes for all the oil to drain down.
MAINTENANCE AND ADJUSTMENT 119
•
Park the vehicle on level ground.
•
Pull up on the rear edge of the seat.
(for KAF400)
A. Dipstick & Oil Filler Hole
B. Seatback
•
Pull up the dipstick, wipe it dry, and insert it into the tube securely.
NOTE
○
It is important to insert the dipstick with its chamfered cap edge rearwards.
Black plate (120,1)
120 MAINTENANCE AND ADJUSTMENT
A. Dipstick
B. Oil Filler Hole
•
Pull out the dipstick and check the oil level. The oil level should be between the “ F ” (Full) and “ L ”
(Low) lines on the dipstick.
•
Reinsert the dipstick until its cap bottom touches the oil filler hole top.
A. Dipstick
B.
“
H
”
(High) Line
C.
“
L
”
(Low) Line
•
If the oil level is too high, remove the excess oil, using a syringe or other suitable device.
•
If the oil level is too low, unscrew the oil filler cap and add the correct amount of oil. Use the same type and brand of oil that is already in the engine.
•
Instal the dipstick
(for KAF950)
•
Pull the dipstick out of the dipstick tube, wipe it dry, and insert it into the tube securely.
Black plate (121,1)
MAINTENANCE AND ADJUSTMENT 121
A. Dipstick
•
Pull out the dipstick and check the oil level. The oil level should be between the F (full) and L (low) holes on the dipstick.
NOTICE
To avoid the engine damage, do not fill the engine oil above the full level.
NOTE
○
Insert dipstick into tube holding its tip as far as possible so that it will not bend.
A. Dipstick
B. F (Full) Hole
C. L (Low) Hole
•
If the oil level is too high, remove the excess oil, using a syringe or other suitable device through the dipstick tube.
•
If the oil level is too low, unscrew the oil filler cap and add slowly the correct amount of oil. Use the same type and brand of oil that is already in the engine.
(for KAF950G only)
NOTE
○
If the vehicle is in 2-person mode, first raise the cargo bed, support with the rod and pull the stored rear seat and place it onto the engine.
Black plate (122,1)
122 MAINTENANCE AND ADJUSTMENT
A. Rear Seat (Folded)
B. Dipstick
(for KAF400)
Oil and/or Oil Filter Change
•
Warm up the engine thoroughly, and then stop the engine.
•
Place an oil pan beneath the engine.
•
Remove the drain plug. on the right side at the bottom of the engine.
•
Remove the dipstick.
A. Drain Plug
B. Torque Converter Case
•
When the vehicle held level, let the oil drain completely.
WARNING
Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
•
If the oil filter is to be changed, first lift the cargo bed to support it with the rod, and then remove the oil filter cartridge and replace it with a new one.
Black plate (123,1)
MAINTENANCE AND ADJUSTMENT 123
A. Cartridge
•
Apply a thin film of oil to the packing and screw the cartridge in until the packing touches the engine, then turn it 3/4 turn.
A. Gasket
•
Install the drain plug with its gasket. Tighten it to the specified torque.
NOTE
○
Replace any damaged gaskets with new ones.
•
Fill the engine up to the "F" (Full) line on the dipstick with good quality motor oil as specified in the table.
•
Start the engine and check for oil leakage.
Tightening Torque
Drain Plug: 6.9 N·m (61 kgf·m)
Cartridge: 9.8 N·m (1 kgf·m)
Black plate (124,1)
124 MAINTENANCE AND ADJUSTMENT
Recommended Engine Oil
Grade: API SG, SH, SJ, SL or SM with JASO
MA, MA1 or MA2
Viscosity: SAE 10W-40
NOTE
○
Do not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch.
Engine Oil Capacity when filter is not removed when filter is removed
0.85 L
1.4 L
Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.
(for KAF950)
Oil and/or Oil Filter Change
When changing or adding oil, use the chart shown in the following pages to select the correct viscosity grade for the temperature expected.
•
Warm up the engine thoroughly, and then stop the
• engine.
•
Place an oil pan beneath the engine.
Remove the drain plug.
Black plate (125,1)
MAINTENANCE AND ADJUSTMENT 125
A. Drain Plug
•
Let the oil drain completely.
WARNING
Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
•
If the oil filter is to be changed, remove the oil filter cartridge from the lower side of the engine and replace it with a new one.
A. Cartridge
•
Apply a thin film of oil to the packing and screw the cartridge in until the gasket touches the engine, then tighten it one more turn.
•
Install the drain plug with new gasket. Tighten it to the specified torque.
Tightening Torque
Drain Plug: 34 N·m (3.5 kgf·m)
(for KAF950G only)
NOTE
○
In 4-person mode, first fold the rear seat and push its assembly into the stored position, and then raise the cargo bed and support it with the rod.
○
In 2-person mode, raise the cargo bed and support it with the rod.
Black plate (126,1)
126 MAINTENANCE AND ADJUSTMENT
A. Gasket
•
Fill the engine up to the F (full) hole on the dipstick with good quality engine oil as specified in the following table.
•
Start the engine and check for oil leakage.
NOTE
○
When filling oil to the filler hole in the cylinder head cover, provide the following measures to allow the air in the crankcase to escape.
1. Pull the engine oil dipstick out a little. (about 5 cm).
2. Raise the filling funnel a little from the cylinder head.
A. Dipstick tube
B. about 5 cm or 2 inches
C. Funnel
NOTE
○
Park the vehicle on a level surface and fill engine oil slowly and evenly up to the specified level. DO
NOT OVERFILL.
Black plate (127,1)
NOTICE
If the oil level in the cylinder head cover gets too high because of filling too fast or filling too much (overfilling), oil may overflow from the filler hole and/or may flow through the crankcase ventilation tube into the intake manifold. Oil in the intake manifold may flow into the combustion chambers and cause hydraulic lock, resulting in severe engine damage.
Recommended Engine Oil
Grade: API CF or CF-4 class
Viscosity: SAE 10W
–
40
Depending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed according to the following chart:
MAINTENANCE AND ADJUSTMENT 127
STARTING TEMPERATURE RANGE ANTICI-
PATED BEFORE NEXT OIL CHANGE
Engine Oil Capacity
When filter is not removed
When filter is removed
3.0 L
3.3 L
128 MAINTENANCE AND ADJUSTMENT
Front Final Gear Case Oil
(for KAF400A & 950)
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, deteriorated, or contaminated oil causes accelerated wear of the differential, pinion, and ring gears and may result in seizure. Seizure can lock the front and rear wheels and skid the front and rear tires, with consequent loss of control. Check the differential oil according to the periodic maintenance chart.
Oil Level Inspection
•
Remove the front final gear case guard by removing the mounting bolts and nuts.
(for KAF950)
A. Guard
B. Nuts
Black plate (128,1)
Black plate (129,1)
MAINTENANCE AND ADJUSTMENT 129
(for KAF950)
A. Bolts
•
With the vehicle level front-to-rear and side-toside, remove the filler cap from the front final gear case.
A. Front Final Gear Case
B. Filler Cap
130 MAINTENANCE AND ADJUSTMENT
(for KAF400A) (For KAF950)
Black plate (130,1)
A. Front Final Gear Case
B. Filler Cap (on the left side)
C. Front Axle
NOTICE
Be careful not to allow any dirt or foreign materials to enter the gear case.
•
Check the oil level. The oil level should come to the bottom thread of the filler opening. If it is low, add oil through the oil filler opening as necessary.
A. Front Final Gear Case
B. Filler Opening
C. Bottom Thread
D. Drain Plug
Black plate (131,1)
MAINTENANCE AND ADJUSTMENT 131
(for KAF400A)
A. Front Final Gear Case
B. Filler Opening
C. Bottom Thread
A. Front Final Gear Case
B. Drain Plug
•
Install the filler cap.
Tightening Torque
Filler Cap: N·m ( kgf·m)
NOTE
○
Use the same type and brand of oil that is already in the gear case.
Oil Change
NOTE
○
Before draining the oil, warm it up by running the vehicle. Warm oil drains easily and picks up any sediment.
Black plate (132,1)
132 MAINTENANCE AND ADJUSTMENT
•
Remove the front final gear case guard.
•
With the vehicle level, place an oil pan beneath the gear case.
•
Remove the filler cap and drain plug.
WARNING
Gear case oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
WARNING
Oil on tires can make them slippery which can cause an accident and injury. When 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 soap and water.
•
After the oil has completely drained out, install the drain plug and gasket. If the gasket is damaged, replace it with a new one.
Tightening Torque
Drain Plug: N·m ( kgf·m)
•
Fill the gear case up to the bottom thread of the filler opening with a good quality oil as specified in the table.
Front Final Gear Case Oil
Oil Capacity about mL
Oil Type
API "GL-5" or API "GL-6"
Hypoid gear oil for Limited Slip Differentials, SAE 85W-140, SAE90 or
SAE140
•
Install the filler cap and gear case guard.
NOTE
○
Tightening torque values for filler cap and drain plug are shown in your English OM, titled
“
Front
Final Gear Case Oil ” section of “ MAINTENANCE
AND ADJUSTMENT
” chapter. Refer to the relevant page and copy those data values into the space provided in this page.
Black plate (133,1)
MAINTENANCE AND ADJUSTMENT 133
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, deteriorated, or contaminated oil causes accelerated wear of the transmission, differential, pinion, and ring gears and may result in seizure.
Seizure can lock the rear wheels and skid the rear tires, with consequent loss of control.
Check the differential oil according to the periodic maintenance chart.
•
Oil Level Inspection
Park the vehicle on level ground.
•
Lift the cargo bed and support it with the rod.
•
Unscrew the oil filler plug, wipe its dipstick dry, and insert it into the filler hole but DO NOT
SCREW IT IN.
A. Transmission Case
B. Oil Filler Plug
NOTICE
Be careful not to allow any dirt or foreign materials to enter the transmission case.
•
Pull out the dipstick and check the oil level. The oil level should be between the "H" (High) and "L"
(Low) lines on the dipstick.
Black plate (134,1)
134 MAINTENANCE AND ADJUSTMENT
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.
•
Remove the drain plug.
(for KAF950)
A. Dipstick
B. "H" (High) Line
C. "L" (Low) Line
•
If the oil level is too high, remove the excess oil, using a syringe or other suitable device, through the oil filler opening.
•
If the oil level is too low, add the correct amount of oil.
•
Install the filler plug.
NOTE
○
Use the same type and brand of oil that is already in the transmission case.
A. Transmission Case
B. Drain Plug
(for KAF400)
A. Transmission Case
B. Drain Plug
C. Guard Plate
WARNING
The exhaust system can get extremely hot during normal operation and cause serious burns. To avoid a serious burn, never touch a hot muffler or exhaust pipe during oil draining.
•
Lift the cargo bed and support it with the rod.
•
Remove the filler plug.
Black plate (135,1)
MAINTENANCE AND ADJUSTMENT 135
WARNING
Oil on tires can make them slippery which can cause an accident and injury. When 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 out, install the drain plug with its gasket. Tighten it to the specified torque. If the gasket is damaged, replace it with a new one.
•
Fill the transmission case up to the "H" (High) line on the dipstick with a good quality oil as specified in the table.
Tightening Torque
Drain Plug: N·m ( kgf·m)
Transmission Case Oil Type
API "GL-5" Hypoid gear oil above 5°C SAE 90 below 5°C SAE 80
Transmission Case Oil Capacity
L
•
Install the filler plug.
NOTE
○
Tightening torque values for transmission case drain plug and transmission case oil capacity are
Black plate (136,1)
136 MAINTENANCE AND ADJUSTMENT shown in your English OM, titled “ Transmission
Case Oil
” section of
“
MAINTENANCE AND AD-
JUSTMENT ” chapter. Refer to the relevant page and copy those data values into the space provided in this page.
Cooling Fan
(for KAF400)
The engine is cooled by the cooling fan attached to the left side of the engine.
Check and clean the screen for mud and other debris.
WARNING
A spinning fan can cause serious injury. To avoid injury when checking and cleaning the screen, turn off the ignition switch and be sure the fan has stopped turning.
A. Cooling Fan
B. Screen
Black plate (137,1)
MAINTENANCE AND ADJUSTMENT 137
Cooling System
(for KAF950)
WARNING
The cooling system can get extremely hot during normal operation and cause serious burns. Do not touch the radiator when it is hot, nor open the radiator cap. Hot coolant inside will cause severe burns.
Radiator and Cooling Fan
Check and clean the grille, screen and radiator fins for obstruction by insects or mud in accordance with the Periodic Maintenance Chart. In dusty areas, the radiator should be cleaned more frequently than the recommended interval.
WARNING
The cooling fan turns on automatically, even with the ignition switch off. Keep your hands and clothing away from the fan blades at all times.
•
Lift the front cargo hood up. Refer to the "Front
Cargo Compartment" section in the "General Information" chapter.
A. Screen
B. Radiator
•
Clean the screen, and radiator fins of any obstructions with a stream of low-pressure water.
•
If insects or mud can not be completely removed, it should be cleaned by an authorized Kawasaki dealer.
NOTICE
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 accessories in front of the radiator or behind the cooling fan. Interference with the radiator airflow can lead to overheating and consequent engine damage.
Black plate (138,1)
138 MAINTENANCE AND ADJUSTMENT
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% with water and has a freezing point of – 35°C ( –
31°F).
•
Coolant Level Inspection
Situate the vehicle on level ground.
•
Lift the front cargo hood up. Refer to the "Front
Cargo Compartment" section in the "General Information" chapter.
•
Check the coolant level through the coolant level gauge on the reserve tank. The coolant level should be between the "F" (Full) and "L" (Low) marks.
NOTE
○
Check the level when the engine is cold (room or atmospheric temperature).
A. Reserve Tank
B. "F" (Full) Mark
C. "L" (Low) Mark
D. Cap
•
If the amount of coolant is insufficient, unscrew the cap from the reserve tank and add coolant through the filler opening to the "F" (Full) mark. Install the cap.
(for KAF950)
Recommended Coolant Solution
Coolant Mixture Ratio:
Water 50%: Antifreeze 50% (1 : 1)
Recommended Antifreeze:
Permanent type antifreeze (ethylene glycol plus corrosion and rust inhibitor chemicals for castiron engines and aluminum radiators).
Black plate (139,1)
MAINTENANCE AND ADJUSTMENT 139
NOTE
○
In an emergency you can add water alone to the coolant reserve tank, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible.
NOTICE
If coolant must be added often, or the reserve tank completely runs dry, there is probably leakage in the system. Have the cooling system inspected by your authorized Kawasaki dealer.
Coolant Change
Have the coolant changed by an authorized Kawasaki dealer.
Cooling Fan Belt(for KAF950)
The fan belt will loosen and may crack after a period of use. Inspect it in accordance with the Periodic
Maintenance Chart. It may break if operated without maintenance.
Inspection should be done by an authorized Kawasaki dealer.
A. Cooling Fan Belt
B. Cooling Fan
Black plate (140,1)
140 MAINTENANCE AND ADJUSTMENT
Spark Plugs
(for KAF400)
The standard spark plug is shown in the table.
The spark plug should be taken out periodically in accordance with the Periodic Maintenance Chart for cleaning, inspection, and resetting of the plug gap.
Maintenance
If the plug is oily or has carbon built up on it, have it cleaned, preferably in a sand-blasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a wire brush or other suitable tool. Measure the gap with a wire-type thickness gauge, and adjust the gap if incorrect by bending the outer electrode. If the insulator is cracked, replace the plug. Use the standard plug.
A. 0.7~ 0.8 mm (0.028 ~ 0.032 in.)
Spark Plug
Standard Plug
Plug Gap
NGK BPR5ES
0.7~ 0.8 mm
Tightening Torque 17 N·m (1.7 kgf·m)
•
Spark Plug Removal
Raise the seat.
•
Carefully pull the spark plug cap from the spark plug.
Black plate (141,1)
A. Spark Plug Cap
B. Engine Oil Dipstick Cap
•
Unscrew the spark plug.
NOTE
○
When installing the spark plug, fit the plug cap securely onto the spark plug, and pull the cap tightly to make sure that it is properly installed.
MAINTENANCE AND ADJUSTMENT 141
Valve Clearance
Valve and valve seat wear decrease valve clearance, upsetting valve timing.
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 serious engine damage.
Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Maintenance Chart.
Inspection and adjustment should be done by an authorized Kawasaki dealer.
Valve Clearance (EX & IN) : mm
NOTE
○
Valve clearance values are shown in your English
OM titled
“
Valve Clearance
” section of
“
MAINTE-
NANCE AND ADJUSTMENT ” chapter. Refer to the relevant page and copy those values into the space provided in this page.
Black plate (142,1)
142 MAINTENANCE AND ADJUSTMENT
Engine Air Cleaner
A clogged engine air cleaner restricts the engine's air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling.
WARNING
A clogged air cleaner may allow dirt and dust to enter the carburetor and the throttle may stick resulting in a hazardous operating condition. Clean the air filter according to the periodic maintenance chart; more often if the vehicle is used in extremely dusty conditions
(KAF400).
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 accordance with the Periodic Maintenance Chart. In dusty areas, the elements should be cleaned more frequently than the recommended interval.
(for KAF950)
The engine air filter restriction gauge shows whether the air cleaner is clogged. Whenever the red band shows in the gauge window, the air filter element should be cleaned. After servicing the air filter element, the restriction gauge should be reset by pushing the button at the end of the gauge.
A. Air Filter Restriction Gauge
•
Element Removal
Raise the seat.
•
Pull up the snaps and remove the air cleaner housing cap from the housing.
(for KAF400)
Black plate (143,1)
MAINTENANCE AND ADJUSTMENT 143
(for KAF950)
A. Air Cleaner Housing Cover
B. Snaps
A. Air Cleaner Housing
B. Cap
C. Snaps
•
Pull the air cleaner element out of the housing.
•
Push a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering.
WARNING
If dirt or dust is allowed to pass through into the carburetor, the throttle may stick or become inoperative resulting in a hazardous operating condition (KAF400).
Black plate (144,1)
144 MAINTENANCE AND ADJUSTMENT
NOTICE
If dirt gets into the engine, excessive engine and possible engine damage may occur.
(for KAF400)
(for KAF950)
A. Element
B. Screw
A. Paper Element
NOTE
○
Element installation is performed in the reverse order of removal.
○
Install the cap with its drain facing downward.
•
Element Cleaning
(for KAF950)
Remove the element (see Element Removal).
•
Clean the paper element by tapping it lightly to loosen dust.
•
Blow away the remaining dust by applying compressed air from the inside to the outside (from the clean side to the dirty side).
•
Inspect the element material for damage. If any part of the element is damaged, the element must be replaced.
Black plate (145,1)
MAINTENANCE AND ADJUSTMENT 145
•
The restriction gauge should be reset by pushing the button at the end of the gauge.
•
Element Cleaning
(for KAF400)
Remove the element (see Element Removal).
•
Clean the foam element in a bath of high flashpoint solvent using a soft bristle brush.
•
Squeeze it dry in a clean towel. Do not wring the element or blow it dry; the element can be damaged.
•
Inspect the foam element for damage. If it is torn, punctured, or hardened, replace it.
NOTE
○
Replace the foam element after cleaning it five times or if it is damaged.
•
Clean the paper element by tapping it lightly to loosen dust.
•
Blow away the remaining dust by applying compressed air from the inside to the outside (from the clean side to the dirty side).
•
Inspect the element material for damage. If any part of the element is damaged, the element must be replaced.
A. Urethane Foam Element
B. Paper Element
Dust and/or Water Inspection
(for KAF400)
•
There is a plastic drain cap at the bottom of the air cleaner housing. If you see any dust and/or water accumulated in the housing, remove the drain cap and expel it.
(for KAF950)
•
Push open the drain hose on the bottom of the air cleaner housing to expel dust and/or water accumulated inside.
146 MAINTENANCE AND ADJUSTMENT
A. Drain Hose (for KAF950)
Black plate (146,1)
Spark Arrester
This vehicle is equipped with a spark arrester approved for off-highway use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. Clean the spark arrester in accordance with the Periodic Maintenance Chart.
NOTICE
The spark arrester must be functioning properly to provide adequate fire protection.
Spark Arrester Cleaning
WARNING
The muffler can become extremely hot during normal operation and cause severe burns.
Since the engine must be running during this procedure, wear heat-resistant gloves while cleaning the spark arrester.
•
Remove the drain plug from the muffler.
(for KAF950: Sample)
A. Spark Arrester (inside the muffler)
B. Drain Plug
•
Apply the parking brake.
•
In an open area away from combustible materials, start the engine with the gear shift lever in the "N"
(Neutral) position.
•
Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler.
Black plate (147,1)
MAINTENANCE AND ADJUSTMENT 147
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas.
Operate only in a wellventilated area.
•
Stop the engine.
•
Install the drain plug.
Black plate (148,1)
148 MAINTENANCE AND ADJUSTMENT
Throttle Pedal
If the throttle pedal has excessive play due to either 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, and adjust the play if necessary.
•
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.
•
Measure the distance the throttle pedal moves before the engine begins to pick up speed. Free play should be ~ mm.
NOTE
○
Free play values are shown in your English OM titled “ Throttle Pedal ” section of “ MAINTENANCE
AND ADJUSTMENT ” chapter. Refer to the relevant page and copy those values into the space provided in this page.
A. Throttle Pedal
B.
~ mm
Throttle Pedal Play Adjustment
•
(for KAF400)
Lift the cargo bed and support it with the rod.
•
Loosen and turn the throttle cable mounting nuts located above the transmission case until the proper amount of throttle pedal play is obtained.
Black plate (149,1)
MAINTENANCE AND ADJUSTMENT 149
A. Throttle Cable
B. Mounting Nuts
•
Tighten the mounting nuts securely.
(for KAF950)
•
Lift the cargo bed and support it with the rod.
•
Loosen the adjuster mounting nuts at the end of the throttle cable.
•
Slide the adjuster until the proper amount of throttle pedal play is obtained.
A. Throttle Cable Adjuster
B. Mounting Nuts
•
Tighten the mounting nuts securely.
Throttle Pedal Stop Position Adjustment
The full throttle pedal stop position can be adjusted to prevent pulling the throttle cable more than
• required.
Loosen the locknut.
•
Screw in the throttle pedal stop bolt.
•
Depress the throttle pedal until the speed control lever above the transmission case is in the fully opened position and hold it there.
•
Turn the throttle pedal stop bolt until the bolt head lightly touches the bottom the throttle pedal.
•
Tighten the locknut securely.
150 MAINTENANCE AND ADJUSTMENT
A. Throttle Pedal
B. Locknut
C. Throttle Pedal Stop Bolt
Black plate (150,1)
Choke Knob
(for KAF400)
Pulling the choke knob makes the carburetor provide a rich mixture for easy starting when the engine is cold.
If starting is difficult or rich fuel mixture trouble occurs, inspect the choke knob, and adjust it if necessary.
Inspection
•
Check that the choke knob returns properly and that the inner cable slides smoothly. If there is any irregularity, have the choke cable checked by an
• authorized Kawasaki dealer.
Lift the cargo bed and support it with the rod.
•
Remove the guard plate by releasing the two air intake ducts and the 6 quick rivets.
Black plate (151,1)
MAINTENANCE AND ADJUSTMENT 151
A. Guard Plate
B. Air Intake Ducts (2 p.c.s.)
C. Clamps
D. Quick Revets (6 p.c.s.)
E. Cap
•
Make sure the choke knob is all the way into its released position.
•
To determine the amount of choke cable play at the knob, pull the choke knob out until the starter lever at the carburetor starts to move; the amount of choke knob travel is the amount of cable play.
A. Starter Lever
B. Mounting Nuts
C. Choke Cable
D. Throttle Link
•
The proper amount of play is 0 ~ 1 mm at the choke knob. If there is too much or too little play, adjust the choke cable.
Black plate (152,1)
152 MAINTENANCE AND ADJUSTMENT
A. Choke Knob
B. 0 ~ 1 mm
Adjustment
•
Loosen and turn the choke cable mounting nuts next to the starter lever until the cable has the proper amount of play.
•
Tighten the nuts after adjustment.
Carburetor
(for KAF400)
The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed.
The following procedure covers the idle speed adjustment.
•
Idle Speed Adjustment
Apply the parking brake.
•
Raise the seat.
•
Remove the guard plate by releasing the two air intake ducts and the 6 quick rivets.
Black plate (153,1)
MAINTENANCE AND ADJUSTMENT 153
•
Remove the cover plate on the idle adjusting screw.
•
Loosen the accel lever stopper screw on the base plate above the transmission case and the idle adjusting screw on the engine.
A. Guard Plate
B. Air Intake Ducts (2 p.c.s.)
C. Clamps (6 p.c.s.)
D. Quick Rivets (6 p.c.s.)
E. Cap
•
Put the gear shift lever in the
“
N
”
(Neutral) position.
•
Start the engine, and warm it up thoroughly.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas.
Operate only in a wellventilated area.
•
Lift the cargo bed to support it with the hook.
A. Accel Lever Stopper Screw
B. Base Plate
C. Accel Lever
D. Idle Adjusting Screw
E. Cover Plate
F. Link Lever
•
Adjust the idle to the lowest stable speed by turning the idle a adjusting screw located on the carburetor.
Idle Speed: 1 175 ±75 r/min (rpm)
Black plate (154,1)
154 MAINTENANCE AND ADJUSTMENT
A. Idle Adjusting Screw
B. Throttle Link
C. Choke Cable
D. Carburetor
•
After adjustment, screw in the idle adjusting screw on the base plate until it lightly touches the link lever.
•
Finally screw in the accel lever stopper screw until it keeps clearance by 1 mm to the accel lever.
NOTE
○
The idling speed could become unstable with the throttle valve stuck closed, if the adjustment screws is turned excessively.
•
Depress and release the throttle pedal a few times to make sure that the idle speed does not change.
Readjust if necessary.
Fuel System
(for KAF400)
Accumulation of moisture or sediment in the fuel system can restrict the flow of fuel and cause carburetor malfunction. The system should be checked in accordance with the Periodic Maintenance Chart.
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions and cause severe burns. Before performing any service, turn the ignition switch “ OFF ” . Do not smoke.
Make sure the area is well ventilated and free from any source of flame or sparks, including any appliance with a pilot light. Make sure the engine is cold before servicing. Wipe any fuel off the engine before starting it.
•
Dust and/or Water Inspection
Lift the cargo bed to support it with the hook.
•
Raise the seat.
•
Remove the guard plate by releasing the two air intake ducts and the 6 quick rivets.
Black plate (155,1)
MAINTENANCE AND ADJUSTMENT 155
A. Guard Plate
B. Air Intake Ducts (2 p.c.s.)
C. Clamps (2 p.c.s.)
D. Quick Rivets (6 p.c.s.)
E. Cap
•
Place a suitable container under the carburetor.
•
Turn out the drain screw a few turns to drain the carburetor, and check to see if water or dirt has accumulated in the carburetor.
A. Drain Screw
B. Carburetor
•
Tighten the drain screw.
NOTE
○
If any water or dirt appears during the above operation, have the fuel system checked by an authorized Kawasaki dealer.
Fuel Filter
The vehicle is equipped the fuel filter at the middle of the fuel line to prevent dirt or other foreign material from entering the carburetor and fuel pump.
Have your authorized Kawasaki dealer inspect and clean or replace the fuel filter in accordance with the Periodic Maintenance Chart, or whenever any foreign material or water can be seen trapped in the fuel filter.
156 MAINTENANCE AND ADJUSTMENT
A. Fuel Filter
B. Fuel Tank
Black plate (156,1)
Fuel Filter
(for KAF950)
Accumulation of moisture or sediment in the fuel system can restrict the flow of fuel and cause injection pump damage. The system should be checked in accordance with the Periodic Maintenance Chart.
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch “ OFF ” . Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Never fill the tank completely to the top. If the tank is filled completely to the top, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.
•
•
Draining
Stop the engine.
•
Pull the rear edge of the seat upward.
•
Place a suitable container under the fuel filter.
Open the air vent plug counterclockwise several turns.
Black plate (157,1)
MAINTENANCE AND ADJUSTMENT 157
A. Fuel Filter
B. Air Vent Plug
C. Priming Pump
•
Turn the drain cap on the bottom of the fuel filter clockwise 1 turn to loosen it. Allow any water and sediment to drain out of the tube.
A. Fuel Filter
B. Drain Cap
C. Drain Tube
•
Tighten the drain cap and operate the priming pump until fuel flows from the air vent plug.
•
Tighten the air vent plug securely.
Tightening Torque
Air Vent Plug: 4.9 N·m (0.50 kgf·m)
•
Thoroughly wipe up any spilled fuel.
•
Crank the engine and check for fuel leaks around the filter.
•
Replacement of Fuel Filter Element
Stop the engine.
•
Place a suitable container under the fuel filter to catch spilled fuel.
Black plate (158,1)
158 MAINTENANCE AND ADJUSTMENT
•
Remove the drain cap at the bottom end of the fuel filter. Discard the O-ring.
•
Remove the fuel filter element with a filter wrench.
•
Replace the old filter element with a new one.
Tighten it by hand until the gasket on the element
• touches the filter body.
Tighten it 1/3 turn more to obtain a snug fit.
•
Replace the old O-ring with a new one. Tighten the drain cap securely.
•
•
Loosen the air vent plug. Operate the priming pump several times until fuel flows out.
•
Tighten the air vent plug.
•
Thoroughly wipe up any spilled fuel.
Crank the engine and check for fuel leaks around the filter.
Injection Pump
(for KAF950)
The injection pump sends the fuel to the injection nozzles under high pressure.
The mechanical governor controls the amount of fuel injected, and is set to satisfy the engine's needs.
The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed changes.
•
Idle Speed Adjustment
Apply the parking brake.
•
Put the gear shift lever in the N (neutral) position.
•
Start the engine, and warm it up thoroughly.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas.
Operate only in a wellventilated area.
•
Lift the cargo bed and support it with the rod.
•
Use a suitable tachometer to measure the idle
RPM. If it does not match the specification, proceed as follows.
•
Remove the injection pump cover by releasing two bolts.
Black plate (159,1)
MAINTENANCE AND ADJUSTMENT 159
A. Cover Bolts
B. Pump Cover
•
Loosen the locknut and the accelerator lever stopper screw on the injection pump.
A. Accelerator Lever Stopper Screw
B. Locknut
C. Accelerator Lever
•
Adjust the idle speed by turning the accelerator lever stopper screw.
Idle Speed: 850 ~ 950 r/min (rpm)
•
After adjustment of the accelerator lever stopper screw, the free play of the throttle pedal must be adjusted as well.
•
Tighten the locknut.
Tightening Torque: 5.6 N·m (0.57 kgf·m)
•
Depress and release the throttle pedal a few times to make sure that the idle speed remains unchanged. Readjust if necessary.
Black plate (160,1)
160 MAINTENANCE AND ADJUSTMENT
Fuel Tank Vent
(for KAF950)
The fuel tank vent hoses must be routed as specified.
The engine may stall or lose power if the fuel tank vent is plugged or if the vent hoses are pinched. Inspect the vent hoses 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 hoses.
Belt Drive Torque Converter
The vehicle is equipped with a belt drive torque converter type automatic transmission. The belt, driven pulley shoes and drain hose should be checked in accordance with the Periodic Maintenance Chart.
The belt and driven pulley shoes inspection should be done by an authorized Kawasaki dealer.
(for KAF400)
A. Belt Drive Torque Converter (inside)
B. Drain Plug A. Fuel Tank Vent Hoses
B. Check Valve
C. Fuel Tank
Black plate (161,1)
(for KAF950)
A. Belt Drive Torque Converter (inside)
B. Drain Plug
Dust and/or Water Inspection
•
Remove the drain plug on the bottom of the converter housing to expel dust and/or water accumulated inside.
MAINTENANCE AND ADJUSTMENT 161
Belt Drive Torque Converter Air Cleaner
A clogged belt drive torque converter air cleaner may cause the torque converter to malfunction.
NOTICE
A clogged air cleaner may allow dirt and dust to enter the belt drive torque converter causing excessive wear of the inner parts and loss of driving power.
The air cleaner elements must be cleaned in accordance with the Periodic Maintenance Chart. In dusty areas, the elements should be cleaned more frequently than the recommended interval. The elements should be replaced if they are damaged.
•
Element Removal
(for KAF400)
Lift the cargo bed and support it with the hook.
•
Raise the seat.
•
Remove the guard plate by releasing the two air intake ducts and the 6 quick rivets.
162 MAINTENANCE AND ADJUSTMENT
A. Guard Plate
B. Air Intake Ducts (2 p.c.s.)
C. Clamps
D. Quick Rivets (6 p.c.s.)
E. Cap
•
Take off the wingbolts and remove the air cleaner housing cap.
•
Pull the air cleaner element out of the housing.
•
Push a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering.
A. Cap
B. Wingbolts
Black plate (162,1)
Black plate (163,1)
MAINTENANCE AND ADJUSTMENT 163
•
Pull the air cleaner element out of the housing.
•
Push a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering.
A. Foam Element
B. Paper Element
NOTICE
If dirt gets into the belt drive torque converter, excessive wear and loss of driving power may result.
NOTE
○
Element installation is performed in the reverse order of removal.
Element Removal
(for KAF950)
•
For the belt drive torque converter air cleaner take off the wingbolts and remove the air cleaner housing cap.
A. Cap
B. Wingbolts
Black plate (164,1)
164 MAINTENANCE AND ADJUSTMENT
A. Foam Element
B. Paper Element
NOTICE
If dirt gets into the belt drive torque converter, excessive wear and loss of driving power may result.
NOTE
○
Element installation is performed in the reverse order of removal.
•
Element Cleaning
Remove the element (see Element Removal).
•
Remove the urethane foam element from the paper element.
•
Clean the foam element in a bath of high flashpoint solvent using a soft bristle brush.
•
Squeeze it dry in a clean towel. Do not wring the element or blow it dry; the element can be damaged.
•
Inspect the foam element for damage. If it is torn, punctured, or hardened, replace it.
NOTE
○
Replace the foam element after cleaning it five times or if it is damaged.
•
Clean the paper element by tapping it lightly to loosen dust.
•
Blow away the remaining dust by applying compressed air from the inside to the outside (from the clean side to the dirty side).
•
Inspect the element material for damage. If any part of the element is damaged, the element must be replaced.
Black plate (165,1)
Brakes
The vehicle is equipped with hydraulically activated drum brakes on all four wheels.
Brake Pedal
Brake Pedal Free Play Inspection
In accordance with the Periodic Maintenance
•
Chart, check the brake pedal free play.
•
Depress the brake pedal lightly by hand.
There should be ~ mm of free play.
MAINTENANCE AND ADJUSTMENT 165
ADJUSTMENT ” chapter. Refer to the relevant page and copy those values into the space provided in this page.
•
If the brake pedal has more or less free play than specified or the pedal action feels rough or
"catchy," have the brake system inspected immediately by an authorized Kawasaki dealer.
Brake Shoe Linings
Brake Shoe Lining Wear Inspection
In accordance with the Periodic Maintenance
Chart have the brake shoe linings checked for wear by an authorized Kawasaki dealer.
Brake Fluid
In accordance with the Periodic Maintenance
Chart, inspect the brake fluid level in the reservoir and change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water.
Fluid Requirement
Use heavy-duty brake fluid only from a fresh, unopened container marked DOT3.
A. Brake Pedal
B.
~ mm
NOTE
○
Free play values are shown in your English OM titled
“
Brakes
” section of
“
MAINTENANCE AND
Black plate (166,1)
166 MAINTENANCE AND ADJUSTMENT
WARNING
Over time, brake fluid can absorb moisture, lowering its boiling point and reducing brake effectiveness. Do not use fluid from a container 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 any length of time to avoid moisture contamination of the fluid. Don
’ t add or change brake fluid in the rain or during conditions of blowing dust or debris.
NOTICE
Brake fluid quickly ruins painted surfaces.
Wipe up any spilled fluid immediately.
(for KAF950)
Fluid Level Inspection
•
With the vehicle on level ground, check that, through the inspection hole in the dashboard, the fluid level in the reservoir is between the upper
(marked MAX) and lower (marked Min.) level lines.
A. Brake Fluid Reservoir
B. Upper Level Line (MAX)
C. Lower Level Line (MIN)
D. Inspection Hole
•
If the fluid level is lower than the lower level line, check for fluid leaks in the brake lines, and open the front cargo hood (see "Front Cargo Compartment" section in the "General Information" chapter) and fill the reservoir to the upper level line.
•
The brake fluid reservoir is inside the access hole, and using a funnel fill the reservoir to the upper level line.
Black plate (167,1)
A. Brake Fluid Reservoir
B. Cargo Compartment Wall
WARNING
Mixing two types and brands of fluid for use in the brake lowers the brake fluid boiling point and could reduce brake effectiveness.
Change the fluid in the brake system completely if the fluid level is low but the type and brand of the fluid already in the reservoir are unknown.
•
Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.
MAINTENANCE AND ADJUSTMENT 167
WARNING
Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake pedal has a soft or "spongy" feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately.
Fluid Change
Have the brake fluid changed by an authorized
Kawasaki dealer.
Black plate (168,1)
168 MAINTENANCE AND ADJUSTMENT
Brake Light Switch
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.
•
Depress the brake pedal. The brake light should go on after about mm of pedal travel.
NOTE
○
Value of the pedal traveling is shown in your English OM titled “ Brake Light Switch ” section of
“
MAINTENANCE AND ADJUSTMENT
” chapter.
Refer to the relevant page and copy those values into the space provided in this page.
(for KAF400)
Adjustment
•
Brake light switch is located above the brake pedal.
A. Brake Pedal
B.
mm
•
If it does not, check the bulb and, if necessary, adjust the brake light switch.
A. Brake Light Switch
B. Throttle Pedal
•
To adjust the brake light switch, move the switch forward or rearward, by turning the adjusting out.
NOTICE
To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.
Black plate (169,1)
MAINTENANCE AND ADJUSTMENT 169
Parking Brake Lever
The parking brake helps hold the vehicle from rolling while parked.
In accordance with the Periodic Maintenance
Chart, check that the parking brake lever functions properly.
(for KAF400)
Inspection
A. Brake Light Switch
B. Adjusting Nut
C. Lights sooner.
D. Lights later.
(for KAF950)
Adjustment
•
Adjustment is best-performed by an authorized
Kawasaki dealer since the brake light switch is hard to access for adjustment.
A. Parking Brake Lever
•
Pull the parking brake lever up and to the rear.
•
After 8 to 12 clicks of lever travel, the vehicle should not roll while packed.
•
If it does, adjust the parking brake lever.
Adjustment
•
Raise the seat.
Black plate (170,1)
170 MAINTENANCE AND ADJUSTMENT
•
Loosen the locknut (upper nut) on the middle of the parking brake lever, and turn the nut next to the locknut until the brake lever will only move 8 to 12 clicks upward.
(for KAF950)
Inspection
•
Pull the rubber boot up on the bottom.
A. locknut
B. Nut
C. Brake Lever
•
Tighten the locknut securely.
NOTE
○
Be sure to hold the cable end with a wrench to prevent the cable from twisting.
○
If the brake lever can not be adjusted with the nuts shown here, or if there is any doubt as to the condition or braking effectiveness, have the parking brake system inspected by an authorized Kawasaki dealer.
A. Parking Brake Lever
•
B. Rubber Boot
Pull the parking brake lever up and to the rear.
•
After 8 to 12 clicks of lever travel, the vehicle should not roll while parked.
Black plate (171,1)
MAINTENANCE AND ADJUSTMENT 171
A. 8 ~ 12 clicks
•
If it does, adjust the parking brake lever.
Adjustment
•
Loosen the locknut (upper nut) on the middle of the parking brake lever, and turn the nut next to the locknut until the brake lever will only move 8 ~
12 clicks upward.
A. Locknut
B. Nut
•
Tighten the locknut securely.
•
Reinstall the rubber boot making sure that the projections on its lower edge are completely pushed into the holes in the bracket.
NOTE
○
Be sure to hold the cable end with a wrench to prevent the cable from twisting.
○
If the brake lever can not be adjusted with the nuts shown here, or if there is any doubt as to the condition or braking effectiveness, have the parking brake system inspected by an authorized Kawasaki dealer.
Black plate (172,1)
172 MAINTENANCE AND ADJUSTMENT
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.
•
Lightly turn the steering wheel left and right.
•
There should be ~ mm of free play.
If there is excessive free play or strange noises, or the steering feels rough or "catchy," have the steering system checked by an authorized Kawasaki dealer.
(for KAF950)
Steering Position Adjustment
The steering wheel position can be adjusted to suit the operator.
•
Open the front cargo hood (see the "Front Cargo
Compartment" section "General Information" chapter).
•
Unscrew the screws and remove the front cargo compartment for easier access to the steering column bracket.
A.
~ mm
A. Front Cargo Compartment
B. Screws
•
Loosen the upper and lower nuts on the steering column bracket and move the steering wheel up or down.
Black plate (173,1)
A. Steering Column Bracket
B. Nuts
•
•
Tighten the bolts and nuts.
Reinstall the front cargo compartment.
•
Close the front cargo hood.
Power Steering System (for KAF950)
Steering may become more difficult than usual for the following reasons:
•
The steering wheel was continuously turned or held to the full turn stops with torque applied by driver. In this case the ECU works to protect the system from overheating by stopping the power assisting. Stop turning the steering wheel and wait until the system temperature drops, and the power steering recovers.
MAINTENANCE AND ADJUSTMENT 173
•
Fuses in the harness may have blown. There are several reasons that the fuses may blow. Refer to the Fuse section in this chapter for details.
•
Battery voltage has dropped. Voltage drop can happen when the engine starts; inspect the battery voltage.
•
Cable harness or connectors may have been disconnected. See an authorized dealer for service.
NOTE
○
If the steering becomes irregular or unusual for any reason other than above, have an authorized 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.
Black plate (174,1)
174 MAINTENANCE AND ADJUSTMENT
Cargo Bed Latches
(for KAF950)
A. Cargo Bed Hook
B. Latch and Lever
C. Mounting Bolts
Cargo bed latches must rest securely on the cargo bed hooks without rattling.
If there is rattling or not snug enough, adjust the
• latch positions as follows;
Release the mounting bolts .
•
Reposition the latch to the suitable place by sliding within the ellipse bolt holes.
•
Retighten the mounting bolts.
NOTE
○
Adjustment must be made on both sides.
Wheels
Rims
The rims are a drop-center, tubeless tire design.
Take care not to damage the sealing surfaces of the tire or rim when removing or installing tires. Note that the rims, like automotive rims, are not symmetrical. All wheels must be installed so that the valve stems are on the outside of the vehicle.
Wheel Nuts
Check for wheel nuts tightness in accordance with the Periodic Maintenance Chart.
Tightening Torque: N·m ( kgf·m)
Tires
The front and rear tires are knobby tubeless tires.
When replacing tires, check the valve stems and cores for damage. Take care not to damage the tire sealing surfaces of the rims.
Standard Tires:
Front
Rear
NOTE
○
Tires are an important part of the suspension of the vehicle. Tire construction characteristics and tire inflation pressure can greatly influence vehicle handling. Kawasaki recommends that you always
Black plate (175,1) replace tires with standard replacement tires as shown above. It is also very important to have tires of the same type and size on all axles, and at the same inflation pressure, on each axle.
○
Installation of non-standard tires, or use of different tires on one axle, can change or impair the handling of the vehicle.
○
Installation of tubeless tires on rims requires compressed air and is normally recommended as a dealer service operation. Nevertheless, a tube can be inserted into the tire by the operator as an emergency repair.
Payload and Tire Pressure
Failure to maintain proper inflation pressures or observe payload limits for your tires can change or impair handling and performance of the vehicle. The maximum recommended load carrying capacity is kg.
Use a tire pressure gauge to accurately set tire pressure.
WARNING
Operating with unequally or improperly pressurized tires can adversely affect steering or handling. Inflate both front tires to the same pressure and both rear tires to the same pressure.
MAINTENANCE AND ADJUSTMENT 175
Tire Air Pressure (when cold)
Normal Use
Front
Rear kPa ( kgf/cm²) kPa ( kgf/cm²)
Tire Wear, Damage
As tire tread wears down, tires become more susceptible to puncture and failure.
•
In accordance with the Periodic Maintenance
Chart, measure the depth of the tread with a depth gauge, and replace any tire that has worn down to the minimum allowable tread depth.
A. Tire Depth Gauge
Minimum Tread Depth: mm
•
Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage. Swelling
Black plate (176,1)
176 MAINTENANCE AND ADJUSTMENT or high spots indicate internal damage, requiring tire replacement.
•
Remove any imbedded stones or other foreign particles from the tread.
NOTE
○
Information such as wheel nut tightening torque, standard tire names, maximum load-carrying capacity of the MULE, and tire pressures are shown in your English OM titled “ Wheels ” section of
“
MAINTENANCE AND ADJUSTMENT
” chapter.
Refer to the relevant page and copy those values into the space provided in this page.
Joint Boots
(for KAF400A & 950)
In accordance with the Periodic Maintenance
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 (for KAF400A & 950)
D. Joint Boots
(for KAF950)
A. Rear Axle
B. Joint Boot
Black plate (177,1)
MAINTENANCE AND ADJUSTMENT 177
Suspension
Rear Shock Absorber Spring Force Adjustment
The spring adjusting sleeves on the rear shock absorbers have 5 positions so that the springs can be adjusted for different riding and loading conditions.
A. Shock Absorber
B. Adjusting Sleeve
178 MAINTENANCE AND ADJUSTMENT
Black plate (178,1)
WARNING
Improper shock absorber adjustment can cause poor handling and loss of stability, which could lead to an accident.
Always adjust the shock absorbers on the left and right side to the same setting.
A. Adjusting Sleeve (Turn here with a hook wrench)
If the spring action feels too soft or too stiff, have the sleeves adjusted by an authorized Kawasaki dealer in accordance with the following table.
•
Turn the adjusting sleeves on the shock absorbers to the desired position.
Spring Action
Position
1
2
3
4
5
Spring
Force
Setting Load
Surface
Speed
|
| Soft Light Good Low
↑ ↑ ↑ ↑
|
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Stronger Hard Heavy Bad High
Black plate (179,1)
Seat Belts
In accordance with the Periodic Maintenance
Chart, check that each seat belt functions properly.
Push the latch plate into the buckle until it clicks.
The latch plate must slide smoothly into the buckle.
The click sound shows it is securely latched. Push the red button in the buckle to make sure it releases freely. Also check the belt webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked or replaced by an authorized Kawasaki dealer.
(for KAF400 & 950F)
MAINTENANCE AND ADJUSTMENT 179
(for KAF950G)
A. Seat Belt
B. Buckle
C. Red Button
A. Latch Plate
B. Buckle
C. Red Button
180 MAINTENANCE AND ADJUSTMENT
Headlight Beam
(for KAF950)
The headlight beams can be adjusted vertically.
•
Remove the holder.
A. Holder
•
Turn the adjusting screw on each headlight rim in or out to adjust the headlight vertically.
A. Adjusting Screws
Black plate (180,1)
(for KAF400)
A. Lamp Body (backside)
B. Adjusting Screws
Black plate (181,1)
MAINTENANCE AND ADJUSTMENT 181
Battery
The battery is located under the left end of the front seat.
DANGER
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.
(for KAF950)
182 MAINTENANCE AND ADJUSTMENT
(for KAF400) (for KAF950G only)
Black plate (182,1)
Battery Removal
•
Release eight (8) screws and remove the rear cover for access
A. Rear Cover
B. Screws
C. Battery
Black plate (183,1)
MAINTENANCE AND ADJUSTMENT 183
(for KAF400)
A. Bolt
B. Holder
C. (
–
) Terminal
D. (+) Terminal
•
Loosen the bolts to remove the battery holder.
A. Holder
B. (+) Terminal
C. (
–
) Terminal
D. Power Steering Fuse Box
•
Disconnect the cables from the battery, first from the ( – ) terminal and then the (+) terminal.
•
Slide and remove the battery to the rear.
•
Clean the battery using a solution of baking soda and water. Be sure that the cable connections are clean.
•
Perform a visual inspection. Inspect for defective or cracked case and cover, and loose or damaged terminal posts or cables. Replace battery and/or cables immediately if any damage is found.
Battery Installation
•
Put the battery in place.
Black plate (184,1)
184 MAINTENANCE AND ADJUSTMENT
•
Securely connect the red cable with protective cap to the (+) terminal, and then securely connect the black cable to the ( – ) terminal.
•
Put a light coat of grease on the terminals to prevent corrosion.
•
Cover the (+) terminal with its protective cap.
•
Reinstall the battery holder and rear cover.
WARNING
Loose battery cables can create sparks which can cause a fire or explosion resulting in injury or death.
Make sure the battery terminal screws are tightened securely and the covers are installed over the terminals.
NOTICE
Do not reverse the battery connections, or damage to the regulator/rectifier unit will result.
WARNING
Electrolyte contains sulfuric acid which is harmful to skin, eyes, and clothing. Wear eye protection and rubber gloves. If spillage occurs on body or clothing, rinse at once with water for at least 15 minutes. Rinse empty package with large quantities of water.
DESTROY EMPTY PACKAGE TO PREVENT
ACCIDENTS!
ALWAYS WEAR EYE PROTECTION!
Battery Characteristics
The battery installed in this Mule is a conventional type battery and requires regular inspection to maintain the proper electrolyte level and a full charge.
In order to maximize battery life and ensure that it will provide the power needed to start your Mule, you must properly maintain the battery's electrolyte level and charge. When used regularly, the charging system in your Mule helps keep the battery fully charged. If your Mule is only used occasionally or for short periods of time, the battery is more likely to discharge.
Due to their internal composition, batteries continually self discharge. The discharge rate depends on the type of battery and ambient temperature. As temperatures rise, so does the rate. Every 15°C
(27°F) doubles the rate.
Electrical accessories, such as digital clocks and computer memory, also draw current from the battery even when the key is switched off. Combine
Black plate (185,1) such ” key-off ” draws with hot temperatures, and a battery can go from fully charged to completely discharged in a matter of days.
Temperature
40°C (104°F)
25°C (77°F)
0°C (32°F)
Self-discharge
Approx. Number of Days From
100% Charged to 100% Discharged
Lead-Antimony
Battery
100 Days
200 Days
550 Days
Lead-Calcium
Battery
300 Days
600 Days
950 Days
7 mA
10 mA
15 mA
20 mA
30 mA
Current Drain (Y50-N18L-A)
Discharging
Ampere
Days from 100%
Charged to 50%
Discharged
60 Days
42 Days
28 Days
21 Days
14 Days
Days from 100% charged to 100 %
Discharged
119 Days
83 Days
56 Day
42 Days
28 Days
In extremely cold weather the fluid in an inadequately charged battery can easily freeze, which can crack the case and buckle the plates. A fully charged, properly maintained battery can withstand sub-freezing temperatures with no damage.
MAINTENANCE AND ADJUSTMENT 185
Battery Sulfation
A common cause of battery failure is sulfation.
Sulfate is a normal by-product of the chemical reactions within a battery. Sulfation occurs when the electrolyte level is low and exposes the plates within the battery to air. The active lead on the plates oxidizes and sulfates, causing permanent damage so that the battery will not hold a charge. Low electrolyte levels also concentrates the acid in the electrolyte, causing further corrosion to the plates that often falls off and settles at the bottom of the battery.
The accumulated corrosion can eventually bridge the plates and cause the battery to short.
Sulfation also occurs when the battery is left in a discharged condition for an extended time. Sulfate is a normal by-product of the chemical reactions within a battery. But when continuous discharge allows the sulfate to crystallize in the cells, the battery plates become permanently damaged and will not hold a change. Battery failure due to sulfation is not warrantable.
Battery Maintenance
(for KAF950)
It is the owner's responsibility to maintain the battery electrolyte level and a full charge. Failure to do so can lead to battery failure and leave you standard.
Inspect the battery fluid level monthly.
•
Remove the battery from the vehicle (see Battery
•
Removal).
•
Remove the battery filler caps.
Check the electrolyte level in each cell.
Black plate (186,1)
186 MAINTENANCE AND ADJUSTMENT
•
If the electrolyte level in any cell is below the bottom of the split ring, fill with distilled water as follows.
•
Fill each cell until the electrolyte level rises to the bottom of the split ring in the vent well. DO NOT
FILL INTO THE SPLIT. DO NOT OVERFILL!
•
Install the battery (see Battery installation).
(for KAF400)
•
The electrolyte level in each cell should be between the upper and lower level lines.
•
If the fluid level is low in any cell, remove the battery filler caps and fill with distilled water until the electrolyte level in each cell reaches the upper level line.
DO NOT OVERFILL.
Overfilling can cause the electrolyte to leak out of the battery vent tube. Battery electrolyte contains sulfuric acid that will corrode vehicle components and parking surfaces, plus cause burns to exposed skin.
A. Split Ring
NOTICE
Add only distilled water to the battery. Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery.
•
After filling the cells, wait five to ten minutes and add additional electrolyte if necessary to bring the electrolyte to proper level. DO NOT OVERFILL!
•
Replace the battery filler cap.
A. Filler Caps
B. Upper Level Line
C. Lower Level Line
Black plate (187,1)
NOTICE
Add only distilled water to the battery. Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery.
If you are riding your Mule infrequently, inspect the battery voltage weekly using a voltmeter. If it drops below 12.5 volts, the battery should be charged using an appropriate charger (check with your Kawasaki dealer or visit buy kawasaki. com) at a rate of 1/10th of the battery capacity. If you will not be using your vehicle for longer than two weeks, the battery should be charged using an appropriate charger. Do not use an automotive-type quick charger that may overcharge the battery and damage it.
Battery Charging
•
Remove the battery from the vehicle (see Battery
Removal).
NOTICE
Always remove the battery from the vehicle for charging. If the battery is charged while still installed, battery electrolyte may spill and corrode the frame or other parts of the vehicle.
•
Before charging, check the electrolyte level in each cell. If the electrolyte level is low in any cell, fill to the bottom of the split ring.
MAINTENANCE AND ADJUSTMENT 187
•
Before turning on the battery charger, connect the charger cables to the battery terminals (red to +, black to – ).
A. Battery Charger
B. Cells
C. (
–
) Terminal
D. (+) Terminal
Black plate (188,1)
188 MAINTENANCE AND ADJUSTMENT
DANGER
Batteries produce hydrogen gas which can cause an explosion.
Charge the battery in well ventilated area.
Keep sparks, flame, and cigarettes away from the battery during charging.
When using a battery charger, connect the battery to the charger before turning on the charger.
This procedure prevents sparks at the battery terminals which could ignite any battery gases.
•
Charge the battery at a rate that is 1/10th of the battery capacity. For example, the charging rate for a 10 Ah battery would be 1.0 ampere.
NOTICE
Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charging rate can be reduced to the level required for this vehicle's battery.
Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the battery plates and cause internal shorting.
Higher-than-normal charging rates also cause the plates to shed active material. Deposits will accumulate, and can cause internal shorting. If the temperature of the electrolyte rises above 45°C (113°F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.
•
After charging, check the electrolyte level in each cell. If the level has fallen, add distilled water to
• bring it back up to the bottom of the split ring.
•
Install the caps on the cells.
Install the battery (See Battery Installation).
Black plate (189,1)
MAINTENANCE AND ADJUSTMENT 189
Fuse
(for KAF400)
There are two plastic fuse cases next to the parking brake under the left end of the seat, one for the main (30 A) and the other for the accessory connector (10 A). If the electrical systems do not function, inspect the fuse. Before replacing a fuse, check the wiring harness and electrical equipment for bare wires or other possible damage.
NOTICE
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. Fuse Cases (30 A)
B. Fuse Cases (10 A)
(for KAF950)
There are three fuse boxes under the seat. If the electrical systems do not function, inspect the fuse.
Before replacing a fuse, check the wiring harness and electrical equipment for bare wires or other possible causes.
NOTICE
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 inside the fuse case lid.
Black plate (190,1)
190 MAINTENANCE AND ADJUSTMENT
A. Fuse Boxes
B. Fuse Box for Power Steering
C. Breaker for Radiator Fan
D. Battery
Power Steering System
There are 40 A and 7.5 A fuses for the power steering system under the front seat.
A.40 A Fuse (Cover removed.)
B. 7.5 A Fuse
If the fuse is blown, steering becomes heavy. Replace 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/connectors. See an authorized 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 the bolted leads first.
Black plate (191,1)
MAINTENANCE AND ADJUSTMENT 191
Breaker
(for KAF950)
The breaker for the radiator fan is located under the seat near the fuse box. If the fan does not function, inspect the breaker. In order to reset the breaker, push the button at the side of the breaker case.
Before resetting, however, check that the radiator fan is free from mud or other obstacle as well as the wiring harness and electrical equipment for bare wires or other possible causes.
A.40 A Fuse
B. Bolted Lead
C. Spare Fuse
WARNING
The electrical system can produce electrical shocks. When replacing the 40 A fuse, first remove the cables from the battery terminals to avoid electric shock.
A. Breaker
B. Reset Button
NOTE
○
When you touch the cooling fan, be sure to disconnect the ( – ) cable of the battery, since the
Black plate (192,1)
192 MAINTENANCE AND ADJUSTMENT cooling fan can turn automatically even with the main switch off.
General Lubrication
In accordance with the Periodic Maintenance
Chart, have the general lubrication performed by an authorized Kawasaki dealer or perform it referring to the Service Manual for this vehicle.
Black plate (193,1)
Cleaning
To prolong the life of your vehicle, wash it down immediately after it has been splashed with sea water or exposed to salt air, or operated on rainy days, rough terrain, or in dusty areas.
Preparation for Washing
Before washing, precautions must be taken to
• keep water off the following parts.
Muffler rear opening - cover with a plastic bag.
•
Ignition switch - cover the keyhole with tape.
•
Air cleaner intake (middle of the rear cab frame top) - close opening with tape, or stuff in rags.
•
Horn button - cover with tape (KAF950).
Where to be Careful
Avoid spraying water with any great force near the following places.
•
Front and rear brakes - if water gets into the brake drums, they will not work effectively until they have dried out.
•
Under the seat - if water gets into the ignition coils or into the spark plug caps, it can ground out the spark. When this happens the vehicle will not operate properly and the affected parts must be wiped dry.
•
Power Steering System
– if water gets into the actuator or is sprayed over the ECU, they may cause malfunction (for KAF950).
MAINTENANCE AND ADJUSTMENT 193
NOTICE
Coin operated, high pressure spray washers are not recommended. Water may be forced into bearings and other components causing eventual failure from rust and corrosion.
Some soaps are highly alkaline and may leave a residue or cause spotting.
After Washing
•
Remove the plastic bag and tape, and open the air cleaner intake.
•
Lubricate as indicated in the "General Lubrication"
• section.
Test the brakes before operation.
•
Start the engine and run it for 5 minutes to dry it thoroughly.
194 MAINTENANCE AND ADJUSTMENT
Bolt and Nut Tightening
In accordance with the Periodic Maintenance
Chart, have the tightness of the bolts, nuts, and fasteners checked by an authorized Kawasaki dealer.
Black plate (194,1)
Black plate (195,1)
STORAGE 195
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
Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.
•
Put in fresh engine oil.
•
Empty the fuel from the fuel tank, and empty the carburetor by loosening the drain screw at the float bowl. Catch the fuel in a suitable container.
(After a period of time, fuel will break down and could clog the fuel system.) Close the drain screw when finished.
WARNING
Gasoline or diesel fuel are extremely flammable and can be explosive under certain conditions. Turn the main switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
WARNING
Gasoline or diesel fuel are a toxic substance.
Dispose of fuel properly. Contact your local authorities for approved disposal methods.
NOTE
○
As an alternative to draining the fuel system, a fuel stabilizer, such as STA-BIL for gasoline, may be used. Follow the manufacturer's instructions for use.
WARNING
Fuel stabilizers may contain poisonous substances. Heed the manufacturer's warnings for use.
(for KAF400)
•
Remove the spark plugs and spray fogging oil directly into each cylinder. Turn the engine over several times with the ignition switch key to coat the cylinder walls. Install the spark plugs.
Black plate (196,1)
196 STORAGE
WARNING
An air/oil mist may be forcibly ejected from the spark plug holes and could get into your eyes. Do not lean over the engine when performing this procedure. If you do get oil in your eyes, wash them immediately with liberal amounts of clean, fresh water and consult a physician as soon as possible.
(for KAF950)
•
Fill each cylinder with 3 cc engine oil by removing the glow plugs.
NOTE
○
Do not use more than 3 cc of engine oil in each cylinder. Too much oil could cause hydraulic lock and engine damage.
•
Install the glow plugs.
Tightening Torque
Glow Plug: 17 N·m (1.7 kgf·m)
•
Detach the fuel solenoid switch connector. Crank the engine very briefly several times, to evenly coat the cylinder walls with the oil.
NOTE
○
Do not crank the engine long enough that it starts, or the oilling procedure must be repeated.
•
Reattach the fuel solenoid switch connector.
A. Glow Plugs
Black plate (197,1)
A. Fuel Solenoid Switch Connector
•
Put boards under the front and rear wheels to keep dampness away from the tire rubber.
•
Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or in the brakes.
•
Lubricate all the cables as indicated in the General Lubrication section.
•
Remove the battery, and store it where it will not be exposed to direct sunlight, moisture, or freezing temperatures. During storage it should be given a slow charge (one ampere or less) about once a month.
STORAGE 197
NOTICE
Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged a battery becomes, the more easily it freezes.
Never remove the sealing strip, or the battery can be damaged.
•
Tie a plastic bag over the exhaust pipe and air cleaner inlet (rear cab frame top) to prevent moisture or small animals from entering.
•
Put a cover over the vehicle to keep dust and dirt from collecting on it.
Removal from Storage:
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas.
Operate only in a wellventilated area.
•
Remove the plastic bags from the exhaust pipe and air cleaner inlet.
•
Clean the terminals of the battery, charge the battery if necessary, and install it in the vehicle.
•
Make sure the spark plugs are tight.
•
Fill the fuel tank with fuel.
198 STORAGE
•
Check all the points listed in the "Daily Safety
Checks" section.
•
Lubricate as indicated in the "General Lubrication" section.
Black plate (198,1)
Black plate (199,1)
TROUBLESHOOTING GUIDE 199
•
Starter Motor Won't Turn
TROUBLESHOOTING GUIDE
Fuse failed (be sure to check for cause of failure) •
Battery leads do not make good electrical contact with battery terminals •
Battery discharged
•
Engine Cranks, But Won't Start
No fuel in tank
•
Fuel filter clogged
•
Water in fuel •
•
Choke is not used when engine is cold (KAF400)
Glow plug light failed (KAF950) •
Air filter clogged or inlet blocked
•
Engine flooded (KAF400) •
•
Fuel tank vent clogged
Fuel line clogged air in fuel system (KAF950)
•
Spark plug wire not on spark plug (KAF400)
•
Spark plug dirty (KAF400)
•
Engine Stops
No fuel in tank
•
Water in fuel •
Fuel filter clogged
•
•
Fuel line clogged
Choke left on too long (KAF400)
•
Air filter clogged or inlet blocked
•
Fuel tank cap vent clogged
•
Engine overheated:
○
Too much idling or low speed running (not enough air flow)
○
Overloaded
Wrong spark plug (KAF400)
○
Radiator clogged
Coolant level too low
○
Coolant deteriorated
Engine oil low
○
Cooling fan breaker functioned (KAF950)
•
No Power
Engine overheated:
○
Too much idling or low speed running (not enough air flow)
○
Overloaded
Wrong spark plug (KAF400)
○
Radiator clogged
Coolant level too low
○
Coolant deteriorated
Engine oil low
○
Cooling fan breaker functioned (KAF950)
•
Compression leakage:
○
Valve clearance insufficient
200 TROUBLESHOOTING GUIDE
•
•
Fuel filter clogged
Air filter clogged or inlet blocked
•
Spark plug dirty or worm (KAF400)
•
Choke left on (KAF400)
•
•
Engine oil incorrect
•
Water in fuel
Drive train trouble
•
Power Steering Won't Work (for KAF950)
ECU functioned to prevent overheating.
•
•
Fuse failed
•
Battery discharged
Cable harness/connectors disconnected
Black plate (200,1)
Black plate (201,1)
ENVIRONMENTAL PROTECTION 201
ENVIRONMENTAL PROTECTION
To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure.
Black plate (202,1)
202 MAINTENANCE RECORD
MAINTENANCE RECORD
Owner Name .....................................................................................................................................
Address .............................................................................................................................................
Phone Number ..................................................................................................................................
Engine Number .................................................................................................................................
Vehicle Number ................................................................................................................................
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
Black plate (203,1)
Date Traveled Distance Maintenance Performed
MAINTENANCE RECORD 203
Dealer Name Dealer Address
Black plate (204,1)
204 MAINTENANCE RECORD
Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
Black plate (205,1)
Date Traveled Distance Maintenance Performed
MAINTENANCE RECORD 205
Dealer Name Dealer Address
Black plate (206,1)
206 MAINTENANCE RECORD
Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
Black plate (207,1)
Date Traveled Distance Maintenance Performed
MAINTENANCE RECORD 207
Dealer Name Dealer Address
Pakua
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