1988 Kawasaki Mule Manual

The 1988 Kawasaki Mule is a utility vehicle designed for off-road and work applications, featuring a durable steel frame, four-wheel drive capability, liquid-cooled engine, automatic transmission with high/low range, hydraulic disc brakes, and cargo bed with 400 lb capacity. Below are key sections for safety, features, operation, maintenance, specifications, and troubleshooting.

1. Features at a Glance 2. Installation & Assembly 3. First-Time Operation 4. Specifications 5. Controls and Operation 6. Maintenance Schedule 7. Engine Service 8. Safety Features 9. Storage & Care 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Steel frame construction, liquid-cooled engine, automatic transmission, four-wheel drive system, hydraulic disc brakes, cargo bed.

Feature	Description
Engine	Liquid-cooled, 4-stroke single cylinder
Transmission	Automatic with high/low range and reverse
Drive System	Selectable 2WD/4WD with limited-slip differential
Brakes	Hydraulic disc brakes front and rear
Cargo Bed	Steel bed with 400 lb capacity, tilt function
Suspension	Independent front, rigid rear axle
Fuel Capacity	4.2 gallons
Towing Capacity	Up to 800 lbs
Seating	Bench seat for operator and passenger
Instrumentation	Speedometer, fuel gauge, warning lights

Installation & Assembly

Unpack and inspect contents. Assemble following manufacturer instructions.

Install steering wheel: Align splines and secure with nut.
Mount cargo bed: Attach using provided hardware and brackets.
Install battery: Connect positive then negative terminals.
Add fluids: Engine oil, coolant, brake fluid as specified.
Check tire pressure: Inflate to recommended PSI.

WARNING! Vehicle is heavy; use proper lifting equipment. Ensure all fasteners are tightened to specification.

First-Time Operation

Perform pre-operation checks before starting engine.

Check fluid levels: Engine oil, coolant, brake fluid.
Inspect tires: Pressure and condition.
Verify controls: Brakes, throttle, steering function properly.
Start engine: Turn key to ON, set choke if cold, turn to START.
Test drive: Check all functions in safe area.

CAUTION! Always wear seat belt. Operate only in designated areas. Keep hands and feet inside vehicle.

Specifications

Engine Type: 4-stroke, single cylinder, liquid-cooled
Displacement: 400cc
Fuel System: Carburetor
Transmission: Automatic CVT with high/low range
Drive System: Selectable 2WD/4WD
Brakes: Hydraulic disc front and rear
Suspension: Independent front, rigid rear axle
Cargo Capacity: 400 lbs
Towing Capacity: 800 lbs
Fuel Capacity: 4.2 gallons
Dimensions: 108" L x 54" W x 72" H

Controls and Operation

Main controls: Ignition switch, gear selector, drive mode selector, brake pedal, accelerator pedal.

Instrument Panel: Key switch, fuel gauge, speedometer, warning lights, 2WD/4WD selector.

Starting Procedure: Turn key to ON, set parking brake, shift to NEUTRAL, press brake, turn to START. Driving: Select 2WD or 4WD as needed, use HIGH range for normal operation, LOW range for heavy loads or steep terrain. Parking: Apply parking brake, shift to PARK.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Daily: Check fluid levels, tire pressure, brake function
Every 100 hours: Change engine oil and filter
Every 200 hours: Replace air filter, check spark plug
Every 500 hours: Change transmission fluid, inspect brakes
Annually: Flush cooling system, lubricate all fittings

Tip: Keep maintenance records for warranty and resale value.

Engine Service

Engine maintenance procedures for optimal performance.

Oil Change: Warm engine, drain oil, replace filter, refill with recommended oil.
Air Filter: Remove cover, clean or replace element, ensure proper sealing.
Spark Plug: Remove old plug, gap new plug to specification, install and torque.
Cooling System: Check coolant level, inspect hoses for cracks or leaks.
Fuel System: Inspect fuel lines, clean carburetor if necessary.

WARNING! Engine components become hot during operation. Allow to cool before servicing.

Safety Features

Roll-over protection structure (ROPS), seat belts, parking brake, neutral safety switch, engine cut-off switch.

Storage & Care

Prepare vehicle for extended storage: Clean thoroughly, change oil, add fuel stabilizer, disconnect battery, store in dry location.

CAUTION! Do not store with fuel in tank for extended periods without stabilizer. Keep battery charged during storage.

Regulatory Information

Designed for off-road use only. Not for highway operation. Meets ANSI/ROHVA standards for recreational off-highway vehicles. Copyright © 1988 Kawasaki Motors Corp., U.S.A. For support, contact Kawasaki customer service or authorized dealers.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, battery	Check fuel level, spark plug, battery charge, safety switches
Loss of power	Air filter, fuel system	Clean/replace air filter, check fuel lines and carburetor
Poor braking	Fluid level, pad wear	Check brake fluid, inspect pads for wear, bleed system if needed
4WD not engaging	Selector, linkage	Check selector operation, inspect linkage for damage
Overheating	Coolant, radiator	Check coolant level, clean radiator fins, inspect water pump

Reset: Disconnect battery for 30 seconds to reset electrical system if needed.

Service: Contact authorized Kawasaki dealer for major repairs.