🏷️ Basic Information

Make:

Kawasaki

Model:

Mule 600 / Mule 610

Model Code:

KAF400

Year:

2005

Generation Identifier:

First Generation (Mule 600/610 Series)

👋 Introduction

Vehicle Segment:

Compact Utility Vehicle (UTV) / Side-by-Side (SxS)

Target Audience:

Farm, ranch, recreational, and light industrial users

Competitors:

John Deere Gator, Polaris Ranger, Cub Cadet Volunteer

Manual Benefit 1:

Empowers DIY repairs, reducing labor costs

Manual Benefit 2:

Provides expert knowledge for efficient troubleshooting

Manual Benefit 3:

Ensures proper maintenance for longevity and performance

Manual Format Advantage:

Digital format offers portability and cost-effectiveness (print only what's needed)

📋 Manual Details

Primary Coverage:

Mechanical Repair, Maintenance, and Diagnostics

Secondary Coverage:

Electrical System, Chassis, and Bodywork

Estimated Page Count:

Approximately 300-500 pages (typical for this model and scope)

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Full Engine Top End, Engine Bottom End, Engine Lubrication System, Engine Removal/Installation

Drivetrain:

Converter System, Transmission, Final Drive

Chassis And Suspension:

Wheels/Tires, Brakes, Suspension, Steering, Frame

Electrical:

Electrical System

Fuel System:

Fuel System (appears twice in provided list, assuming comprehensive coverage)

Maintenance:

Periodic Maintenance, Quick Reference Guide for Maintenance

Troubleshooting Diagnostics:

Trouble shooting and diagnose mechanical and other problems

Repair:

Detailed step-by-step repair instructions for all covered systems

Special Procedures:

Engine Removal/Installation, Converter System Service

Depth:

Comprehensive, suitable for novices and experienced technicians

Diagnostic Tools:

Implicitly covers diagnostic procedures and information

Illustrations:

Detailed diagrams and photos

Supplementary Info:

Exploded Views, Appendix

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text (standard for well-created PDFs)

Printability:

Printable pages as needed

Illustration Quality:

High-quality diagrams and photographs suitable for print

Binding:

Not Applicable (Digital Download)

Paper Recommendation:

N/A (Digital)

⚙️ Engine Specifications

Engine Family:

Kawasaki FE Series

Engine Type:

4-stroke, OHV, V-Twin, Air-cooled Gasoline Engine

Engine Displacement:

401 cc (24.47 cubic inches)

Bore X Stroke:

64.0 mm x 62.0 mm

Compression Ratio:

8.3:1

Horsepower:

Approx. 11.8 HP @ 3,400 RPM (typical for the FE200/210 variant used)

Torque:

Approx. 20.3 lb-ft @ 2,400 RPM (typical for the FE200/210 variant used)

Fuel Delivery:

Carburetor (Mikuni VM-type, specific model may vary)

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

4.0 US gallons (15.1 L)

Oil Type:

SAE 10W-40 API SG or higher (verify specific classification in manual)

Oil Capacity:

1.4 US qt (1.3 L) without filter change, 1.5 US qt (1.4 L) with filter change (verify exact capacity)

Ignition Type:

CDI (Capacitor Discharge Ignition)

Cooling Method:

Forced Air Cooling

🔧 Transmission

Transmission Type:

CVT (Continuously Variable Transmission) with De-Carbonizer Belt

Drive Modes:

2WD / 4WD selectable

Gear Selection:

Forward, Neutral, Reverse

Final Drive Type:

Shaft Drive with Bevel Gear Differential

Cvt Fluid Type:

Specific Kawasaki CVT Fluid or equivalent (refer to manual for precise specification)

Final Drive Oil Type:

SAE 80 API GL-4 Hypoid Gear Oil (verify)

Final Drive Oil Capacity:

Approx. 0.3 US qt (0.3 L) (verify)

📐 Dimensions

Overall Length:

Approx. 96.3 inches (2445 mm)

Overall Width:

Approx. 51.2 inches (1300 mm)

Overall Height:

Approx. 73.6 inches (1870 mm)

Bed Length:

Approx. 30.7 inches (780 mm)

Bed Width:

Approx. 36.2 inches (920 mm)

Bed Depth:

Approx. 7.9 inches (200 mm)

Cargo Bed Capacity:

220 lbs (100 kg)

Curb Weight:

Approx. 827 lbs (375 kg)

Towing Capacity:

700 lbs (317.5 kg)

Payload Capacity:

816 lbs (370 kg)

Front Tire Size:

AT20 x 7-10 (standard)

Rear Tire Size:

AT20 x 10-8 (standard)

Wheelbase:

Approx. 49.4 inches (1255 mm)

Ground Clearance:

Approx. 6.1 inches (155 mm)

🛡️ Safety Features

Rollover Protection:

ROPS (Roll-Over Protective Structure) equipped (standard for UTVs)

Braking System:

Hydraulic Disc Brakes (Front and Rear), Parking Brake

Seatbelts:

Driver and Passenger Seatbelts

Lighting:

Headlights, Taillights, Brake Lights

💡 Technology Features

Infotainment System:

Basic, typically no integrated infotainment system beyond a basic gauge cluster.

Driver Assistance Features:

None typically equipped; focus is on utility and core mechanical function.

Connectivity Features:

None

🔧 Maintenance

Initial Oil Change:

Typically around 10-20 hours or 1 month of use.

Regular Oil Change:

Every 100 hours or 6 months (whichever comes first).

Air Filter Cleaning:

Every 50 hours or as needed based on operating conditions.

Spark Plug Replacement:

Typically every 1,000 hours or 2 years (refer to manual for specific plug type and gap).

Cvt Belt Inspection:

Every 100 hours or 1 year for wear and tension.

Engine Oil Specification:

SAE 10W-40 API SG or higher (confirm exact API classification in manual).

Brake Fluid Specification:

DOT 3 Hydraulic Brake Fluid (verify).

Common Wear Item 1:

CVT Belt Wear: Regular inspection and replacement is crucial for consistent performance.

Common Wear Item 2:

Air Filter Fouling: Due to dusty operating conditions, requires frequent cleaning/replacement.

Common Maintenance Task:

Carburetor Cleaning/Adjustment: Can be sensitive to fuel quality and debris over time.

📚 Vehicle History

Kawasaki Powersports History:

Kawasaki Heavy Industries has a long-standing reputation in motorcycle, ATV, and utility vehicle manufacturing, known for robust engineering and reliability.

Mule Series Introduction:

The Mule utility vehicle line was introduced in 1988, evolving over the years to meet diverse work and recreational needs. The 600/610 series represented a more compact and accessible offering within the UTV market.

Manufacturing Location:

Kawasaki UTVs are typically manufactured in Japan or the United States.

🏆 Awards & Recognition

Award Type:

Not applicable for this specific model's manual. The vehicle itself is known for reliability and utility in its segment.