Vehicle Segment:
Compact Utility Vehicle (UTV) / Side-by-Side
Intended Use:
Off-road utility, property maintenance, light hauling, recreational use
Competitors:
John Deere Gator, Polaris Ranger (earlier models), Cub Cadet Volunteer, other compact UTVs of the era
Ease Of Use:
Designed for user-friendly operation and maintenance, making DIY repairs accessible
Cost Effectiveness:
Enables owners to save significant money on maintenance and repairs
Versatility:
Covers all aspects of service and repair for maximum vehicle uptime
Covered Model Years:
2003, 2004, 2005, 2006, 2007, 2008, 2009
Engine Variants Covered:
All engine types for KAF400 Mule 600/610
Trim Levels Covered:
All trim levels
Transmission Types Covered:
All transmission types
Estimated Page Count:
Comprehensive (Specific page count not provided in product description, but implied to be extensive)
Type:
Complete Workshop Service Repair Manual
Delivery Method:
Instant Email Delivery
Accessibility:
Printable (single page, chapter, or whole manual), Downloadable to tablets and smartphones
Software Requirements:
Adobe Reader (or compatible PDF viewer)
Engine Management:
Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system
Drivetrain:
Transmission (gearbox) service, differential, drive shafts, clutch operation, final drive
Chassis And Suspension:
Front suspension, rear suspension, steering system, braking system (hydraulic), wheel bearings, tires
Electrical System:
Wiring diagrams, lighting system, battery, charging system (alternator/generator), starter motor, fuses, switches, instrumentation
Bodywork And Frame:
Frame inspection and repair, body panel removal and installation, seat, cargo bed
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments, carburetor tuning
Diagnostics And Troubleshooting:
Step-by-step troubleshooting guides for common problems, diagnostic charts
Repair And Rebuild:
Detailed instructions for component repair and complete engine/transmission rebuilds
Assembly And Disassembly:
Complete breakdown and reassembly procedures for all major vehicle components
Depth:
Comprehensive (A-Z coverage from basic maintenance to advanced repairs)
Visual Aids:
Includes pictures and diagrams to illustrate procedures
Engine Type:
4-stroke, single-cylinder, OHC, air-cooled gasoline engine
Displacement:
Approximately 401 cc (specific cubic centimeters may vary slightly based on exact KAF400 variant, but this is the common designation)
Bore X Stroke:
72.0 mm x 49.6 mm (Typical for this engine series)
Compression Ratio:
9.0:1 (Typical)
Horsepower:
Approximately 11.3 HP @ 3400 RPM (Subject to variation and regulation)
Torque:
Approximately 20.1 Nm @ 2600 RPM (Subject to variation)
Fuel Delivery:
Carburetor (Likely Keihin, specific model numbers would be in the manual)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approximately 15.0 Liters (3.9 US gal) for Mule 610
Ignition:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Forced air cooling
Type:
Continuously Variable Transmission (CVT) with Hi/Lo range and Reverse
Drive System:
Shaft drive to rear differential, often with selectable 2WD/4WD (depending on specific Mule 600/610 variant)
Clutch:
Automatic centrifugal clutch
Gear Selection:
Selector lever for High, Low, Neutral, Reverse
Length:
Approx. 2,470 mm (97.2 in) for Mule 610
Width:
Approx. 1,290 mm (50.8 in) for Mule 610
Height:
Approx. 1,780 mm (70.1 in) for Mule 610 (to top of roll bar)
Cargo Bed Dimensions:
Approx. 760 mm (30 in) L x 1,050 mm (41.3 in) W x 150 mm (5.9 in) D (Mule 610)
Curb Weight:
Approx. 437 kg (963 lbs) for Mule 610
Payload Capacity:
Approx. 180 kg (396 lbs) for Mule 610 cargo bed
Towing Capacity:
Approx. 362 kg (800 lbs) for Mule 610
Features:
Basic instrumentation cluster (speedometer, fuel gauge, engine hour meter, warning lights). No advanced infotainment systems.
Features:
Limited driver assistance features, focus on core utility and mechanical operation. Differential lock may be available on some variants for enhanced traction.
Engine Oil Change:
Every 100 hours of operation or annually (check specific manual for precise intervals)
Air Filter Cleaning:
Every 20 hours of operation or as needed based on dusty conditions
Spark Plug Replacement:
Refer to manual, typically around 300-500 hours or as needed for performance
Valve Adjustment:
Refer to manual, usually every 200-300 hours or annually
Engine Oil Type:
SAE 10W-40 API SE or SF (refer to manual for specific viscosity and API rating)
Engine Oil Capacity:
Approx. 1.5 Liters (1.6 US qt) without filter change; 1.6 Liters (1.7 US qt) with filter change.
Transmission Fluid Type:
Kawasaki Genuine Gear Oil (or equivalent API GL-4, SAE 80W-90)
Transmission Fluid Capacity:
Refer to manual (typically around 0.5 - 0.8 Liters for main gearbox)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Common Wear Items:
CVT belt, brake shoes/drums, wheel bearings, suspension bushings
Carburetor Tuning:
Carburetors can sometimes require adjustment due to fuel variations or wear, requiring manual guidance.
Kawasaki History:
Kawasaki Heavy Industries, Ltd. is a Japanese conglomerate corporation known for its motorcycles, engines, heavy equipment, aerospace, and defense products.
Mule Lineage:
The Mule line has been a staple in Kawasaki's utility vehicle offerings, known for their robust and practical design for work environments.
Manufacturing Location:
Typically manufactured in Japan, though assembly may occur in other locations.
