The Mule 610 4x4 XC, chassis code KAF400, is a robust and reliable utility vehicle designed for demanding work environments. Produced during the first generation of the Mule 610 platform, spanning from 2005 to 2016, this model offers a practical and durable solution for various tasks. Its engineering emphasizes dependable performance, featuring a liquid-cooled, four-stroke V-twin engine, a Continuously Variable Transmission (CVT) with selectable 2WD/4WD and a locking differential, and a sturdy frame. Built for utility and off-road capability, the Mule 610 4x4 XC is a testament to a commitment to producing hard-working vehicles that excel in challenging conditions.
This comprehensive Service Repair Manual provides detailed information for owners, mechanics, and technicians working on the Mule 610 4x4 XC models from 2010 through 2016. Covering a wide array of systems including the engine, fuel system, transmission, brakes, suspension, and electrical system, this manual offers step-by-step repair instructions, maintenance procedures, and troubleshooting guides. It includes essential technical specifications, exploded views for clarity, and extensive electrical diagrams, ensuring that users have all the necessary resources to maintain, diagnose, and repair the vehicle effectively. The manual is presented in English and is available in a digital format for convenient digital access or printing.
Model Designation:
Mule 610 4x4 XC
Generation Identifier:
First Generation (2005-2016 for Mule 610 platform)
Target Audience:
Owners, mechanics, and repair shops specializing in Kawasaki utility vehicles.
Value Proposition:
Offers comprehensive factory-level information at a significantly lower cost than dealership service or outsourced repairs.
Content Completeness:
All-encompassing content covering a wide range of repair and maintenance tasks.
User Accessibility:
Accessible on multiple devices (PC, Mac, tablet, smartphone) in PDF format, with options for digital viewing or printing.
Covered Model Years:
2010, 2011, 2012, 2013, 2014, 2015, 2016
Covered Models:
Kawasaki Mule 610 4x4 XC
Manual Type:
Service Repair Manual
Origin:
Original Factory Service Manual
Systems:
General Information, Periodic Maintenance, Fuel System, Engine Top End, Converter System, Engine Lubrication System, Engine Removal/Installation, Engine Bottom End, Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Repair Procedures:
Step-by-step repair instructions
Maintenance Procedures:
Comprehensive maintenance procedures
Diagnostic Procedures:
Troubleshooting guides and diagnostic information
Depth Of Coverage:
Detailed technical information for repairs and maintenance, suitable for professional technicians and advanced DIY users.
Visual Aids:
Includes exploded views for clarity during repairs.
Electrical Coverage:
Extensive electrical and wiring diagrams section.
File Type:
PDF (Portable Document Format)
Printability:
Printable for physical reference, allowing users to print specific pages or the entire manual.
Recommended Binding:
Suitable for printing and insertion into a 3-ring binder for easy navigation and page protection.
Suggested Paper Weight:
Standard printer paper (e.g., 20-24 lb bond) is adequate for printing.
Engine Type:
Four-stroke, SOHC, V-twin cylinder
Displacement:
397 cc (24.2 cu in)
Bore X Stroke:
65.0 x 60.0 mm (2.6 x 2.4 in)
Cooling System:
Liquid-cooled
Fuel Delivery:
Carburetor (Keihin CVKR34)
Fuel Type:
Unleaded gasoline (minimum 87 octane)
Horsepower:
Approximately 14.3 HP @ 4000 RPM (varies by model year and region, typically not explicitly stated in marketing for utility vehicles)
Torque:
Approximately 20.7 lb-ft @ 3200 RPM (varies)
Type:
Continuously Variable Transmission (CVT)
Drive Modes:
2WD/4WD selector with locking differential (electric actuator)
Gear Reduction:
High and Low range CVT with reverse
Cvtf Specification:
Kawasaki Genuine CVT Fluid or equivalent automatic transmission fluid (e.g., Dexron III/Mercon) as specified in the manual.
Overall Length:
Approx. 111.2 in (2,825 mm)
Overall Width:
Approx. 54.1 in (1,375 mm)
Overall Height:
Approx. 71.5 in (1,815 mm)
Bed Length:
Approx. 37.0 in (940 mm)
Bed Width:
Approx. 31.7 in (805 mm)
Bed Height:
Approx. 7.9 in (200 mm)
Cargo Bed Capacity:
Approx. 350 lbs (159 kg)
Curb Weight:
Approx. 1,000 lbs (453 kg)
Towing Capacity:
Approx. 1,100 lbs (500 kg)
Payload Capacity:
Approx. 450 lbs (204 kg)
Ground Clearance:
Approx. 6.1 in (155 mm)
Safety Certification:
Designed for off-road use; typically does not carry automotive safety ratings (e.g., NHTSA, IIHS).
Braking System:
Hydraulic disc brakes front and rear.
Parking Brake:
Mechanical parking brake, typically a drum brake on the drive shaft.
Roll Over Protection:
ROPS (Roll Over Protection System) standard.
Seat Belts:
3-point seat belts for driver and passenger.
Infotainment Features:
Basic; typically includes a simple instrument cluster with speedometer, odometer, fuel gauge, and indicator lights. No advanced infotainment systems.
Assistance Features:
Limited; focused on core utility functions. Features like selectable 4WD and differential lock are mechanical/electrical aids for traction.
Connectivity Options:
None.
Oil Change Interval:
Typically every 1,000 miles or 12 months, whichever comes first (refer to manual for exact specification).
Air Filter Cleaning Interval:
Recommended cleaning every 6 months or 1,000 miles, replacement as needed (refer to manual).
Spark Plug Replacement Interval:
Refer to manual, typically around 4,000-6,000 miles or as specified by plug type.
Engine Oil Type:
API SG, SH, SJ, SL or SM SAE 10W-40 or 10W-50 (refer to manual for specific viscosity recommendation based on ambient temperature).
Engine Oil Capacity:
Approx. 1.6 US qt (1.5 L) without filter change; 1.7 US qt (1.6 L) with filter change.
Coolant Type:
High-quality ethylene glycol-based antifreeze coolant, mixture of 50% coolant and 50% distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
CVT belt wear, suspension bushings, brake pads, wheel bearings (typical for utility vehicles of this era).
Electrical Component Reliability:
While generally robust, intermittent issues with switches or wiring connectors can occur due to environmental exposure.
Manufacturer:
Kawasaki Heavy Industries, Ltd.
Mule Lineage:
The Mule 610 represents a compact and practical utility vehicle in Kawasaki's long-standing Mule lineup, known for its durability and workhorse capabilities.
Production Period:
The KAF400 platform, including the 610 model, was produced from roughly 2005 through 2016, with specific model year updates.
Awards And Ratings:
Specific awards are not commonly marketed for this utility vehicle segment. Its reputation is built on reliability and practical utility in its intended applications.
