Model Type:
Utility Vehicle (UTV) / All-Terrain Vehicle (ATV) / Side-by-Side
Model Years Covered:
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Platform Code Family:
Mule 600 Series
Vehicle Segment:
Compact Utility Vehicle, designed for light-duty agricultural, recreational, and property maintenance tasks.
Key Competitors:
John Deere Gator (early models), Cub Cadet Volunteer, Polaris Ranger (early models), Yamaha Rhino (early models).
Utility Focus:
Emphasizes practicality, maneuverability, and cargo hauling for its intended use.
Ease Of Use:
Designed with user-friendliness and straightforward operation in mind.
Engine System:
Engine overhaul, cylinder head, valve train, piston, crankshaft, lubrication system, cooling system, fuel system (carburetor), ignition system, starting system.
Transmission System:
Continuously Variable Transmission (CVT) operation, maintenance, belt inspection and replacement, clutch service, differential service.
Drivetrain System:
Shaft drive, universal joints, axle shafts, final drive housing.
Suspension System:
Front and rear suspension components, shock absorbers, bushings, control arms.
Braking System:
Hydraulic brake system, brake fluid, master cylinder, brake calipers, brake pads, brake drums (rear), brake cables.
Steering System:
Steering column, tie rods, steering knuckle, steering linkage components.
Electrical System:
Battery, charging system (generator/alternator), starter motor, lighting (headlights, taillights, brake lights), ignition coil, wiring diagrams, fuses, switches.
Chassis And Body:
Frame inspection, body panels, seats, cargo bed, roll bar (ROPS), guards.
Maintenance Tasks:
Oil and filter changes, air filter replacement, spark plug service, fuel filter replacement, coolant flush and replacement, brake pad/shoe replacement, lubrication points, tire pressure checks.
Diagnostic Procedures:
Troubleshooting common issues, symptom-based diagnostics, electrical circuit testing, engine performance diagnostics.
Repair Procedures:
Engine rebuild, carburetor adjustment/rebuild, CVT belt replacement, brake system repair, suspension component replacement, electrical component repair, radiator service.
Installation Procedures:
Component removal and installation for all major systems.
Depth Of Coverage:
Comprehensive. Covers basic maintenance, routine servicing, troubleshooting, diagnostics, and complete mechanical and electrical component repair and overhaul.
Engine Type:
Four-stroke, air-cooled, single-cylinder gasoline engine.
Engine Displacement:
Approximately 391cc (23.8 cubic inches).
Bore X Stroke:
Specific values would be detailed in the manual, but typical for this class.
Horsepower Rating:
Typically around 11-13 HP (at crankshaft, dependent on specific tuning and year).
Torque Rating:
Specific values would be detailed in the manual.
Fuel Delivery:
Carburetor (Mikuni or similar).
Fuel Type:
Unleaded gasoline.
Ignition Type:
CDI (Capacitor Discharge Ignition).
Oil Type:
Kawasaki recommends specific motorcycle or small engine oil grades (e.g., SAE 10W-40 or 20W-50, API SG or higher).
Cooling Method:
Forced air cooling.
Transmission Type:
CVT (Continuously Variable Transmission) with belt drive.
Drive Modes:
2WD (Rear Wheel Drive) typically, with some models potentially offering 4WD capabilities (manual would specify).
Clutch Type:
Torque converter and centrifugal clutch assembly.
Gear Selection:
Typically High (H), Low (L), Neutral (N), and Reverse (R).
Cvt Fluid Type:
Specific CVT fluid or recommended oil type as per Kawasaki's specifications (detailed in manual).
Overall Length:
Approximate: 95.5 - 100 inches (varies slightly by year/configuration).
Overall Width:
Approximate: 48.4 - 50 inches.
Overall Height:
Approximate: 70.3 - 71.7 inches.
Cargo Bed Dimensions:
Approximate: 33.5 x 37.2 x 7.9 inches (Length x Width x Depth).
Cargo Bed Capacity:
Approximately 200-300 lbs (check manual for exact rating).
Curb Weight:
Approximate: 765 - 815 lbs (varies by configuration).
Towing Capacity:
Typically rated around 500-1100 lbs (check manual for exact rating).
Payload Capacity:
Approximately 350-450 lbs (includes rider and cargo).
Engine Oil Change:
Typically every 50-100 hours of operation or annually, whichever comes first (refer to manual for precise intervals).
Air Filter Inspection:
Regular inspection, cleaning, or replacement as needed, especially in dusty conditions (e.g., every 25-50 hours).
Spark Plug Replacement:
Recommended replacement every 100-200 hours or annually.
Cv Belt Inspection:
Periodic inspection for wear, cracks, and proper tension (e.g., every 50-100 hours or annually).
Engine Oil Capacity:
Approximate: 1.5 - 1.8 liters (1.6 - 1.9 US qt).
Coolant Type:
Permanent type antifreeze/coolant, 50/50 mix with distilled water (specific Kawasaki recommendation should be followed).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Carburetor Fouling:
Common with infrequent use or poor fuel quality; requires cleaning and adjustment.
Cv Belt Wear:
Aggressive use or improper belt tension can lead to premature wear.
Starter Solenoid Issues:
Can sometimes develop wear or connection problems.
Kawasaki Motorsports:
Kawasaki Heavy Industries has a long and reputable history in motorcycle and powersports manufacturing, known for engineering and performance.
Mule Series Origin:
The Mule utility vehicle line was introduced in the late 1980s, evolving into various configurations, with the Mule 600 series representing a more compact and entry-level offering.
Manufacturing Origin:
Kawasaki powersports vehicles are typically manufactured in Japan or through their international assembly plants.
