Category:
Compact Utility Vehicle (UTV) / Side-by-Side
Target Audience:
Owners and operators of Kawasaki Mule 600/610 4x4 vehicles for light-duty agricultural, property maintenance, and recreational use.
Competitors 2005:
John Deere Gator, Cub Cadet Volunteer, Polaris Ranger (early models), Yamaha Rhino.
Utility Focus:
Designed for practical work and utility tasks, with a focus on reliability and maneuverability.
Compact Size:
Smaller footprint compared to larger UTVs, making it suitable for tighter trails and spaces.
4X4 Capability:
Selectable 4WD system for enhanced traction in challenging terrain.
Engine:
Engine overhaul, disassembly, assembly, tuning, lubrication system, cooling system, fuel system, ignition system.
Transmission:
CVT (Continuously Variable Transmission) service, belt inspection/replacement, gearbox maintenance, differential service.
Drivetrain:
4x4 system operation, front and rear differential service, driveshaft inspection, U-joints, axle shafts.
Brakes:
Hydraulic brake system, brake pad/shoe replacement, caliper/wheel cylinder service, bleeding procedures, parking brake adjustment.
Electrical:
Wiring diagrams, battery maintenance, starting system, charging system (alternator/stator), lighting system, ignition switch, fuses, relays.
Chassis Suspension Steering:
Front and rear suspension components, shock absorbers, ball joints, bushings, steering linkage, tie rods, wheel alignment specifications.
Bodywork Frame:
Body panel removal/installation, seat maintenance, cargo bed service, frame inspection and repair guidelines.
Fuel System:
Carburetor service and adjustment, fuel filter replacement, fuel tank and lines.
Maintenance:
Routine maintenance procedures, lubrication points, oil change intervals, filter replacement schedules.
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation.
Overhaul:
Detailed procedures for complete engine and transmission overhauls.
Diagnostics:
Diagnostic procedures for electrical and mechanical systems, including testing methods.
Depth:
Comprehensive (covers everything from basic maintenance to complete engine and drivetrain rebuilds).
User Level:
Suitable for professional technicians, experienced DIY mechanics, and serious hobbyists.
Type:
4-stroke, OHV, V-twin, liquid-cooled (although some sources indicate air-cooled for KAF400. Clarification from manual is key.)
Bore X Stroke Mm:
Approx. 64 x 62 mm (typical for this class, confirm in manual).
Compression Ratio:
Typically around 9.3:1 (confirm in manual).
Valve Configuration:
Overhead Valve (OHV)
Horsepower Hp:
Approximately 14-15 HP (at specified RPM, consult manual for exact figure).
Torque Lb-Ft:
Not typically published as a primary spec, but estimated around 20-22 lb-ft (confirm in manual).
Induction:
Carburetor (Mikuni VM series or similar, confirm in manual).
Fuel Type:
Unleaded gasoline, 87 octane minimum.
Fuel Tank Capacity Liters:
Approximately 4.0 gallons / 15.1 liters (confirm in manual).
Type:
Automatic (CVT - Continuously Variable Transmission)
Drive Modes:
2WD / 4WD selectable
Gear Selection:
Forward (Hi/Low), Neutral, Reverse
Cooling:
CVT oil cooling via heat exchanger or air cooling (confirm in manual).
Cv Belt Maintenance:
Includes inspection, adjustment, and replacement procedures for the drive belt.
Overall Length Mm:
Approx. 2300-2350 mm (confirm exact for 600/610 variant).
Overall Width Mm:
Approx. 1140-1150 mm (confirm exact for 600/610 variant).
Overall Height Mm:
Approx. 1740-1750 mm (to highest point, confirm for 600/610 variant).
Wheelbase Mm:
Approx. 1630-1640 mm (confirm exact for 600/610 variant).
Ground Clearance Mm:
Approx. 160-165 mm (confirm for 600/610 variant).
Cargo Bed Length Mm:
Approx. 700-750 mm (confirm exact for 600/610 variant).
Cargo Bed Width Mm:
Approx. 1000-1050 mm (confirm exact for 600/610 variant).
Cargo Bed Height Mm:
Approx. 200-250 mm (confirm exact for 600/610 variant).
Cargo Bed Capacity Kg:
Approx. 150-200 kg (confirm specific model rating).
Curb Weight Kg:
Approx. 300-350 kg (confirm specific model/trim).
Towing Capacity Kg:
Typically around 450-500 kg (confirm specific model rating).
Payload Capacity Kg:
Approx. 250-300 kg (total vehicle capacity, confirm specific model rating).
Rollover Protection:
ROPS (Roll-Over Protective Structure) standard on all models, meeting relevant safety standards for UTVs.
Braking System:
Hydraulic disc brakes front and rear.
Parking Brake:
Mechanical parking brake, typically on rear wheels or transmission output shaft.
Seat Belts:
Standard 3-point seat belts.
Lighting:
Headlights, tail lights, brake lights.
Engine Oil Change:
Every 60 hours or 6 months (whichever comes first), use SAE 10W-40 API SG or higher.
Oil Filter Replacement:
Every engine oil change, or every 120 hours/12 months.
Air Filter Cleaning Replacement:
Inspect every 30 hours, clean/replace as needed. More frequent in dusty conditions.
Spark Plug Replacement:
Check gap every 60 hours, replace as needed. Typical plug: NGK CR6HSA or equivalent.
Cv Belt Inspection:
Inspect every 60 hours for wear and damage. Replace if more than 1mm of thickness is lost or if cracks appear.
Engine Oil Type:
SAE 10W-40, API SG or higher
Engine Oil Capacity Liters:
Approx. 1.8 L (including filter) (confirm in manual).
Transmission Cvtf:
Specific CVT fluid required (consult manual for exact specification, typically a proprietary Kawasaki fluid or equivalent). Do NOT use standard ATF.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors (typically a 50/50 mix with distilled water).
Carburetor Icing:
Can be susceptible to carburetor icing in cold, humid conditions.
Cv Belt Wear:
Regular inspection and timely replacement of the CVT belt is crucial to prevent sudden loss of power or belt failure.
Throttle Response:
Some users report less immediate throttle response compared to higher-performance UTVs.
Seat Comfort:
Basic seat design may be less comfortable for extended periods compared to more premium models.
Kawasaki Motorsports:
Kawasaki Heavy Industries has a long history in motorsports, motorcycles, and powersports equipment, known for engineering and performance.
Mule Lineage:
The Mule line has been a staple in the utility vehicle market since its introduction in the late 1980s, evolving in size, power, and features.
Kaf400 Generation:
The KAF400 platform represents an entry-level, compact offering within the Mule range, designed for cost-effectiveness and maneuverability.
Manufacturing Location:
Primarily manufactured in Japan and/or USA (confirm specific year/model batch).
Production Years Kaf400:
The KAF400 platform was in production for a significant period, with the 600/610 models being key iterations.
