🏷️ Basic Information

Make:

Kawasaki

Model:

Mule 600 / Mule 610 4x4

Year:

2005

Chassis Code:

KAF400

Product Code:

KAF400-2005-SVC-PDF

👋 Introduction

Market Position:

The Kawasaki Mule series is a popular line of utility vehicles known for their ruggedness and versatility in various work and recreational applications. This manual serves as a critical resource for owners and technicians needing to maintain and repair these vehicles.

Competitive Analysis:

The Mule 600 and 610 4x4 compete in the compact utility vehicle segment, often against models from John Deere, Kubota, and Yamaha. A comprehensive service manual is essential for maintaining the reliability and longevity of these workhorses in demanding environments.

Key Features:

Digital PDF format for instant access, lifetime replacement policy, detailed step-by-step procedures, OEM specifications, exploded diagrams, comprehensive troubleshooting guidance, wide system coverage.

📋 Manual Details

Coverage Areas:

Kawasaki Mule 600, Kawasaki Mule 610 4x4

Page Count:

Unknown (Digital PDF, typically hundreds of pages for a comprehensive service manual)

Manual Type:

Service Repair Shop Manual

Language:

English

Format:

Digital PDF Download

📖 Manual Coverage

Systems Covered:

General Information, Assembly and Disassembly, Routine Maintenance, Engine Removal and Installation, Fuel System, Lubrication and Cooling System, Engine Specifications, Transmission, Drive Chain & Sprockets, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting, Chassis, Suspension, Braking System, Wheels and Tires, Frame, Clutch, Drivetrain, Exhaust System, Ignition System, Lighting System, Wiring Diagrams, Troubleshooting

Procedures Included:

Tune-ups, lubrication, major engine rebuilds, transmission rebuilds, clutch adjustment, brake service, suspension adjustments, electrical diagnostics, troubleshooting, component replacement, fluid changes, scheduled maintenance, disassembly and reassembly procedures

Technical Depth:

Comprehensive. Covers everything from routine maintenance to major component overhauls. Includes OEM specifications for torque values, fuel pressure, electrical data, compression ranges, and tolerances. Detailed step-by-step instructions with exploded diagrams, charts, and illustrations.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, suitable for professional printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine:

Kawasaki FE290D (4-stroke, OHV, V-twin gasoline engine)

Engine Displacement:

290 cc (17.7 cubic inches)

Bore X Stroke:

70.0 mm x 75.0 mm (2.76 in x 2.95 in)

Compression Ratio:

8.7:1

Cooling System:

Forced Air Cooling

Ignition System:

CDI (Capacitor Discharge Ignition)

Fuel System:

Carburetor (e.g., Mikuni BS Series)

Oil Type:

SAE 10W-40 API SE or SF (Refer to manual for exact specification)

Oil Capacity:

Approximately 1.4 L (1.5 US qt) (Refer to manual for exact capacity)

🔧 Transmission

Transmission Type:

Continuously Variable Transmission (CVT) with High/Low Range

Drive System:

Shaft Drive, Selectable 4WD

Gear Ratios:

Refer to manual for specific High and Low range ratios

Clutch Type:

Automatic Belt Drive

Differential:

Limited Slip Differential (Front and Rear on 4x4 models)

📐 Dimensions

Exterior Length:

Approx. 2,495 mm (98.2 in)

Exterior Width:

Approx. 1,275 mm (50.2 in)

Exterior Height:

Approx. 1,810 mm (71.3 in)

Wheelbase:

Approx. 1,700 mm (66.9 in)

Ground Clearance:

Approx. 135 mm (5.3 in)

Cargo Bed Capacity:

Approx. 180 kg (396 lbs)

Towing Capacity:

Approx. 363 kg (800 lbs)

Curb Weight:

Approx. 500 kg (1102 lbs) (Varies by model/configuration)

Tire Size Front:

AT22x8-10 (Common)

Tire Size Rear:

AT22x10-10 (Common)

Wheel Bolt Pattern:

4x110 mm

🛡️ Safety Features

Ratings:

Not typically rated by NHTSA or IIHS for passenger vehicle safety standards. Designed as an off-road utility vehicle.

Active Features:

Four-wheel drive, differential lock, robust braking system (disc brakes front and rear)

Passive Features:

Seat belts, roll-over protection structure (ROPS), headrests, grab handles

💡 Technology Features

Infotainment:

Basic functionality, typically no complex infotainment systems. Features may include a 12V accessory outlet.

Driver Assistance:

None typical for this class of utility vehicle.

Connectivity:

N/A

🔧 Maintenance

Service Intervals:

The manual details specific intervals for oil changes (e.g., every 50-100 operating hours or annually), filter replacements, spark plug inspection, drive belt inspection, valve adjustments, and brake system checks. Consult the manual for precise intervals.

Fluid Specifications:

Engine Oil: SAE 10W-40 API SE/SF, Gearbox/Differential Oil: SAE 80W-90 API GL-4 (specific fill points and types are detailed in the manual), Brake Fluid: DOT 3 or DOT 4.

Known Issues:

Common issues addressed in the manual may include CVT belt wear, carburetor adjustment/cleaning, carburetor icing in cold weather, charging system issues, and occasional starter problems. The manual provides detailed diagnostic and repair procedures for these.

Air Filter Part Number:

Refer to manual or OEM parts catalog for specific part number (e.g., 11013-2077 or equivalent).

Oil Filter Part Number:

Refer to manual or OEM parts catalog for specific part number (e.g., 16097-0004 or equivalent).

Spark Plug Type:

NGK BPR5ES (or equivalent, check manual for exact spec and gap)

📚 Vehicle History

Brand Heritage:

Kawasaki has a long-standing reputation for producing reliable and durable powersports vehicles, including motorcycles, ATVs, and utility vehicles. Their engineering expertise is evident in the robust construction of the Mule line.

Model Evolution:

The Mule 600 and 610 series represent Kawasaki's entry into the compact utility vehicle market, offering a more affordable and maneuverable option compared to larger utility vehicles. They have seen minor updates and refinements over their production run.

Production:

The KAF400 chassis, encompassing the Mule 600 and 610 models, was in production for several years, with the 2005 model being a significant year for this platform.

🏆 Awards & Recognition

Recognitions:

Kawasaki Mule vehicles are generally recognized for their durability and utility in various work environments. Specific awards for the 2005 KAF400 model are not widely publicized, but the line is consistently rated well for its intended purpose.