Kawasaki MULE 610 4×4 MULE 600 Vehicle Service Manual PDF

Description

Kawasaki MULE 610 4×4 MULE 600 Vehicle Service Manual – PDF DOWNLOAD

FILE DETAILS:

Kawasaki MULE 610 4×4 MULE 600 Vehicle Service Manual – PDF DOWNLOAD 

Language : English
Pages : 411
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Kawasaki MULE 610 4×4 MULE 600 Vehicle Service Manual – PDF DOWNLOAD 

tables 1
LIST OF ABBREVIATIONS 6
Units of Mass 22
Units of Volume 22
Units of Force 22
Units of Length 22
Units of Torque 22
Units of Pressure 22
Units of Speed 22
Units of Power 22
Basic Torque for General Fasteners of Engine Parts 30
Basic Torque for General Fasteners of Frame Parts 30
Throttle Pedal Free Play 34
Idle Speed 34
Idle Speed 35
Valve Clearance (when cold) 39
Belt Width 40
Belt Deflection 40
shims 41
Wear Shoe Width 42
Engine Oil 43
Transmission Oil 44
Tire Tread Depth 45
Standard Tire 45
Front Final Gear Case Oil 46
Brake Pedal Free Play 48
Brake Drum Inside Diameter 51
Brake Shoe Lining thickness 52
Parking Brake Lever Travel 53
Steering Wheel Free Play 54
Spark Plug Gap 55
Specific Gravity 56
Brake Light Switch Timing 56
Idle Speed 70
Choke Knob Free Play 73
Cylinder Compression 92
Rocker Arm Push Rod Runout 95
Cylinder Head Warp 96
Valve Seating Surface Outside Diameter 97
Valve Seating Surface Width Standard 97
Valve Spring Free Length 101
Valve Head Thickness 101
Valve Stem Bend 101
Valve Stem Diameter 101
Valve Guide Inside Diameter 102
Valve/Guide Clearance (Wobble Method) 102
Driven Pulley 114
Drive Pulley 115
Cover Bushing Inside Diameter [A] 122
Sheave Bushing Inside Diameter [A] 122
Spring Free Length [A] 123
Shoe Side Clearance 124
Sheave Bushing Inside Diameter 129
Spring Free Length [A] 129
Inner and Outer Rotor Clearance 140
Outer Rotor Outside Diameter 140
Outer Rotor Thickness 140
Pump Housing Inside Diameter 141
Pump Housing Depth 141
Pump Shaft Outside Diameter 141
Pump Shaft Bearing Inside Diameter 141
Relief Valve Spring Free Length 142
Cam Lobe Height 162
Crankcase Side Camshaft Journal Diameter 162
Crankcase Cover Side Camshaft Journal Diameter 162
Camshaft Bearing Inside Diameter (Crankcase) 162
Camshaft Bearing Inside Diameter (Crankcase Cover) 162
Piston Ring/Groove Clearance 166
Piston Ring Thickness 166
Piston Ring End Gap 167
Piston Pin Outside Diameter 167
Piston Pin Hole Inside Diameter 167
Connecting Rod Small End Inside Diameter 167
Piston Diameter 168
Cylinder Inside Diameter 168
Cylinder Bore Out-Round 168
Connecting Rod Bend 170
Connecting Rod Twist 170
Connecting Rod Big End Width 170
Crankpin Width 170
Connecting Rod Big End Inside Diameter 171
Crankpin Outside Diameter 171
Crankshaft Runout 171
Crankcase Side Crankshaft Main Journal Diameter 171
Crankshaft Main Bearing Inside Diameter (Crankcase Side) 172
Balancer Shaft Journal Diameter 173
Balancer Shaft Bearing Inside Diameter (Crankcase) 173
Balancer Shaft Bearing Inside Diameter (Crankcase cover) 173
Shift Fork Ear Thickness 201
Shifter Groove Width [A] 201
Reverse Chain 20-Link Length [B] 202
Shifter Block Outside Diameter 204
Shifter Groove Width 204
Shift Shaft Pin Diameter [A] 207
Shifter Groove Width [B] 207
Toe-in of Front Wheels 220
Tie-rod Length (distance between flange end and locknut) 220
Maximum Tire Air Pressure (to seat beads when cold) 223
Tire Air Pressure (when cold) 224
LSD Clutch Torque 239
Outside Friction Plate Thickness [A] 239
Inside Friction Plate Thickness [B] 239
Bevel Gear Backlash 242
Bevel Gear Backlash 253
Drive Gear Shims [4] 254
Standard Length of Assembling: 265
Standard Length of Assembling: 268
Recommended Brake Fluid 278
Spring Action 299
Battery Troubleshooting Guide 358
Regulator/Rectifier Output Voltage 363
Stator Coil Resistance 364
Ignition Coil Air Gap 368
Ignition Coil Winding Resistance 368
Testing Solenoid 371
Testing Starter Motor 372
Carbon Brush Length 375
Commutator Groove Depth 375
Commutator Outside Diameter 376
Commutator Runout 376
Armature Winding Resistance 376
Commutator to Shaft Resistance 376
Positive Brush to Ground Resistance 377
Negative Brush to Ground Resistance 377
Testing Relay 378
Oil Temperature Sensor Resistance 386
Internal Resistance Unit: kΩ 387
toc 1
Read OWNER’S MANUAL before operating 6
EMISSION CONTROL INFORMATION 7
1 7
2 7
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (United States Mo 8
Foreword 9
General Information 11
Before starting to perform an inspection service or carry out a 12
Battery Ground 12
Edges of Parts 12
Solvent 12
Cleaning vehicle before disassembly 12
Arrangement and Cleaning of Removed Parts 13
Storage of Removed Parts 13
Inspection 13
Replacement Parts 13
Assembly Order 13
Tightening Sequence 14
Tightening Torque 14
Force 14
Gasket, O-ring 14
Liquid Gasket, Locking Agent 14
Press 15
Ball Bearing and Needle Bearing 15
Oil Seal, Grease Seal 15
Circlips, Cotter Pins 15
Lubrication 16
Direction of Engine Rotation 16
Electrical Wires 16
KAF400-A1 Left Side View 17
KAF400-A1 Right Side View 17
KAF400-B1 Left Side View 18
KAF400-B1 Right Side View 18
Prefixes for Units 22
Units of Temperature: 22
Periodic Maintenance 23
The scheduled maintenance must be done in accordance with this c 24
The following tables list the tightening torque for the major fa 26
Inside Circlip Pliers: 33
Fuel System 34
Throttle Pedal Free Play Inspection 34
Throttle Pedal Free Play Adjustment 34
Idle Speed Inspection 34
Idle Speed Adjustment 35
Air Cleaner Element Cleaning 35
Fuel Hoses And Connections Inspection 36
Fuel Hoses Replacement 37
Fuel Filter Replacement 37
Fuel System Cleanliness Inspection 38
Engine Top End 38
Valve Clearance Inspection 38
Valve Clearance Adjustment 39
Torque – 39
Spark Arrester Cleaning 39
Converter System 40
Drive Belt Inspection 40
Drive Belt Deflection Inspection 40
Drive Belt Deflection Adjustment 41
Torque – 41
Converter Driven Pulley Shoe Inspection 41
Converter Air Cleaner Element Cleaning/Inspection 42
Converter Dust or Water Drain 43
Engine Lubrication System 43
Engine Oil Change 43
Torque – 43
Oil Filter Replacement 44
Special Tool – 44
Special Tool – 44
Torque – 44
Transmission 44
Transmission Oil Change 44
Torque – 44
Wheels/Tires 45
Wheels Nuts Tightness Inspection 45
Torque – 45
Tire Wear Inspection 45
Final Drive (KAF400-A/C models) 45
Front Final Gear Case Oil Change 45
Torque – 46
Torque – 46
Brakes 46
Brake Fluid Level Inspection 46
Brake Fluid Change 47
Torque – 48
Torque – 48
Brake Pedal Play Inspection 48
Torque – 48
Brake Master Cylinder Cup and Dust Seal Replacement 49
Special Tool – 49
Torque – 49
Brake Hose and Pipe Inspection 50
Brake Hose and Pipe Replacement 50
Torque – 51
Torque – 51
Brake Wear Inspection 51
Brake Wheel Cylinder Assembly Replacement 52
Sealant – 53
Torque – 53
Parking Brake Lever Inspection 53
Steering 54
Steering Inspection 54
Steering Joint Dust Boot Inspection 54
Frame 55
Seat Belt Inspection 55
Torque – 55
Electrical System 55
Spark Plug Cleaning/Inspection 55
Spark Plug Gap Inspection 55
Electrolyte Level Inspection 55
Electrolyte Specific Gravity Inspection 56
Brake Light Switch Inspection 56
General Lubrication 57
Pivots and Points: Lubricate with Grease 57
Cables: Lubricate with Rust Inhibitor 57
Cables: Lubricate with Motor Oil 57
Bolts, Nuts, and Fasteners 58
Tightness Inspection 58
Nut, Bolt, and Fasteners to be checked 58
Fuel System 61
Throttle Pedal Free Play Inspection 67
Throttle Pedal Free Play Adjustment 67
Full Throttle Pedal Position Adjustment 67
Throttle Cable Installation 67
Throttle Cable Lubrication 67
Throttle Cable Inspection 67
Control Panel Assembly Removal 68
Control Panel Assembly Installation 68
Torque – 68
Governor Assembly Removal 72
Governor Assembly Installation 72
Governor Assembly Inspection 72
Choke Knob Free Play Inspection 73
Choke Knob Free Play Adjustment 73
Choke Cable Installation 73
Choke Cable Lubrication 73
Choke Cable Inspection 74
Idle Speed Inspection 75
Idle Speed Adjustment 75
Fuel System Cleanliness Inspection 75
Carburetor Removal 75
Carburetor Installation 76
Torque – 76
Carburetor Disassembly 76
Carburetor Assembly 78
Torque – 78
Carburetor Cleaning 79
Carburetor Inspection 79
Pilot Screw Setting 80
Air Cleaner Element Removal 81
Air Cleaner Element Installation 81
Air Cleaner Housing Removal 81
Air Cleaner Housing Installation 82
Torque – 82
Air Cleaner Housing Dust and/or Water Installation 82
Fuel Pump Removal 83
Fuel Pump Installation 83
Torque – 83
Fuel Pump Inspection 83
Fuel Filter Removal 85
Fuel Filter Installation 85
Fuel Filter Inspection 85
Fuel Tank Removal 86
Fuel Tank Installation 86
Fuel Tank Cleaning/Inspection 86
Engine Top End 87
Compression Gauge, 20 kgf/cm : 91
Cylinder Compression Measurement 92
Special Tools – 92
Cylinder Head Removal 92
Cylinder Head Installation 93
Torque – 94
Torque – 94
Push Rod Inspection 95
Valve Mechanism Removal/Installation 95
Rocker Arm Inspection 95
Cylinder Head Warp 96
Valve Clearance Inspection 97
Valve Clearance Adjustment 97
Valve Seat Inspection 97
Valve Seat Repair 98
Special Tools – 98
Valve Spring Free Length 101
Valve Head Thickness 101
Valve Stem Bend 101
Valve Stem Diameter 101
Valve Guide Inside Diameter 102
Measuring Valve/Guide Clearance (Wobble Method) 102
Exhaust Pipe Removal 103
Muffler Removal 103
Exhaust Pipe and Muffler Installation 104
Torque – 104
Exhaust Pipe and Muffler Inspection 104
Spark Arrester Cleaning 104
Converter System 105
Outside Circlip Pliers: 111
Air Cleaner Element Removal 112
Air Cleaner Element Cleaning/Inspection 112
Air Cleaner Housing Removal 112
Torque Converter Removal 113
Special Tool – 113
Torque – 113
Special Tool – 113
Special Tools – 114
Special Tool – 114
Torque Converter Installation 114
Special Tools – 115
Torque – 115
Special Tool – 116
Torque – 116
Torque – 116
Torque Converter Case Removal 117
Torque Converter Case Installation 118
Torque – 119
Drive Belt Removal 120
Drive Belt Installation 120
Drive Belt Inspection 120
Drive Belt Deflection Inspection 120
Drive Belt Deflection Adjustment 120
Drive Pulley Removal 121
Drive Pulley Disassembly 121
Special Tool – 121
Special Tool – 121
Drive Pulley Inspection 122
Spider Shoe Side Clearance Adjustment 123
Special Tool – 123
Bushing Installation 125
Special Tool – 125
Special Tool – 125
Drive Pulley Assembly 125
Torque – 125
Special Tool – 125
Special Tool – 126
Torque – 126
Torque – 126
Drive Pulley Installation 126
Driven Pulley Removal 127
Driven Pulley Disassembly 127
Special Tool – 127
Special Tool – 127
Driven Pulley Inspection 129
Converter Driven Pulley Shoe Inspection 129
Bushing Installation 130
Special Tool – 130
Driven Pulley Assembly 130
Torque – 130
Special Tool – 130
Special Tool – 131
Special Tool – 131
Driven Pulley Installation 131
Engine Lubrication System 133
WARNING 138
Oil Level Inspection 138
Engine Oil Change 139
Oil Filter Replacement 139
Oil Pump Removal 140
Oil Pump Installation 140
Oil Pump Inspection 140
Relief Valve Removal 141
Relief Valve Installation 142
Relief Valve Inspection 142
Oil Screen Removal 143
Oil Screen Installation 143
Oil Screen Cleaning/Inspection 143
Oil Temperature Sensor Removal 144
Oil Temperature Sensor Installation 144
Torque – 144
Engine Removal/Installation 145
Alignment Jig: 148
Engine Removal 149
Engine Installation 150
Special Tool – 150
Torque – 150
Engine Bottom End 153
Piston Ring Compressor Grip: 158
Crankcase Cover Removal 159
Crankcase Cover Assembly 159
Special Tool – 159
Crankcase Cover Installation 159
Torque – 159
Camshaft, Tappet Removal 160
Camshaft, Tappet Installation 160
Torque – 161
Camshaft Disassembly 161
Camshaft Assembly 161
Camshaft Inspection 161
Camshaft Bearing/Journal Wear 162
Piston Removal 163
Piston Installation 164
Special Tools – 165
Torque – 165
Piston Cleaning 165
Piston Ring and Ring Groove Wear 166
Piston Ring End Gap 167
Piston Pin, Piston Pin Hole, and Connecting Rod Wear 167
Piston Diameter 168
Cylinder Inside Diameter 168
Connecting Rod Removal 169
Connecting Rod Installation 169
Crankshaft Removal 169
Crankshaft Installation 169
Cleaning/Inspection 169
Connecting Rod Bend/Twist 170
Connecting Rod Big End/Crankpin Width Wear 170
Connecting Rod Big End Bearing/Crankpin Wear 171
Crankshaft Runout 171
Crankshaft Main Bearing/Journal Wear 171
Balancer Shaft Removal 173
Balancer Shaft Installation 173
Balancer Shaft Bearing/Journal Wear 173
The function of the breather is to create a negative pressure in 174
Breather Valve Removal 175
Breather Valve Installation 175
Torque – 175
Breather Valve Inspection 175
Transmission 177
Outside Circlip Pliers: 185
CAUTION 186
Transmission Oil Level Inspection 186
Transmission Oil Change 186
Transmission Case Removal 187
Transmission Case Installation 188
Special Tool – 189
Torque – 189
Torque – 189
Transmission Case Disassembly 189
Special Tool – 191
Special Tool – 191
Special Tool – 191
Transmission Case Assembly 193
Torque – 193
Torque – 195
Special Tool – 195
Torque – 195
Special Tool – 198
Sealant – 199
Torque – 199
Transmission Cable Installation 200
Torque – 200
Transmission Shift Cable Inspection 201
Shift Rod Bending 201
Shift Fork Ear and Shifter Groove Wear 201
Transmission and Shift Mechanism Inspection 202
2WD/4WD Shift Cable Adjustment 203
2WD/4WD Shift Cable Lubrication 203
2WD/4WD Shift Cable Inspection 204
2WD/4WD Shift Mechanism Removal 204
2WD/4WD Shift Mechanism Inspection 204
Differential Shift Cable Adjustment 205
Differential Shift Cable Lubrication 205
Differential Shift Cable Inspection 206
Differential Shift Mechanism Removal 206
Differential Shift Mechanism Installation 207
Torque – 207
Torque – 207
Differential Shift Mechanism Inspection 207
Differential Gear Removal 207
Differential Gear Installation 208
Torque – 208
Differential Gear Inspection 209
Bearing Replacement 210
Special Tools – 210
Special Tool – 210
Ball Bearing Inspection 210
Needle Bearing Inspection 210
Oil Seal Inspection 210
Wheels/Tires 215
Jack: 219
Toe-in is the amount that the front wheels are closer together i 220
Toe-in Adjustment 220
Torque – 220
Wheel Removal 221
Special Tool – 221
Wheel Installation 221
Torque – 221
Wheel (Rim) Inspection 221
Wheel (Rim) Replacement 222
Tire Removal 223
Tire Installation 223
Tire Wear Inspection 224
Final Drive 225
Bearing Puller: 231
Front Final Gear Case Oil Level Inspection 232
Torque – 232
Front Final Gear Case Oil Change 232
Front Final Gear Case Removal 232
Front Final Gear Case Installation 233
Front Final Gear Case Disassembly 233
Special Tool – 233
Special Tool – 233
Front Final Gear Case Assembly 235
Torque – 235
Torque – 235
Special Tool – 235
Sealant – 236
Torque – 236
Special Tool – 236
Differential Unit Disassembly 236
Differential Unit Assembly 238
Torque – 239
LSD Clutch Torque Inspection 239
LSD Clutch Plate Inspection 239
Pinion Gear Unit Disassembly 240
Special Tool – 240
Special Tool – 240
Pinion Gear Unit Assembly 240
Torque – 240
Front Final Bevel Gear Adjustment 241
Torque – 241
Special Tool – 241
Special Tool – 242
Front Final Gear Case (Backlash-Related Parts) 243
Correct Tooth Contact Pattern: No adjustment is required 246
Incorrect Tooth Contact Patterns (Example 1) 246
Incorrect Tooth Contact Patterns (Example 2) 246
Bevel Gear Inspection 247
Differential Gear Inspection 247
Ball Bearing Inspection 247
Oil Seal Inspection 247
Driven Bevel Gear Removal 248
Driven Bevel Gear Installation 248
Torque – 248
Driven Bevel Gear Disassembly 248
Special Tools – 249
Driven Bevel Gear Assembly 249
Special Tools – 249
Torque – 249
Special Tool – 250
Special Tool – 251
Drive Bevel Gear Removal 251
Special Tool – 251
Drive Bevel Gear Installation 252
Special Tool – 252
Torque – 252
Bevel Gear Adjustment 252
Special Tool – 253
Special Tool – 253
Torque – 253
Bevel Gear Case (Backlash-Related Parts) 254
Bevel Gear Inspection 255
Ball Bearing/Oil Seal Inspection 255
Front Propeller Shaft Removal 256
Front Propeller Shaft Installation 256
Rear Propeller Shaft Removal 258
Rear Propeller Shaft Installation 259
Torque – 259
Propeller Shaft Inspection 260
Front Axle Removal (KAF400-A/C) 261
Front Axle Installation (KAF400-A/C) 261
Front Axle Removal (KAF400-B) 261
Front Axle Installation (KAF400-B) 261
Torque – 261
Rear Axle Removal 262
Rear Axle Installation 262
Axle Inspection 262
Dust Boot Inspection (KAF400-A/C) 262
Front Axle Joint Boot Replacement (KAF400-A/C) 263
Special Tool – 266
Special Tool – 267
Ball Bearing Inspection 268
Grease Seal Inspection 269
Brakes 271
Front Brake 272
Rear Brake 274
Clutch Spring Compressor: 277
Brake Fluid Recommendation 278
Brake Fluid Level Inspection 278
Brake Fluid Change 278
Brake Line Air Bleeding 278
Torque – 279
Torque – 279
Brake Pedal Play Inspection 280
Master Cylinder Removal 280
Master Cylinder Installation 280
Torque – 280
Master Cylinder Disassembly/Assembly 280
Master Cylinder Inspection 281
Brake Hose and Pipe Inspection 282
Brake Hose and Pipe Replacement 282
Brake Drum Removal 283
Special Tool – 283
Special Tools – 283
Brake Drum Installation 283
Special Tool – 283
Special Tool – 283
Torque – 283
Torque – 283
Brake Drum Wear 284
Brake Panel Assy Removal 285
Brake Panel Assy Installation 285
Sealant – 285
Sealant – 286
Bond – 286
Torque – 286
Brake Panel Disassembly 286
Brake Panel Assembly 288
Torque – 289
Wheel Cylinder Removal/Installation 290
Wheel Cylinder Assembly 290
Wheel Cylinder Inspection 290
Brake Shoe Lining Wear 290
Brake Shoe Spring Inspection 291
Grease Seal Replacement 291
Special Tool – 291
Special Tool – 291
Special Tool – 291
Torque – 291
Parking Brake Lever Travel Adjustment 292
Parking Brake Cable Lubrication/Inspection 292
Suspension 293
Outside Circlip Pliers: 297
Strut (Front Shock Absorber) Removal 298
Strut (Front Shock Absorber) Installation 298
Torque – 298
Rear Shock Absorber Preload Adjustment 299
Special Tool – 299
Rear Shock Absorber Removal 299
Rear Shock Absorber Installation 299
Torque – 299
Rear Shock Absorber Inspection 300
Front Suspension Arm Removal 301
Front Suspension Arm Installation 302
Torque – 302
Front Suspension Arm Inspection 302
Swingarm Removal 303
Swingarm Installation 303
Torque – 304
Swingarm Inspection 304
Swingarm Joint Replacement 304
Special Tool – 304
Special Tool – 304
Steering 305
Inside Circlip Pliers: 309
Steering Wheel Free Play Inspection 310
Steering Wheel Centering 310
Torque – 310
Steering Wheel and Steering Shaft Removal 310
Steering Wheel and Steering Shaft Installation 311
Torque – 311
Steering Gear Assembly Removal 312
Steering Gear Assembly Installation 312
Torque – 312
Steering Gear Preload Adjustment 313
Torque – 313
Tie-rod Length Adjustment 313
Dust Boot Inspection 313
Steering Knuckle Removal 314
Steering Knuckle Installation 314
Torque – 314
Knuckle Bearing Removal 315
Special Tool – 315
Special Tool – 315
Knuckle Bearing Installation 315
Special Tool – 315
Special Tool – 315
Knuckle Joint Removal 315
Special Tool – 315
Special Tool – 315
Knuckle Joint Installation 316
Special Tool – 316
Special Tool – 316
Frame 317
Seat Removal 324
Seat Installation 324
Seat Belt Removal 324
Seat Belt Installation 324
Torque – 324
Control Panel Removal 325
Glove Compartment Removal 326
Front Cargo Hood Removal 327
Front Cargo Compartment Removal 327
Front Cargo Compartment Installation 328
Cargo Bed Removal 329
Cargo Bed Assembly 330
Cargo Bed Installation 330
Cargo Bed Latch Position Inspection 331
Cargo Bed Latch Position Adjustment 331
Front Bar Removal 332
Front Bar Installation 332
Torque – 332
Rear Bar Removal 332
Rear Bar Installation 332
Torque – 332
Front Fender Installation 333
Front Guard Removal 334
Front Guard Installation 334
Floor Center Panel Removal 334
Floor Center Panel Installation 335
Front Final Gear Case Guard Removal 335
Front Final Gear Case Guard Installation 335
Bottom Guard Removal 335
Bottom Guard Installation 336
Transmission Case Guard Removal 336
Transmission Case Guard Installation 336
Center Cover Removal 336
Center Cover Installation 336
Side Covers Removal 337
Side Covers Installation 337
Guard Plate Removal 337
Guard Plate Installation 338
Electrical System 339
Spark Plug Wrench, Hex 21: 349
Oil Temperature Warning Indicator Light [A] 350
There are a number of important precautions that are musts when 352
Wiring Inspection 354
Battery Removal 355
Battery Installation 355
Electrolyte Level Inspection 355
Electrolyte Specific Gravity Inspection 355
Charging Condition Inspection 355
Initial Charging 356
Ordinary Charging 357
Battery Charging Rate/Time Table 358
Battery Test Charging 359
Special Tool – 359
Alternator Rotor and Stator Removal 360
Alternator Rotor and Stator Installation 362
Torque – 362
Torque – 363
Torque – 363
Charging System Operational Inspection 363
Stator Coil Resistance 364
Regulator/Rectifier Inspection 364
Charging System Circuit 366
WARNING 367
Spark Plug Removal 367
Special Tool – 367
Spark Plug Installation 367
Torque – 367
Spark Plug Cleaning/Inspection 367
Spark Plug Gap Inspection 367
Ignition Coil Removal 367
Ignition Coil Installation 368
Torque – 368
Ignition Coil inspection 368
Special Tool – 368
Ignition System Circuit 369
Starter Motor Removal 370
Starter Motor Installation 370
Torque – 371
Starter Solenoid Inspection 371
Starter Motor Inspection 371
Starter Motor Disassembly 372
Starter Motor Assembly 374
Starter Motor Brush Inspection 375
Brush Spring Inspection 375
Armature Inspection 375
Yoke Assembly Inspection 377
Pinion Clutch Inspection 377
Starter Circuit Relay Inspection 377
Electric Starter Circuit 379
Headlight Beam Adjustment 380
Headlight Bulb Replacement 380
Tail/Brake Light Replacement 383
Light Switch Bulb Replacement 384
Indicator Light Bulb Replacement 384
Lighting System Circuit 385
Brake Light Switch Inspection 386
Oil Temperature Sensor Inspection (KAF400-A/C) 386
Oil Temperature Warning Indicator Control Unit Inspection (KAF40 386
Special Tool – 386
Oil Temperature Warning Control System Circuit 387
Switch Inspection 388
Neutral Switch Connections 388
Reverse Light Switch Connections (Europe Model) 388
Horn Switch Connections (Europe Model) 388
Fuse Removal 389
Fuse Installation 389
Fuse Inspection 389
Appendix 391
NOTE 392
Engine Doesn’t Start, Starting Difficulty: 392
Starter motor not rotating: 392
Starter motor rotating but engine doesn’t turn over: 392
Engine won’t turn over: 392
No fuel flow: 392
Engine flooded: 392
No spark; spark weak: 392
Compression Low: 392
Poor Running at Low Speed: 392
Spark weak: 392
Fuel/air mixture incorrect: 392
Compression low: 392
Other: 392
Poor Running or No Power at High Speed: 392
Firing incorrect: 392
Fuel/air mixture incorrect: 392
Compression low: 393
Knocking: 393
Miscellaneous: 393
Overheating: 393
Firing incorrect: 393
Fuel/air mixture incorrect: 393
Compression high: 393
Engine load faulty: 393
Converter and/or belt excessive heating: 393
Lubrication inadequate: 393
Front final gear case overheating (KAF400-A/C): 393
Cooling system component incorrect: 393
Converter Operation Faulty: 393
Belt slipping: 393
Converter engagement speed too low: 393
Converter engagement speed too high: 393
Shifting too quickly: 393
Shifting too slowly: 393
Gear Shifting Faulty: 393
Doesn’t go into gear: 393
Jumps out of gear: 393
Overshifts: 394
Abnormal Engine Noise: 394
Knocking: 394
Piston slap: 394
Valve noise: 394
Other noise: 394
Abnormal Drive Train Noise: 394
Converter noise: 394
Transmission noise: 394
Final drive noise: 394
Abnormal Frame Noise: 394
Shock absorber noise: 394
Brake noise: 394
Other noise: 394
Exhaust Smokes Excessively: 394
White smoke: 394
Black smoke: 394
Brown smoke: 394
Handling and/or Stability Unsatisfactory: 394
Steering wheel hard to turn: 394
Noise when turning (KAF400-A/C): 394
Steering wheel shakes or excessively vibrates: 394
Steering wheel pulls to one side: 395
Shock absorption unsatisfactory: 395
Brake Doesn’t Hold 395
Battery Discharged: 395
Battery Overcharged: 395

DESCRIPTION:

Kawasaki MULE 610 4×4 MULE 600 Vehicle Service Manual – PDF DOWNLOAD 

Foreword:

• This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics,  the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
• In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.
• For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this servicemanual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

S.V 16/03/2025