Pulling the CVT cover on a Mule this afternoon goes easier with this 409-page Kawasaki Mule 600 service manual PDF (OEM 99924-1349-01) open beside you. It is written for the KAF400 utility vehicle series and covers seven model designations, the Mule 610 4x4 included. Wiring diagrams for the ignition and charging circuits anchor the electrical chapter, one of the longest in the book, and the appendix finishes with a troubleshooting guide plus cable, wire, and hose routing. Converter work has its own chapter, running from the drive and driven pulleys through the torque converter. Measure your drive belt width first: standard is 26.1 to 27.3 mm, and anything under 25.2 mm comes out; gap the plug at 0.7 to 0.8 mm. Out at the back fence, it's you, the Mule, and nobody to ask. Bookmarked chapters and a live text layer take you to the one section you need in a couple of clicks.
What's Inside This Kawasaki Mule 600, Mule 610 4x4 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 9-20 | Before Servicing, Model Identification, General Specifications |
| Periodic Maintenance | 21-58 | Periodic Maintenance Chart, Torque and Locking Agent, Periodic Maintenance Procedures |
| Fuel System | 59-84 | Throttle Pedal and Cable, Governor Link Mechanism, Carburetor |
| Engine Top End | 85-102 | Cylinder Head, Valves, Exhaust Pipe and Muffler |
| Converter System | 103-130 | Torque Converter, Drive Pulley, Driven Pulley |
| Engine Lubrication System | 131-142 | Oil Pump and Relief Valve, Oil Screen |
| Engine Removal/Installation | 143-150 | Engine Removal, Engine Installation |
| Engine Bottom End | 151-174 | Camshaft and Tappets, Cylinders and Pistons, Crankshaft and Connecting Rods |
| Transmission | 175-212 | Transmission Case, Transmission and Shift Mechanism, Differential Gears and Shift Mechanism |
| Wheels/Tires | 213-222 | Wheel Alignment, Wheels, Tires |
| Final Drive | 223-268 | Front Final Gear Case, Bevel Gear Case, Propeller Shafts |
| Brakes | 269-290 | Brake Fluid, Brake Pedal and Master Cylinder, Brake Panel Assemblies |
| Suspension | 291-302 | Struts and Rear Shock Absorbers, Front Suspension Arms, Swingarm |
| Steering | 303-314 | Steering Wheel and Main Shaft Assembly, Steering Gear Assembly, Steering Knuckles |
| Frame | 315-336 | Seat and Seat Belts, Control Panel, Cargo Bed |
| Electrical System | 337-388 | Battery, Charging System, Ignition System |
| Appendix | 389-409 | Troubleshooting Guide, Cable, Wire, And Hose Routing |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine Oil Drain Plugs Torque | 6.9 N·m (0.70 kgf·m, 61 in·lb) | p. 133 |
| Ring Gear Cover Bolts M10 Torque | 47 N·m (4.8 kgf·m, 35 ft·lb) | p. 233 |
| Drive Belt Width Standard | 26.1 - 27.3 mm | p. 29 |
| Drive Belt Width Service Limit | 25.2 mm | p. 29 |
| Spark Plug Gap | 0.7 - 0.8 mm | p. 30 |
| Oil Filter Joint Torque | 6.9 N·m (0.70 kgf·m, 61 in·lb) | p. 133 |
| Battery Capacity | 12 V 14 Ah | p. 19 |
| Carburetor Mounting Nuts Torque | 6.9 N·m (0.70 kgf·m, 61 in·lb) | p. 61 |
| Choke Valve Screws Torque | 0.90 N·m (0.09 kgf·m, 7.8 in·lb) | p. 61 |
| Air Cleaner Housing Bolts Torque | 17 N·m (1.7 kgf·m, 12 ft·lb) | p. 80 |
| Fuel Pump Bracket Bolt Torque | 5.4 N·m (0.55 kgf·m, 48 in·lb) | p. 80 |
| Ring Gear Cover Bolts M8 Torque | 25 N·m (2.6 kgf·m, 19 ft·lb) | p. 233 |
Kawasaki Mule 600, Mule 610 4x4 Common Problems This Manual Covers
Kawasaki Mule 610 KAF400 engine no-start or hard starting with no fuel flow or flooded engine
Check fuel flow to the carburetor first and drain a flooded float chamber, then pull the spark plug and set the gap to 0.7 to 0.8 mm per page 30. Work through the no-start and starting difficulty charts on page 390. When refitting the carburetor, torque the mounting nuts to 6.9 N·m (page 61).
Manual Section: Engine Troubleshooting p. 390Drive belt and converter overheating or converter not operating properly under load
Inspect the drive belt and measure its width at several points. Standard is 26.1 to 27.3 mm; replace the belt below 25.2 mm (page 108). Check belt deflection against 22 to 32 mm, with a service limit of 22 to 50 mm. Then run the converter operation and belt heating checks on page 391.
Manual Section: Converter System p. 108Engine lubrication or cooling system problem with the engine overheating under heavy load
Check engine oil level first and fill to spec; capacity is 0.85 L without a filter change or 1.4 L with the filter removed (page 29). Torque the drain plugs to 6.9 N·m (page 133). Then work through the overheating, lubrication and cooling system checks on page 391.
Manual Section: Miscellaneous Engine/Drive Train Troubleshooting p. 391Front final gear case noise or heavy steering on 4x4 models while turning
Check the front final gear case oil level and condition first; KAF400-A/C cases hold 0.2 L (page 44). Drain and refill if the oil is low or contaminated. Then run the drive train noise and steering checks on page 392 and inspect the gear case following the Final Drive section on page 223.
Manual Section: Final Drive p. 223Brake system does not hold the vehicle with poor brake performance from the pedal
Check brake fluid level and condition at the master cylinder, then inspect the brake pedal and master cylinder for proper operation. Remove and inspect the brake panel assemblies following the Brakes section on page 269. Cross-check the brake performance items in the handling and stability chart on page 392.
Manual Section: Brakes p. 269Charging system problem with battery repeatedly discharged or overcharged after normal use
Verify the battery is the specified 12 V 14 Ah unit (page 19). Test the charging system following the Electrical System section starting on page 337, and trace the charging circuit against the wiring diagram. Replace the battery only after the charging system checks out.
Manual Section: Electrical System p. 337Frequently Asked Questions
What is the torque specification for the engine oil drain plug on the Kawasaki Mule 600 and Mule 610 4x4?
The engine oil drain plug for the Kawasaki KAF400 must be tightened to a torque of 6.9 N·m (0.70 kgf·m, 61 in·lb). p. 41
What are the torque specifications for the differential case bolts and bevel gear case bolts on the Kawasaki Mule 600 and Mule 610 4x4?
The differential case bolts are tightened to 49 N·m (5.0 kgf·m, 36 ft·lb). On the Mule 610 4x4 (KAF400-A/C), the bevel gear case bolts are tightened to 20 N·m (2.0 kgf·m, 14 ft·lb). p. 26
What are the replacement specifications for the CVT drive belt on the Kawasaki Mule 600 and Mule 610 4x4?
The standard width for the drive belt is 26.1 to 27.3 mm (1.03 to 1.07 in.). The service limit for the belt width is 25.2 mm (0.99 in.). p. 38
What are the replacement specifications for the spark plug on the Kawasaki Mule 600 and Mule 610 4x4?
The standard spark plug for the KAF400 is the NGK BPR5ES. The spark plug gap should be set between 0.7 and 0.8 mm (0.028 to 0.032 in.). p. 346
What is the standard valve clearance for the Kawasaki Mule 600 and Mule 610 4x4 KAF400 engine?
The valve clearance for the KAF400 engine, when checked while the engine is cold, should be between 0.10 and 0.15 mm (0.0039 to 0.0059 in.). p. 29
How will I receive this Kawasaki Mule 600 and Mule 610 4x4 Service Manual?
This is a 409-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Is printing allowed for this Kawasaki Mule 600 and Mule 610 4x4 Service Manual?
Yes. Print the pages or sections you need for your own shop use. Any standard printer works.
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