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kawasaki 600 mule service manual

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kawasaki 600 mule service manualSAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE A Table of Contents is included after the Foreword. Always follow safe operat- Engine exhaust, some of its constituents, ing and maintenance practices.To assist you in keeping this record, we have pro- vided space at the end of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, bills, etc., as verifica- tion of this maintenance. It is the result of Kawasaki’s engineering exper- tise and a tradition of manufacturing high-quality consumer products. Please read this Owner’s Manual carefully before starting your new Mule so that you will be thoroughly familiar with the proper operation of your vehicle’s controls, its features, capabilities, and limitations. Winch Installation. LOCATION OF PARTS.HOW TO OPERATE. LOCATION OF LABELS.Daily Checks.LOADING INFORMATION. Starting the Engine.GENERAL INFORMATION.Throttle-linked choke system. ENVIRONMENTAL PROTECTION.134 Spark Plug. MAINTENANCE RECORD.135 Valve Clearance.Engine Air Cleaner.Spark Arrester.Throttle Pedal. Practice basic maneuvers the floor while gripping the handhold. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. Carburetor 4. Front Cargo Compartment 10. Air Cleaner Intake 16. Latch 5. Dashboard 26. Fuel Tank Cap Torque Converter) 23. Fuel Gauge 20. Belt Drive Torque Converter 24. Muffler. Hour Meter 39. Glove Compartment 29. Choke Knob 34. Gear Shift Lever 40. Brake Fluid Level 30. Horn Button 35. Front Cargo Latch 41. Brake Light Switch 31. Engine Oil Temperature 36. 2WD-4WD Shift Lever 42. Warning (Hot Surface) 12. Important Emission Control Information 13. Engine Oil Information. Brake Fluid.http://www.terminalseal.com/admin/fckeditor/editor/filemanager/connectors/php/img/konica-minolta-bizhub-c353-service-manual.xml

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Accessories, Kawasaki has no control over the de- Cargo weight should be equally distributed from sign or application of accessories. Refer to the “Trailer Hitch Bracket” section in the “General Informa- tion” chapter.An auxiliary light or an accessory may be con- nected to this connector. Replace the latches at each end of the tailgate. The tailgate can now be lowered. The gate is held level to the cargo bed floor with wire loops. Do not leave the cargo bed unlatched. A. Supporting Rod B. Cargo Bed Bottom (Tilted Condition) A. Latch NOTICE B. Handgrip C. Fuel Tank Cap Do not carry more than 181 kg (400 lb) in the cargo bed. Follow guidelines left of the steering wheel, provides a rich mixture for provided in the “LOADING INFORMATION”. Prolonged engine opera- tion can result in engine damage from over- The oil temperature warning light comes on when- heating. Turn the ig- the seat. The gasoline octane rating listed is recom- nition switch to “OFF”. When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA-BIL) with the gasoline in the fuel tank. Fuel stabilizer additives inhibit oxidation of the fuel which minimizes gummy deposits. Store only light items to avoid front cargo hood. Store only light-weight items in it damage to the inside of the compartment. While lifting the latch lever at the front of the cargo hood, push and close the cargo hood. The key can be removed from the switch only when it is in the “OFF” position. A. Push here. WARNING An open front cargo hood can distract or im- pair visibility of the operator, causing loss of vehicle control and potential serious injury A. All electrical circuits off. Keys All electrical equipment can be used. Hour meter works. This UV has a key, which is used for the ignition Electric starter is engaged by holding switch, and one spare key. Included with the key is ignition switch key in this position, a key number, which is stamped on the key itself.http://www.ka-base.no/images_content/konica-minolta-bizhub-c253-operating-manual.xml It’s possible the The hour meter shows the total hours that the vehi- dealer may have the number in its records. If the key cle has been operated. Use the low gearing for maximum torque at low speeds, for climbing hills, pulling a trailer, or keeping constant low speeds. The high gearing raises the speed range for ordinary off-highway use. Be sure The parking brake lever is located at the left side to apply the parking brake before leaving the of the seat. Always wear the seat seatbacks. To loosen the belt, pull the buckle.Push the pedal down to increase engine bracket for a trailer hitch. Trailer towing equipment speed. Kawasaki offers winches and installation brack- ets as optional equipment. Contact an authorized Kawasaki dealer for more information. The time required is minimal, and habitual performance of these checks will help ensure safe, reliable operation. If any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating condition. DANGER Throttle-linked choke system Exhaust gas contains carbon monoxide, a This vehicle is equipped with the choke that con- colorless, odorless poisonous gas.Do not make this last con- nection at the carburetor or battery. Take care not to touch the positive and negative cables together, and do not lean over the bat- tery when making this last connection. Be sure to apply the parking brake before leaving the vehicle. The gear shift lever cannot be shifted when the vehicle is in motion.This vehicle is equipped with a catalytic converter NOTE in the exhaust system.Never use leaded gasoline. Leaded gasoline significantly reduces In order to protect the emission control parts, the capability of the catalytic converter.Your common sense and good judgement are your best defenses against accident and injury in everything you do.http://superbia.lgbt/flotaganis/1653276617 Your safety and the safety of others depends on you and your common sense. Use good judgement in the operation of this or any other motor vehicle. This vehicle is designed for an operator and one Unfamiliar Terrain passenger only. Before shifting into re- ing steep inclines, or driving on bumpy, sandy or verse, stop the vehicle completely. In and the surface and steepness of the hill are among this mode, the rear wheels can turn at different the critical considerations in climbing, descending or speeds allowing the vehicle to turn tighter and more. If you can’t Do not attempt to climb hills or steep inclines until see what is on the other side of the crest of a hill, you have mastered the controls and basic operating slow down until you can get a clear view. This is caused by the ve- pick a straight, safe path for descent to avoid any ob- hicle’s automatic transmission which releases the stacles. Sliding any vehicle may be haz- tipping or loss of control. When driving across shallow water, choose a to be swept into the current. The initial mainte- nance is vitally important and must not be neglected. If you are in doubt as to any adjustment or vehicle operation, please ask your authorized Kawasaki dealer to check the Mule. Every 250 hrs. or 10 OPERATION or 1 000 km hrs.Every 250 hrs. or 10 OPERATION or 1 000 km hrs.Every 250 hrs. or 10 OPERATION or 1 000 km hrs.Stop the engine, then wait Engine Oil several minutes until the oil settles. NOTICE WARNING Racing the engine before the oil reaches ev- The cargo bed requires a supporting hook ery part can cause engine damage.Tighten it to sistent use of these products meets or exceeds war- the specified torque. When draining or filling the gear case, be careful that no oil gets on the tires or rims. Clean off any oil that inadvertently gets on them with soap and water.http://familymn.com/images/collins-32s-1-service-manual.pdf WARNING Vehicle operation with insufficient, deterio- rated, or contaminated oil causes acceler- ated wear of the transmission, differential, pinion, and ring gears and may result in. To avoid a serious burn, never touch a hot muffler or exhaust pipe during oil drain- ing. The to the left side of the engine.Do not wring the element or blow it dry; the element can be dam- aged. Clean the spark arrester in accordance with the Periodic Maintenance Chart. NOTICE The spark arrester must be functioning prop- erly to provide adequate fire protection. If the throttle pedal has excessive play due to ei- ther cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed. The following procedure covers the idle speed ad- justment.DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. The system should be checked in accordance with the Periodic Maintenance Chart. WARNING Gasoline is extremely flammable and can be explosive under certain conditions and cause severe burns. Replace any kinked, deteriorated, or damaged Have your authorized Kawasaki dealer inspect hoses.If any part of the element is damaged, the element must If dirt gets into the belt drive torque con- be replaced.Brake Shoe Linings The vehicle is equipped with hydraulically acti- Brake Shoe Lining Wear Inspection vated drum brakes on all four wheels. In accordance with the Periodic Maintenance. Turn the ignition switch to the “ON” position. NOTICE To avoid damaging the electrical connec- tions inside the switch, be sure that the. Kawasaki recommends that you always pressure and both rear tires to the same replace tires with standard replacement tires as pressure. If any irregularities are found, have the seat belt system checked or replaced by an authorized Kawasaki dealer. WARNING Uneven shock absorber adjustment can cause poor handling and loss of stability, which could lead to an accident. DANGER Battery contains sulfuric acid and produce hydrogen gas. If your Mule is only used occasionally or Current Drain (Y50-N18L-A) for short periods of time, the battery is more likely to Days from discharge. Days from 100 Discharging 100 Charged Due to their internal composition, batteries contin- Charged to 50 Ampere to 100. If you will not be using your vehicle for longer than two weeks, the battery should be charged using an appropriate charger. In this case, the repair or replacement of the battery is not included in the warranty. For example, the charging rate Battery posts, terminals and related acces- for a 10 Ah battery would be 1.0 ampere. sories contain lead and lead compounds, chemicals known to the State of California to NOTICE cause cancer and reproductive harm. If the electrical systems do not func- tion, inspect the fuse. Turn the WARNING engine over several times with the ignition switch Gasoline is extremely flammable and can key to coat the cylinder walls. The warranty does not cover the cost of regularly-scheduled maintenance. The warranty also does not apply to the normal wear of items such as tires, brake pads, transmission drive belts, chains, sprockets, etc. You can go to any Kawasaki dealer for warranty repairs. Your Kawasaki dealer will inspect your vehicle and give you the results of the inspection. The dealer will perform the repairs at no cost to you if it is determined that the problem is covered by the warranty. This owner’s manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you. When using your Kawasaki Utility Ve- hicle (UV), please follow these Tread Lightly.Date Traveled Distance Maintenance Performed. Repair Manual DOWNLOAD 05. Best Kawasaki KAF400 Mule 610 4x4 and. Mule 600 Service Repair ManualThis is the most complete.Repair Manual DOWNLOAD 05. Best Kawasaki KAF400 Mule 610 4x4 and. Mule 600 Service Repair ManualThis is the most complete Service Repair Manual for the 2005 Kawasaki KAF400 Mule 610 4x4 and. Mule 600 ever compiled by mankind. This DOWNLOAD contains of high quality diagrams andThis is a must for the Do-It-Yourselfer. You will not be dissatisfied. Models Covers:Service Repair Manual Covers. General Information. Periodic Maintenance. Fuel System. Engine Top End. Converter System. Engine Lubrication System. Engine Bottom End. Transmission. Final Drive. Brakes. Suspension. Steering. Frame. Electrical System. Appendix. Most likely this means that the seller is no longer selling this product. By continuing to use this website you are giving consent to cookies being used. All of our manuals come as easy-to-use PDF files. Our downloads are FAST and EASY to use. We include instructions on how to use your manual. This manual is UNLOCKED so that you can download and place on as many devices as you want or print it out. Step-by-step instructions and exploded views are included to make your repairs simple and quick. Something went wrong. View cart for details. All Rights Reserved. User Agreement, Privacy, Cookies, Do not sell my personal information, and AdChoice Norton Secured - powered by Verisign. Use Promo Code: GOODTIMES Use Promo Code: GOODTIMES A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out the work satisfactorily.Invalid fields exist in below form. Invalid fields exist in below form. If you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.If you wish to opt out, please close your SlideShare account. Learn more. You can change your ad preferences anytime. Great assistance by guys from ???WRITE-MY-PAPER.net ???The team of writers operates very quickly. It's called ? www.HelpWriting.net ? Hope this helps!The right is reserved to make changes at any time without prior notice and without incurring an obligationto make such changes to products manufactured previously. See your dealer for the latest information onproduct improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the timeof publication.The blow -by gases are led to the breather chamber through the crankcase. Then, it is led to the intake manifold. Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned to the bottom of the crankcase. 2. Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and ignition system having optimum ignition timing characteristics. A maintenance free ignition system provides the most favorable ignition timing and helps main- tain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere.Please do not remove these systems, or alter them in any waywhich results in an increase in noise level. EachHowever, it contains enough detail and basic in- chapter in turn has its own comprehensive Ta-formation to make it useful to the owner who de- ble of Contents.sires to perform his own basic maintenance and For example, if you want ignition coil informa-repair work. A basic knowledge of mechanics, tion, use the Quick Reference Guide to locatethe proper use of tools, and workshop proce- the Electrical System chapter. Then, use thedures must be understood in order to carry out Table of Contents on the first page of the chap-maintenance and repair satisfactorily. When- ter to find the Ignition Coil section.ever the owner has insufficient experience or Whenever you see these WARNING anddoubts his ability to do the work, all adjust- CAUTION symbols, heed their instructions!ments, maintenance, and repair should be car- Always follow safe operating and maintenanceried out only by qualified mechanics. practices. In order to perform the work efficiently and WARNINGto avoid costly mistakes, read the text, thor-oughly familiarize yourself with the procedures This warning symbol identifies specialbefore starting work, and then do the work care- instructions or procedures which, if notfully in a clean area. Whenever special tools or correctly followed, could result in per-equipment are specified, do not use makeshift sonal injury, or loss of life.tools or equipment. Precision measurementscan only be made if the proper instruments are CAUTIONused, and the use of substitute tools may ad- This caution symbol identifies specialversely affect safe operation.Any owner maintenance or This manual contains four more symbols (inrepair procedure not performed in accordance addition to WARNING and CAUTION) which willwith this manual may void the warranty.Genuine parts provided 0Indicates a procedural sub-step or how to do the work of the procedural step it follows. It as spare parts are listed in the Parts Catalog. Don’t take shortcuts.In these illustrations you will find the In this manual, the product is divided into instructions indicating which parts require spec-its major systems and these systems make up ified tightening torque, oil, grease or a lockingthe manual’s chapters. The Quick Reference agent during assembly. To facilitate actual operations, notes, illustra-tions, photographs, cautions, and detailed descriptions have been included in each chapter wherevernecessary. This section explains the items that require particular attention during the removal andreinstallation or disassembly and reassembly of general parts. Especially note the following:Battery Ground Before completing any service on the vehicle, disconnectthe battery wires from the battery to prevent the engine fromaccidentally turning over. High-flush point solvent should be used according to directionsof the solvent manufacturer.Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt orother foreign materials entering into sealed areas during ve-hicle disassembly can cause excessive wear and decreaseperformance of the vehicle. Arrange theparts according to the order the parts were disassembledand clean the parts in order prior to assembly.Storage of Removed Parts After all the parts including subassembly parts have beencleaned, store the parts in a clean area. Put a clean clothor plastic sheet over the parts to protect from any foreignmaterials that may collect before re-assembly.Inspection Reuse of worn or damaged parts may lead to serious ac-cident. Visually inspect removed parts for corrosion, discol-oration, or other damage. Refer to the appropriate sectionsof this manual for service limits on individual parts. Replacethe parts if any damage has been found or if the part is be-yond its service limit.Replacement Parts Replacement Parts must be KAWASAKI genuine orrecommended by KAWASAKI. Gaskets, O-rings, Oil seals,Grease seals, circlips or cotter pins must be replaced withnew ones whenever disassembled.Assembly Order In most cases assembly order is the reverse of disassem-bly, however, if assembly order is provided in this ServiceManual, follow the procedures given. Then tighten them according to the specified se-quence to prevent case warpage or deformation which canlead to malfunction. Conversely when loosening the bolts,nuts, or screws, first loosen all of them by about a quar-ter turn and then remove them. If the specified tighteningsequence is not indicated, tighten the fasteners alternatingdiagonally.Tightening Torque Incorrect torque applied to a bolt, nut, or screw maylead to serious damage. Tighten fasteners to the specifiedtorque using a good quality torque wrench. Often, the tightening sequence is followed twice initialtightening and final tightening with torque wrench.Force Use common sense during disassembly and assembly,excessive force can cause expensive or hard to repair dam-age. When necessary, remove screws that have a non-permanent locking agent applied using an impact driver.Use a plastic-faced mallet whenever tapping is necessary.Gasket, O-ring Hardening, shrinkage, or damage of both gasketsand O-rings after disassembly can reduce sealing per-formance. Remove old gaskets and clean the sealingsurfaces thoroughly so that no gasket material or othermaterial remains. Install new gaskets and replace usedO-rings when re-assembling.Liquid Gasket, Locking Agent For applications that require Liquid Gasket or aNon-Permanent Locking Agent, clean the surfaces sothat no oil residue remains before applying liquid gasketor locking agent. Do not apply them excessively. Exces-sive application can clog oil passages and cause seriousdamage. Be sure to maintain proper alignment and usesmooth movements when installing.Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal isabsolutely necessary. Replace with new ones wheneverremoved. Press bearings with the manufacturer and sizemarks facing out. Press the bearing into place by puttingpressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure betweenthe inner and outer race and result in bearing damage.Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removalis necessary. Replace with new ones whenever removed.Press new oil seals with manufacture and size marks facingout. Make sure the seal is aligned properly when installing. Apply specified grease to the lip of seal before installingthe seal.Circlips, Cotter Pins Replace circlips or cotter pins that were removed with newones. Take care not to open the clip excessively when in-stalling to prevent deformation. Lubri-cation points are called out throughout this manual, applythe specific oil or grease as specified.Direction of Engine Rotation When rotating the crankshaft by hand, the free playamount of rotating direction will affect the adjustment. Ro-tate the crankshaft to positive direction (clockwise viewedfrom output side).Electrical Wires A two-color wire is identified first by the primary color andthen the stripe color. Unless instructed otherwise, electricalwires must be connected to those of the same color. The initial maintenance is vitally important and must not be neglected.L: Apply a non-permanent locking agent to the threads. MO: Apply molybdenum disulfide oil (the weight ratio of the mixture between engine oil and disulfide grease is 10: 1). O: Apply an oil to the threads, seated surface, or washer. R: Replacement Parts S: Tighten the fasteners following the specified sequence. SS: Apply a silicone sealant to the threads.Use this table for only the bolts and nuts which do not require a specific torque value. All of thevalues are for use with dry solvent-cleaned threads.Basic Torque for General Fasteners of Engine Parts Threads dia.WARNING Clean the element in a well-ventilated area, and take ample care that there are no sparks or flame any- where near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element. Replace the hose if it has been sharply bent or kinked. WARNING Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odor- less, poisonous gas.If necessary, replace the belt with a new peeling. Push hard, but with no more force than 59 N (6 kgf, 13 lb). Belt Deflection Standard: 22 ? 32 mm (0.87 ? 1.26 in.) Service Limit: 22 ? 50 mm (0.87 ? 1.97 in.) If the belt deflection of all of the three locations is within the specified range, the deflection is normal. If the belt deflection is not within the specified range, first measure the drive belt width (see Drive Belt Inspection). Less deflection will maintain better performance for more time as the belt width decreases by normal wear, which causes the deflection to increase with usage. Even if the deflection is adjusted, when the belt deflection is greater than the service limit, replace the drive belt. WARNING Clean the element in a well-ventilated area, and take ample care that there are no sparks or flame any- where near the working area. If it is torn, punc- tured, or hardened, replace it. If any part of the element is damaged, the element must be replaced. If the tire is tire cracked, replace it.0Lumps or high spots on the tread or sidewalls indicate internal damage, requiring tire replacement.0Remove any foreign objects from the tread. Since the tire may wear unevenly, take measurements at several places. If any of the measurements is less than the service limit, replace the tire. WARNING When draining or filling the final gear case, be care- ful that no oil gets on the tire or rim. Clean off any oil that inadvertently gets on them with a high-flash point solvent. WARNING Incorrect adjustment with insufficient free play can cause brake heating and drag. Skidding and loss of control may result. CAUTION Use only brake fluid, isopropyl alcohol, or ethyl al- cohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterio- ration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventu- ally deteriorate the rubber used in the brake.0Push the piston assembly in all the way with a screwdriver and install the piston stop bolt.If the drum is worn unevenly or scored, lightly turn the drum on a brake drum lathe or replace it. Do not turn the drum beyond the service limit. Brake Drum Inside Diameter Standard: 165.00 ? 165.16 mm (6.4961 ? 6.5023 in.) Service Limit: 165.75 mm (6.526 in.) WARNING Incorrect adjustment with insufficient free play can cause brakes to overheat and drag. Skidding and loss of control may result. If there is any signs of deterioration, cracks, or damage, replace the steering gear assembly together with these boots. Now customize the name of a clipboard to store your clips. Learn more - opens in a new window or tab This amount is subject to change until you make payment. 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