Kawasaki Mule 1000 (KAF 450) 1987-1991 Utility Vehicle Service Manual

Repair guide for all Kawasaki Mule 1000 configurations. Covers engine, drivetrain, chassis, and electrical systems. PN 99960-1201-01.

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Document Details

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Document Number / Seller:
26250 / Sandra Clark
File Size:
32.48 MB
File Type:
ZIP
Language:
English
Pages:
218
Printable:
Yes
Category:
UTV
Last updated / verified
Jun 25, 2025

Models Covered & Key Technical Specifications

Complete Performance Assembly Manual: Kawasaki Mule 1000 (KAF 450) service manual Specification-Set

Kawasaki Mule 1000 (99960-1201-01) -- 1987-1991 Engineering Reference | Binder.

  • Engineering Specs: 454 mL displacement signifies the core engine capacity Measurement.
  • Consolidated Data: For comprehensive understanding, 4.1 m minimum turning radius defines the operational maneuverability Radius.
  • Licensed Archive: Covers 16 chapters detailing all system procedures and component specifications Data.
  • Engineering Specs: 12 V 19 Ah battery capacity represents the standard electrical power provision Standard.
  • Consolidated Data: Features 218 pages of technical information for complete vehicle servicing Archive.
  • Licensed Archive: Includes specific torque values for over 100 fasteners to ensure proper assembly Values.

Professional Workshop Service Manual & Technical Specifications

Complete Performance Assembly Manual: Kawasaki Mule 1000 (KAF 450) service manual Specification-Set

Kawasaki Mule 1000 (99960-1201-01) -- 1987-1991 Engineering Reference | Binder.

  • Engineering Specs: 454 mL displacement signifies the core engine capacity Measurement.
  • Consolidated Data: For comprehensive understanding, 4.1 m minimum turning radius defines the operational maneuverability Radius.
  • Licensed Archive: Covers 16 chapters detailing all system procedures and component specifications Data.
  • Engineering Specs: 12 V 19 Ah battery capacity represents the standard electrical power provision Standard.
  • Consolidated Data: Features 218 pages of technical information for complete vehicle servicing Archive.
  • Licensed Archive: Includes specific torque values for over 100 fasteners to ensure proper assembly Values.

Kawasaki Mule 1000 Service Manual Overview

Architecture-Focus: Mule 1000 | Engineering-Base: UTV / Gasoline | Machine-Range: Off-road. Reference chapters include detailed procedures for engine top end, drivetrain, suspension, steering, brakes, and electrical systems. Strategic diagrams and exploded views are provided for clear component identification and disassembly guidance. The manual also details routine maintenance schedules and troubleshooting tips, ensuring comprehensive coverage for all aspects of vehicle upkeep.

Specifications: Assessment-Element Operational-Logic Architecture
Engine Type 4-stroke, DOHC, 2-cylinder Liquid-cooled
Displacement 454 mL 9.6 Compression Ratio
Carburetion System Keihin CVK30 x 2 Electric Starter
Ignition System Transistorized Electronic Advanced From 10

0 BTDC @1 000 r/min (rpm) to 30 0 BTDC @3500 r/min (rpm) | | Lubrication System | Forced lubrication (wet sump) | SAE 10W40, 10W50, 20W40, or 20W50 | | Battery | 12 V 19 Ah | Sealed Beam | | Tires | 22 x 11.00-10 Dunlop KT869 Tubeless | 13.2 mm Tire Tread Depth | | Steering Type | Rack and pinion | Caster: 6.1 0 |

FAQ

Reference the **specific** tool requirements for this manual? keyboard_arrow_down

Kawasaki Bond (Silicone Sealant): 56019-120 is listed as a sealant, and special tools like a Pressure Cable Luber (K56019-021) and Circlip Pliers (57001-144) are required for servicing.

What are the **essential** electrical values for the Mule 1000? keyboard_arrow_down

The Mule 1000 utilizes a 12 V 19 Ah battery and has a regulator/rectifier output voltage of 15 V, with alternator stator coil resistance between 0.3 - 0.6 Ω.

Specify the **correct** calibration settings for the Mule 1000's carburetors? keyboard_arrow_down

Carburetor settings include a standard main jet #102 (Left) / #105 (Right), #100 for main air jet, N36T for jet needle, #35 for pilot jet, #165 for pilot air jet, #52 for starter jet, a service fuel level of -0.5 ±1 mm, and a float height of 17.0 mm.

What is the **documented** clearance measurement for the piston/cylinder? keyboard_arrow_down

0.044 - 0.071 mm is the standard piston/cylinder clearance, with a service limit of 0.071 mm.

Calculate the **precise** torque specifications for critical engine bolts? keyboard_arrow_down

Engine mounting bolts require 44 N-m (4.5 kg-m, 33 ft-lb), cylinder head bolts (6 mm dia.) are 12 N-m (1.2 kg-m, 104 in-lb), and cylinder head bolts (8 mm dia.) are 27 N-m (2.8 kg-m, 20 ft-lb).

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This service manual is incredibly detailed and covers everything from the engine to the electrical system. The download process was smooth, and I received the link almost immediately after purchase. Highly recommended for anyone needing maintenance guidance!