Kawasaki KAF300 Mule 500 Mule 550 Utility Vehicle Service & Repair Manual • Part # JK1AFBB1MB500001.
Kawasaki Models Covered & Key Technical Specifications
Models: Kawasaki KAF300, Mule 500, Mule 550
Sub-models / Variants: KAF300-A1, KAF300-B1, KAF300-B2
Trade Names: Mule
Model Years: 1991–1997
Serial Numbers: JK1AFBA1MB500001, JK1AFBB1PB500001, AF300B-600001, JK1AFBB1TB504651, AF300B-600251
Technical Data:
- Engine displacement: 286 mL
- Engine configuration: 4-stroke, OHV, 1-cylinder
- Cooling system: Forced air-cooled
- Bore and stroke: 78.0 x 60.0 mm
- Transmission type: Belt drive torque converter
- Drive system: 2WD
- Fuel system: Mikuni BV24-18 carburetor
- Maximum cargo bed load: 160 kg
- Maximum vehicle load: 300 kg
- Tire size (Front/Rear): 22 x 9.00-10, 22 x 11.00-10
Kawasaki Manual Features & Content Preview
Official 1991–1997 Kawasaki Mule 500 / 550 Service Manual
- Covers 1991–1997 Kawasaki Mule 500 and Mule 550 utility vehicles, including KAF300-A1, KAF300-B1, and KAF300-B2 model variants
- Original OEM publication (Second Edition, November 1997) outlining comprehensive repair data
- Contains 15 detailed chapters with exploded-view diagrams for every major engine, transmission, and chassis system
- Instant download delivery directly to your device
- Permanent availability in your purchase account — no re-buy required
- Fully searchable OCR text layer lets you jump straight to specific torque specs or part references
- Formatted for standard letter and A4 shop printing
What the Manual Documents
The Kawasaki Mule 500 service manual provides all necessary technical documentation to maintain the KAF300 platform. Inside, you will find dedicated chapters covering the fuel system, top-end engine components, converter transmission, and lubricating systems. It also details the electrical equipment, steering, and braking assemblies. Need to visualize a complex tear-down? Exploded views clearly illustrate the primary torque converter, rocker arm mechanisms, and piston ring orientation. This makes finding the correct sequence for any mechanical repair much faster for professional technicians and shop owners.
Specification Highlights
The manual highlights crucial factory parameters to keep your utility vehicle running to spec. For the 286 mL powerplant, Engine Top End specifications define valve clearances at 0.12 mm. The lubrication system requires a standard oil capacity of 1.1 liters. Assembly data specifies cylinder head bolt torque values at 25 Nm, and the intake valve guide inside diameter sits squarely at 7.000–7.015 mm. Please note that improper handling of heavy machinery or pressurized systems carries inherent risks. Always verify procedures against factory standards and ensure proper protective equipment is used before working on this chassis.
Customer Reviews
Read what our customers say about this Kawasaki UTV manual and share your own experience.