Kawasaki MULE 600, MULE 610 4x4 Service Manual

2004 Kawasaki MULE 600/610 4x4 service manual covers detailed procedures, specifications, and troubleshooting for all systems. Includes part numbers like 57001-1620.

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Document Details

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Document Number / Seller:
31223 / Matthew Stewart
File Size:
9.68 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
UTV
Last updated / verified
Jul 22, 2025

Models Covered & Key Technical Specifications

Kawasaki MULE 600, MULE 610 4x4 (2004 Edition) Service Manual: Kawasaki MULE 600, MULE 610 4x4 - Comprehensive Utility Vehicle Service & Repair Manual

Documentary Collection | Set.

  • Measured Engine Specs: 401 cm³ establishes the total displacement volume. (S1)
  • Baseline Battery Specs: For starting the engine, 12 V 14 Ah provides the necessary electrical power. (S2)
  • Integral Cooling Specs: Positive air-cooled maintains optimal engine operating temperatures. (S2)
  • Applied Load Specs: The maximum vehicle load is 420 kg, including occupants and cargo. (S2)
  • Fundamental Output Specs: 9.9 KW signifies the peak engine horsepower output. (S3)
  • Operational Torque Specs: 29.7 N·m is the maximum torque delivery at 2,400 r/min. (S1)

Professional Workshop Service Manual & Technical Specifications

Kawasaki MULE 600, MULE 610 4x4 (2004 Edition) Service Manual: Kawasaki MULE 600, MULE 610 4x4 - Comprehensive Utility Vehicle Service & Repair Manual

System-Coverage: Engine, Transmission, Brakes, Suspension, Steering, Electrical System, Fuel System, Lubrication System, Converter System, Engine Bottom End // Model-Portfolio: MULE 600, MULE 610 4x4 / Utility Vehicle // System-Coverage: Maintenance, Repair, Specifications, Troubleshooting

Identifier Baseline Context
Torque 20 N·m (14 ft-lb) Engine Oil Drain Plug
Specification 3 mm Tire Tread Depth Service Limit
Torque 34 N·m Wheel Nuts Tightness

The service manual covers the complete range of systems and procedures for the Kawasaki MULE 600 and MULE 610 4x4 utility vehicles. It details maintenance protocols, diagnostic procedures, and component specifications essential for proper upkeep and repair. Rigorously requiring adherence to all documented procedures, this manual ensures optimal performance and longevity of your vehicle.

Maintenance Procedures

The service manual details all periodic maintenance tasks, including fluid changes, filter replacements, and lubrication schedules. It outlines specific steps for inspecting and servicing critical components such as the engine, transmission, brakes, and suspension systems.

System Overviews

It provides thorough system overviews, explaining the function and operation of key vehicle systems. This includes detailed descriptions of the engine's lubrication system, the torque converter operation, and the fuel delivery system.

Specifications and Diagrams

This document includes extensive specifications for all major components, providing precise measurements and tolerances for diagnostics and repairs. Exploded views and diagrams are provided throughout to aid in identification and assembly. ...documents torque specifications for engine mounting bolts to ensure proper gasket seal integrity.

FAQ

Check the **standard** brake pedal play. keyboard_arrow_down

2-5 mm (0.08-0.20 in.) is the standard brake pedal play for the Kawasaki MULE 600/610 4x4.

What does the **necessary** adjustment procedures cover? keyboard_arrow_down

The procedure for adjusting the throttle pedal free play involves loosening adjuster nuts and sliding the adjuster to achieve the proper free play, ensuring correct engine idle speed.

Reference the **recommended** pressure specifications. keyboard_arrow_down

For cylinder compression, the usable range is 340-590 kPa (3.5-6.0 kgf/cm², 50-85 psi) at 530 r/min, with specific values for diagnosing issues if the reading is outside this range.

Customer Reviews

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Reviews (5)

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Rated 4 out of 5 stars
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I found the troubleshooting guide particularly useful. The download process was smooth, and customer support was very responsive to my inquiries!
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I appreciated how professional the service was when I had questions. The manual itself is very detailed and thorough!
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This manual is a must-have for anyone with a MULE 600/610. The instructions are clear and easy to follow. Highly recommend!
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Rated 4 out of 5 stars