2008 Kawasaki MULE 600 Owners Manual

2008 Kawasaki MULE 600 Manual

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  • 2008 Kawasaki MULE 600 | Owners Manual - Page 1
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 2
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 3
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION HOW TO OPERATE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE j j j j j j A Table of Contents is included after the Foreword.
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 4
    Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. DANGER DANGER
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 5
    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) and evaporative emission (3) control systems in compliance with applicable regulations of the United States Environmental Protections Agency and
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 6
    repair recommendations specified in the appropriate Kawasaki Service Manual. Maintenance and Warranty Proper maintenance is necessary that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should keep a maintenance record
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 7
    PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 8
    its features, capabilities, and limitations. To ensure a long, trouble-free life for your Mule, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their Mule, a Service Manual is available for purchase from any authorized Kawasaki
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 9
    TABLE OF CONTENTS BASIC SAFE DRIVING ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Choke Knob...Engine Oil Temperature Warning Light (
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 10
    Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ...Battery ...Fuse ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ...ENVIRONMENTAL PROTECTION ... 85 85 88 89 91 93 96 97 97 99 100 102 102 105 106 107 108
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 11
    judgement. Practice basic maneuvers so you can drive confidently and safely. Read the Owner's Manual Read and understand this Owner's Manual. This is especially important for inexperienced drivers. Refer to this Owner's Manual if you have any questions. Off-Highway Use Only This vehicle is not an
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 12
    10 BASIC SAFE DRIVING Wearing Seat Belt Both the operator and passenger should wear the seat belts whenever the vehicle is operated. This will help prevent injury in case of a sudden stop or collision. Also, to reduce chance of injury, always keep arms and legs inside the cab frame while the vehicle
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 13
    SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Track: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) ENGINE Type Displacement (A/C)
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 14
    12 SPECIFICATIONS Bore × Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio: Forward
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 15
    SPECIFICATIONS 13 Transmission Gear Ratio: Forward Reverse Front Final Gear Case Oil Front Final Gear Case Oil Capacity Transmission Case Oil Transmission Case Oil Capacity FRAME Type Castor Trail Tire Size: Front Rear Rim Size Front Rear Fuel Tank Capacity 10 × 7.0 10 × 8.5 15.5 L (4.1 US gal)
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 16
    14 SPECIFICATIONS ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load (A): KAF400A (B): KAF400B 420 kg (924 lb) 181 kg (400 lb) (C): KAF400C 12 V 14 Ah 12 V 35 W × 2 12 V 5/21 W × 2 MODEL INFORMATION
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 17
    SERIAL NUMBER LOCATIONS 15 SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the vehicle. 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. In the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 18
    16 LOCATION OF PARTS LOCATION OF PARTS 1. 2. 3. 4. 5. 6. Headlights Cab Frame Front Cargo Hood Front Cargo Compartment Steering Wheel Seat 7. 8. 9. 10. 11. 12. Seat Belts Cargo Bed Grille (Front Bumper) Air Cleaner Intake Parking Brake Air Cleaner (Carburetor) 13. 14. 15. 16. 17. Battery
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 19
    LOCATION OF PARTS 17 18. Handgrip 19. Air Cleaner (Belt Drive Torque Converter) 20. Belt Drive Torque Converter 21. 22. 23. 24. Latch Dashboard Tail/Brake Light Muffler 25. Fuel Tank 26. Fuel Tank Cap 27. Fuel Gague
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 20
    18 LOCATION OF PARTS 28. 29. 30. 31. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Parking Brake Warning Light 33. 34. 35. 36. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A/C) 37. Ignition Switch 38. Accessory Connector 39.
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 21
    LOCATION OF LABELS 19 LOCATION OF LABELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Warning (Off-Highway Utility Vehicle) Notice (Shifting) Warning (General) Warning (Front Cargo Hood) Warning (Passengers in Cargo Bed) Warning (Cargo Bed) Important Information (Tires/Max. Load) Carrier Hook
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 22
    20 LOCATION OF LABELS
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 23
    LOCATION OF LABELS 21 (1) (4) (2) (5)
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 24
    22 LOCATION OF LABELS (3)
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 25
    LOCATION OF LABELS 23 (6) (8) (7) (KAF400A/C) (7) (KAF400B)
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 26
    24 LOCATION OF LABELS (9) (KAF400A) (10) (9) (KAF400B) (9) (KAF400C) (11)
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 27
    LOCATION OF LABELS 25 (12) (Other than California model) (13) (12) (California model only) (14) (California model only)
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 28
    26 LOCATION OF LABELS (15)
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 29
    the vehicle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has front body work and fenders are not designed to carry cargo or to support your weight. They may break. Because any vehicle is sensitive to
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 30
    28 LOADING INFORMATION subtract trailer tongue weight from the • Always Maximum Load capacity. Refer to the "Trailer Hitch Bracket" section in the "General Information" chapter. Maximum Load Weight of operator, passenger, and cargo must not exceed 420 kg (926 lb). vehicle is not designed to carry
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 31
    GENERAL INFORMATION 29 GENERAL INFORMATION Lighting/Electrical Accessory Connector The lighting/electrical accessory 12 volt connector is located on the dashboard. An auxiliary light or an accessory may be connected to this connector. j Brake Pedal The brake pedal is the left pedal on the foot
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 32
    The cargo bed can be tilted by releasing the latch on the right side, and then lifting the bed with the handgrips. Support the bed in the tilted position with the supporting hook provided on the bottom of the cargo bed. A. Latch B. Handgrip C. Fuel Tank Cap A. Tail Gate B. Latch Handle C. Wire Loop
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 33
    any part of your body, such as hands or arms, between the bed and cab frame or vehicle frame when lifting and lowering the bed. A. Supporting Hook B. Cargo Bed Bottom (Tilted Condition) WARNING The bed will fall down onto you if not
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 34
    32 GENERAL INFORMATION j Choke Knob The choke knob located on the dashboard, to the left of the steering wheel, provides a rich mixture for cold starting. Pull the choke knob all the way to start the engine. Warm the engine up using the choke and throttle until the idle speed is stable, and then
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 35
    GENERAL INFORMATION 33 Engine Oil Temperature Warning Light (KAF400 A/C) The oil temperature warning light comes on whenever the engine oil temperature rises too high while the vehicle is in operation. If it stays on, stop the engine and check the engine oil level after the engine cools down. Refer
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 36
    on unleaded regular grade gasoline only. Use clean, fresh unleaded gasoline with a minimum Antiknock Index of 87. The Antiknock Index is posted on service station pumps in the U.S.A. The octane rating of a gasoline is a measure of its resistance to detonation or "knocking." The Antiknock Index is an
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 37
    unleaded gasoline and methanol (wood alcohol) whenever possible, and never use "gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTBE). You may use gasoline containing up
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 38
    the fuel system. Before storage it is recommended that you drain all fuel from the fuel tank and carburetors. See the "STORAGE" chapter in this manual. Fuel Gauge The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank. When the red indicator needle comes near
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 39
    GENERAL INFORMATION 37 j Glove Compartment A glove compartment is provided at the right end of the dashboard. Store only light items to avoid damage to the inside of the compartment. Release the plug in the bottom of the glove compartment to remove any water that may have entered. Do not put items
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 40
    38 GENERAL INFORMATION j A. Latch Release Button B. Hood A. Latch Lever B. Hood Hood Closing While lifting the latch lever at the front of the cargo hood, push and close the cargo hood. the hood is closed, push the two parts of the • After hood to ensure the hood is latched.
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 41
    GENERAL INFORMATION 39 j Ignition Switch This is a three-position, key-operated switch. 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 impair visibility of the operator, causing loss of vehicle control
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 42
    40 GENERAL INFORMATION j OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. Hour meter works. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is in "N" (neutral) position. Upon release, key will return to "
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 43
    GENERAL INFORMATION 41 j Hour Meter The hour meter shows the total hours that the vehicle has been operated. This meter cannot be reset. Light Switch Turn on the headlights and taillights by pushing the light switch in, with the ignition switch key in the "ON" position. The lights go off when the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 44
    42 GENERAL INFORMATION j Shift Levers This vehicle is equipped with three different shift levers: the gear shift lever, the 2WD-4WD shift lever (KAF400A/C only) and the differential shift lever. Gear Shift Lever The gear shift lever is located on the dashboard, to the right of the steering shaft.
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 45
    GENERAL INFORMATION 43 efficiency. 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. Stop the vehicle before moving the Hi-Lo shift lever. j NOTICE Use
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 46
    44 GENERAL INFORMATION j Parking Brake Lever The parking brake lever is located at the left side of the seat. Pull the lever up and to the rear to apply the parking brake. To release, push in and hold the knob on the end of the lever and push the lever all the way down. Spring pressure helps return
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 47
    GENERAL INFORMATION 45 WARNING If the vehicle should move after it is parked, it might be damaged or cause injury. Be sure to apply the parking brake before leaving the vehicle. j Parking Brake Warning Light The parking brake warning light goes on when the parking brake is applied with the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 48
    46 GENERAL INFORMATION j Seat The seat can be raised for vehicle maintenance and adjustment. Pull up on the rear edge of the seat. Seat Belts The vehicle is equipped with lap-style seat belts both for the operator and passenger. Always wear the seat belts when operating and riding in the vehicle.
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 49
    GENERAL INFORMATION 47 To wear the seat belt properly, follow this procedure: 1. Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted. 2. Push the latch plate into the buckle until it clicks. 3. Adjust the seat belt for a SNUG FIT. j WARNING Too
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 50
    48 GENERAL INFORMATION j To unfasten the belt, press the red button in the buckle. Throttle Pedal The throttle pedal is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 51
    GENERAL INFORMATION 49 j Trailer Hitch Bracket (Accessory) This vehicle can be equipped with an optional bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, observe the following precautions: WARNING Improper towing of a
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 52
    operation of a winch could cause an accident resulting in serious injury or death. Do not install or operate a winch without reading and understanding the operator's manual supplied with the winch. A. Winch-installing position
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 53
    . 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. j WARNING Failure to perform these checks before operation may result
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 54
    52 HOW TO OPERATE Transmission Case Oil ...Oil level between H and L lines, no leaks. Throttle ...Throttle pedal free play 2 ∼ 5 mm (0.1 ∼ 0.2 in.). Throttle pedal operates smoothly and returns to rest position when released. Steering ...Steering wheel free play 0 ∼ 20 mm (0 ∼ 0.8 in.). Action
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 55
    HOW TO OPERATE 53 Starting the Engine Throttle-linked choke system This vehicle is equipped with the choke that controls the throttle operation without pressing the throttle pedal when starting the engine. Using this choke system, start the engine with the following procedure. DANGER Exhaust gas
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 56
    54 HOW TO OPERATE NOTICE j Do not operate the electric starter continuously for more than 5 seconds, or the starter may overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and for battery power to recover. Jump Starting If your
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 57
    HOW TO OPERATE 55 WARNING Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive. Do not make this last connection at the battery or carburetor. Take care not to touch the positive and negative cables together, and do not lean over the battery when
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 58
    56 HOW TO OPERATE Moving Off j the brake pedal. • Depress the gear shift lever into the "H" (High) and "L" • Put (Low) position for KAF400A/C or "F" (Forward) pothe parking brake. • Release increase engine speed by pressing on • Gradually the throttle pedal. sition for KAF400B. Braking żPractice
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 59
    HOW TO OPERATE 57 Stopping the Engine the throttle pedal completely. • Release the gear shift lever into the "N" (Neutral) posi• Put tion. the parking brake to help prevent the vehicle • Apply from rolling. • Turn the ignition switch key to the "OFF" position. Parking the Mule • Stop the vehicle
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 60
    58 HOW TO OPERATE the ignition switch key to prevent unau• Remove thorized use. parking inside a garage or other structure, • When be sure the structure is well ventilated and the vehicle is not close to any source of flame or sparks. This includes any appliance with a pilot light. Hi-Lo Shifting (
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 61
    HOW TO OPERATE 59 żWhen shifting the lever from "L" to "N", if it is hard to move the shift lever passing "H" position and does not move to "N" position, return the shift lever to "L" once and repeat to move the lever to "N" position slowly. Reversing Gears the throttle pedal, and stop the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 62
    60 HOW TO OPERATE 2WD-4WD Shifting (KAF400A/C) j the stopper under the 2WD-4WD shift lever • Pull knob and while holding it against the knob, move • the shift lever to the all way down "4WD". To shift back into "2WD" position, pull and hold the stopper, then move the shift lever all the way up "
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 63
    HOW TO OPERATE 61 Shifting the Differential j żDo not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph). NOTE Shifting to Locked-Axle Mode the stopper under the differential shift lever • Pull knob and while holding it against the knob, move the shift
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 64
    your vehicle may result in an unsafe operating condition. Before operation, make sure that the vehicle is not overloaded and that you have followed the instructions in the "Loading Information" chapter.
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 65
    SAFE OPERATION 63 Driving in Reverse Start the engine following the procedure in the "Starting the Engine" section. Before shifting into reverse, stop the vehicle completely. Refer to the Gear Shift Lever in the "Shift Levers" section and "Reversing Gears" section. Turn around and look behind you
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 66
    64 SAFE OPERATION Turning the Vehicle The vehicle will turn in a smaller radius with the differential unlocked (in differential mode). In this mode, the rear wheels can turn at different speeds allowing the vehicle to turn tighter and more smoothly. Even in this mode, however, avoid sharp turns to
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 67
    SAFE OPERATION 65 Climbing Hills Do not attempt to climb hills or steep inclines until you have mastered the controls and basic operating maneuvers of this vehicle. Always go straight uphill and, if the incline is steep and/or the surface is loose, use "4WD" with the differential locked for greater
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 68
    66 SAFE OPERATION Descending Hills Slow down or stop at the top of a hill so you can pick a straight, safe path for descent to avoid any obstacles. Normally you should descend straight down a hill since driving at an angle could cause the vehicle to lean to one side and possibly tip over. Proceed
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 69
    SAFE OPERATION 67 Traversing Hillsides When driving across the side of a hill, reduce vehicle speed and exercise extreme caution to prevent tipping or loss of control. Avoid hills with slippery sides that will cause you to lose traction. Also avoid traversing hillsides covered with rocks or other
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 70
    68 SAFE OPERATION Driving through Water Avoid driving through water whenever it is possible. When driving across shallow water, choose a location to enter and exit the water where the banks are not too steep or slippery. Check before entering for rocks, holes or other obstacles which may cause you
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 71
    listed in the HOW TO OPERATE chapter. D * • ż = Clean, adjust, lubricate, replace parts as necessary. = Service to be performed by an authorized Kawasaki Dealer or someone equally competent. = Service more frequently when operated in mud, dust, or other harsh riding conditions. = Emission Related
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 72
    70 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 500 hrs. or 10 000 km of use OPERATION After 50 hrs. Every 250 or 1 000 km hrs. or 5 000 km of use of
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 73
    MAINTENANCE AND ADJUSTMENT 71 FREQUENCY First Service Regular Service Every 500 hrs. or 10 000 km of use OPERATION After 50 hrs. Every 250 or 1 000 km hrs. or 5 000 km of use of
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 74
    72 MAINTENANCE AND ADJUSTMENT FREQUENCY First Service Regular Service Every 500 hrs. or 10 000 km of use OPERATION After 50 hrs. Every 250 or 1 000 km hrs. or 5 000 km of use of
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 75
    bed will fall down onto you if not supported with the hook. Always latch the supporting hook when lifting the bed for engine maintenance change the oil and filter according to the periodic maintenance chart in the owner's manual. A. Dipstick & Oil Filler Hole B. Seatback up the dipstick, wipe it
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 76
    74 MAINTENANCE AND ADJUSTMENT j A. Dipstick B. Oil Filler Hole out the dipstick and check the oil level. The • Pull oil level should be between the "F" (Full) and "L" (Low) lines on the dipstick. A. Dipstick B. "H" (High) Line C. "L" (Low) Line the oil level is too high, remove the excess oil,
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 77
    MAINTENANCE AND ADJUSTMENT 75 the oil filter is to be changed, first lift the cargo • If bed to support it with the hook, and then remove the oil filter cartridge and replace it with a new one. j A. Drain Plug B. Torque Converter Case the vehicle held
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 78
    76 MAINTENANCE AND ADJUSTMENT Recommended Engine Oil Grade: API SG, SH, SJ, SL, or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 j żDo not add any chemical additive to the oil. NOTE Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 79
    the front and rear tires, with consequent loss of control, accident, and injury. Check the oil level and change the oil according to the owner's manual. j Oil Level Inspection gear case. the vehicle level front-to-rear and side-to • With -side, remove the filler cap from the front final
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 80
    78 MAINTENANCE AND ADJUSTMENT j A. Front Final Gear Case B. Filler Cap (on the left side) C. Front Axle A. Front Final Gear Case B. Filler Opening C. Bottom Thread NOTICE Be careful not to allow any dirt or foreign materials to enter the gear case. the oil level. The oil level should come to •
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 81
    MAINTENANCE AND ADJUSTMENT 79 WARNING Oil on tires can make them slippery which can cause an accident and injury. 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. the oil has completely
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 82
    the oil level and change the oil according to the owner's manual. A. Transmission Case B. Dipstick C. Oil Filler Plug NOTICE Be careful Inspection • • • Park the vehicle on level ground. Lift the cargo bed and support it with the hook. Unscrew the oil filler plug, and dipstick, wipe its dipstick
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 83
    MAINTENANCE AND ADJUSTMENT 81 Oil Change żBefore draining the oil, warm it up by running the NOTE vehicle. Warm oil drains easily and picks up any sediment. the vehicle level, apply the parking brake se• With curely. an oil pan beneath the transmission case. • Place Remove the drain plug. • j
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 84
    oil above 5°C (41°F) SAE 90 below 5°C (41°F) SAE 80 Transmission Case Oil Capacity KAF400A/C: 2.4 L (2.5 US qt) KAF400B: 2.2 L (2.3 US qt) j the cargo bed and support it with the hook. • Lift Remove the filler plug. • WARNING Oil on tires can make them slippery which can cause an accident and
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 85
    MAINTENANCE AND ADJUSTMENT 83 Cooling Fan The engine is cooled by the cooling fan attached to the left side of the engine. Check and clean the screen for mud and other debris. Spark Plug The standard spark plug is shown in the table. The spark plug should be taken out periodically in accordance
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 86
    84 MAINTENANCE AND ADJUSTMENT j Spark Plug Standard Plug Plug Gap NGK BPR5ES 0.7 ∼ 0.8 mm (0.028 ∼ 0.032 in.) A. Spark Plug Cap B. Engine Oil Dipstick Cap • Unscrew the spark plug. żWhen installing the spark plug, fit the plug cap seNOTE curely onto the spark plug, and pull the cap lightly to
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 87
    MAINTENANCE AND ADJUSTMENT 85 Valve Clearance Valve and valve seat wear decrease valve clearance, upsetting valve timing. Engine Air Cleaner A clogged engine air cleaner restricts the engine's air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. NOTICE
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 88
    86 MAINTENANCE AND ADJUSTMENT NOTICE If dirt gets into the engine, excessive engine wear and possible engine damage may occur. j A. Air Cleaner Housing Cover B. Snaps the screw and pull the air cleaner element • Remove out of the housing. a clean, lint-free towel into the air cleaner • Push
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 89
    MAINTENANCE AND ADJUSTMENT 87 the foam element in a bath of high flash • Clean -point solvent using a soft bristle brush. it dry in a clean towel. Do not wring the • Squeeze element or blow it dry; the element can be dam- • aged. Inspect the foam element for damage. If it is torn, punctured, or
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 90
    88 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with a spark arrester approved for off-highway use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. Clean the spark arrester in accordance with the Periodic Maintenance Chart. j NOTICE The
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 91
    MAINTENANCE AND ADJUSTMENT 89 the engine. • Stop Install the drain plug. • Throttle Pedal If the throttle pedal has excessive play due to either cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle may not open fully. If the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 92
    90 MAINTENANCE AND ADJUSTMENT j A. Throttle Pedal B. 2 ∼ 5 mm (0.1 ∼ 0.2 in.) A. Throttle Cable B. Mounting Nuts Throttle Pedal Play Adjustment the cargo bed and support it with the hook. • Lift and turn the throttle cable mounting nuts • Loosen located above the transmission case until the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 93
    the engine is cold. If starting is difficult or rich fuel mixture trouble occurs, inspect the choke knob, and adjust it if necessary. the choke cable checked by an authorized Kawasaki dealer. Lift the cargo bed and support it with the hook. Raise the seat. Remove the guard plate by releasing
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT j A. Guard Plate B. Air Intake Ducts (2 p.c.s.) C. Clamps D. Quick Rivets (6 p.c.s.) E. Cap A. B. C. D. Starter Lever Mounting Nuts Choke Cable Throttle Link • • Make sure the choke knob is all the way into its released position. To determine the amount of choke
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 95
    MAINTENANCE AND ADJUSTMENT 93 Carburetor The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. The following procedure covers the idle speed adjustment. Idle Speed Adjustment the parking brake. • Apply Raise the seat
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 96
    can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area. the cargo bed to support it with the hook. • Lift Remove • screw. the cover plate on the idle adjusting the axel lever stopper screw on the base • Loosen plate above
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 97
    MAINTENANCE AND ADJUSTMENT 95 and release the throttle pedal a few times • Depress to make sure that the idle speed does not change. Readjust if necessary. High Altitude Use The original carburetor settings for this vehicle are best for sea level use. When the vehicle is used at high altitude, the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 98
    and free from any source of flame or sparks; this includes any appliance with a pilot light. Dust and/or Water Inspection the cargo bed to support it with the hook. • Lift Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and the 6 quick rivets. A. Guard Plate
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 99
    MAINTENANCE AND ADJUSTMENT 97 j A. Drain Screw B. Carburetor A. Fuel Filter B. Fuel Tank • Tighten the drain screw. żIf any water or dirt appears during the above operNOTE ation, have the fuel system checked by an authorized Kawasaki dealer. Fuel Filter The vehicle is equipped the fuel filter
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 100
    98 MAINTENANCE AND ADJUSTMENT j
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 101
    MAINTENANCE AND ADJUSTMENT 99 Belt Drive Torque Converter The vehicle is equipped with a belt drive torque converter type automatic transmission. The belt, driven pulley shoes and drain hose should be checked in accordance with the Periodic Maintenance Chart. The belt and driven pulley shoes
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 102
    should be replaced if they are damaged. Element Removal A. Guard Plate B. Air Intake Ducts (2 p.c.s.) C. Clamps D. Quick Rivets (6 p.c.s.) E. Cap the cargo bed and support it with the hook. • Lift Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and the 6 quick
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 103
    MAINTENANCE AND ADJUSTMENT 101 NOTICE If dirt gets into the belt drive torque converter, excessive wear and loss of driving power may result. żElement installation order of removal. NOTE is performed in the reverse j Element Cleaning A. Cap B. Wingbolts the element (see Element Removal). •
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 104
    102 MAINTENANCE AND ADJUSTMENT the element material for damage. If any • Inspect part of the element is damaged, the element must be replaced. The vehicle is equipped with hydraulically activated drum brakes on all four wheels. Brake Pedal Brakes Brake Pedal Free Play Inspection j In accordance
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 105
    MAINTENANCE AND ADJUSTMENT 103 "catchy," have the brake system inspected immediately by an authorized Kawasaki dealer. Brake Shoe Linings NOTICE Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immediately. Brake Shoe Lining Wear Inspection In accordance with the Periodic
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 106
    104 MAINTENANCE AND ADJUSTMENT brake fluid reservoir is inside the access hole, • The and using a funnel fill the reservoir to the upper level line. the brake forcefully for a few seconds and • Apply check for fluid leakage around the fittings. WARNING Air in brake line can make the brake feel
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 107
    MAINTENANCE AND ADJUSTMENT 105 Brake Light Switch When the brake pedal is depressed, the brake light goes on. The brake light switch should be inspected in accordance with the Periodic Maintenance Chart. Adjustment light • Brake pedal. switch is located above the brake Inspection the ignition
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 108
    106 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. j Inspection A. B. C. D. Brake Light Switch Adjusting Nut Lights
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 109
    MAINTENANCE AND ADJUSTMENT 107 the locknut (upper nut) on the middle of • Loosen the parking brake lever, and turn the nut next to the locknut until the brake lever will only move 8 ∼ 12 clicks upward. Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 110
    108 MAINTENANCE AND ADJUSTMENT Standard Tires Wheels Rims The rims are a drop-center, tubeless tire design. Take care not to damage the sealing surfaces of the tire or rim when removing or installing tires. Note that the rims, like automotive rims, are not symmetrical. All wheels must be installed
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 111
    MAINTENANCE AND ADJUSTMENT 109 żInstallation of tubeless tires on rims requires compressed air and is normally recommended as a dealer service operation. Nevertheless, a tube can be inserted into the tire by the operator as an emergency repair. accordance with the Periodic Maintenance • In Chart,
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 112
    110 MAINTENANCE AND ADJUSTMENT Joint Boots In accordance with the Periodic Maintenance Chart, inspect the joint boots on the front axles, tie rod ends, and steering knuckles for cracks, holes, damage or deterioration. If there is any one of them, have the joint boot replaced by an authorized
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 113
    MAINTENANCE AND ADJUSTMENT 111 Spring Action Position 1 2 3 4 5 Spring Force | | | Ļ Stronger Setting Load Soft Ĺ | Ļ Hard Light Ĺ | Ļ Heavy Surface Good Ĺ | Ļ Bad Speed Low Ĺ | Ļ High j WARNING A. Adjusting Sleeve If the spring action feels too soft or too stiff, have the sleeves adjusted by an
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 114
    112 MAINTENANCE AND ADJUSTMENT Seat Belts In accordance with the Periodic Maintenance Chart, check that each seat belt functions properly. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. The click sound indicates it is securely latched.
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 115
    MAINTENANCE AND ADJUSTMENT 113 Battery The battery is located under the left end of the seat. DANGER Battery contains sulfuric acid and produce hydrogen gas. Sulfuric acid can cause burns and hydrogen gas can cause an explosion. Read and heed the battery safety label. j A. B. C. D. Bolt Holder
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 116
    114 MAINTENANCE AND ADJUSTMENT the battery in place, and route the battery vent • Put hose through the hole in the floor board. the capped lead to the (+) terminal, and • Connect then connect the black lead to the (-) terminal. a light coat of grease on the terminals to pre• Put vent corrosion. the
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 117
    MAINTENANCE AND ADJUSTMENT 115 Current Drain (Y50-N18L-A) Discharging Ampere 7 mA 10 mA 15 mA 20 mA 30 mA Days from Days from 100% 100% Charged Charged to 50% to 100% discharged discharged 60 Days 42 Days 28 Days 21 Days 14 Days 119 Days 83 Days 56 Days 42 Days 28 Days often falls off and settles at
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 118
    116 MAINTENANCE AND ADJUSTMENT your Kawasaki dealer or visit buy kawasaki. com) at a rate of 1/10th of the battery capacity. If you will not be using your vehicle for longer than two weeks, the battery should be charged using an appropriate charger. Do not use an automotive-type quick charger that
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 119
    , the charging rate for a 10 Ah battery would be 1.0 ampere. NOTICE Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charging rate can be reduced to the level required for this vehicle's battery. Charging the battery at a rate higher than
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 120
    118 MAINTENANCE AND ADJUSTMENT WARNING Lead is a toxic substance. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. Fuse There are two plastic fuse cases next to the parking brake under the left end of the seat, one for the main (30 A) and
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 121
    MAINTENANCE AND ADJUSTMENT 119 General Lubrication In accordance with the Periodic Maintenance Chart, have the general lubrication performed by an authorized Kawasaki dealer or perform it referring to the Service Manual for this vehicle. j A. Fuse Cases (30 A) B. Fuse Cases (10 A)
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 122
    120 MAINTENANCE AND ADJUSTMENT Cleaning To prolong the life of your vehicle, wash it down immediately after it has been splashed with sea water or exposed to salt air, or operated on rainy days, rough terrain, or in dusty areas. NOTICE Coin operated, high pressure spray washers are not recommended
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 123
    MAINTENANCE AND ADJUSTMENT 121 Bolt and Nut Tightening In accordance with the Periodic Maintenance Chart, have the tightness of the bolts, nuts, and fasteners checked by an authorized Kawasaki dealer. j
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 124
    finished. żAs an alternative to draining the fuel system, a fuel stabilizer, such as STA-BIL, may be used. Follow the manufacturer's instructions for use. NOTE WARNING Fuel stabilizers may contain poisonous substances. Heed the manufacturer's warnings for use. the spark plug and spray fogging oil
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 125
    STORAGE 123 WARNING An air/oil mist may be forcibly ejected from the spark plug holes and could get into your eyes. Do not lean over the engine when performing this procedure. If you do get oil in your eyes, wash them immediately with liberal amounts of clean, fresh water and consult a physician as
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 126
    124 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Starter Motor Won't Turn Fuse failed (be sure to check for cause of failure) Battery leads do not make good electrical contact with battery terminals
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 127
    receipt of your correspondence we will contact the dealership and work with them in resolving your problem. In order to provide a permanent record, all warranty and service resolutions take place only through written correspondence. Please send your correspondence to: CONSUMER RELATIONS KAWASAKI
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 128
    126 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 129
    MAINTENANCE RECORD 127 MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Traveled Distance Maintenance Performed
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 130
    128 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 131
    MAINTENANCE RECORD 129 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 132
    130 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 133
    MAINTENANCE RECORD 131 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 134
    132 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki MULE 600 | Owners Manual - Page 135
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