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Kawasaki

Kawasaki Mule 600 UTV ATV Side By Side Complete Workshop Service Repair Manual 2005 2006 2007 2008 2009 2010 2011 2012 2013

Kawasaki Mule 600 UTV ATV Side By Side Complete Workshop Service Repair Manual 2005 2006 2007 2008 2009 2010 2011 2012 2013

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Vehicle data plateRef 6744
Brand
Kawasaki
Vehicle
Powersports
Models covered
Mule, Mule 600, UTV
Years
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Mule 600
Model Type:
Utility Vehicle (UTV) / All-Terrain Vehicle (ATV) / Side-by-Side
Generation
Model Years Covered:
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Codes
Platform Code Family:
Mule 600 Series
👋 Introduction
Market Position
Vehicle Segment:
Compact Utility Vehicle, designed for light-duty agricultural, recreational, and property maintenance tasks.
Competitive Analysis
Key Competitors:
John Deere Gator (early models), Cub Cadet Volunteer, Polaris Ranger (early models), Yamaha Rhino (early models).
Key Features
Utility Focus:
Emphasizes practicality, maneuverability, and cargo hauling for its intended use.
Ease Of Use:
Designed with user-friendliness and straightforward operation in mind.
📋 Manual Details
Coverage Areas
Primary Coverage:
All Models, All Engines, All Trim Levels, All Transmission Types within the specified model years.
Page Count
Estimated Page Count:
Extensive (Specific count not provided, but described as 'Complete' and covering A-Z procedures).
Manual Type
Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine System:
Engine overhaul, cylinder head, valve train, piston, crankshaft, lubrication system, cooling system, fuel system (carburetor), ignition system, starting system.
Transmission System:
Continuously Variable Transmission (CVT) operation, maintenance, belt inspection and replacement, clutch service, differential service.
Drivetrain System:
Shaft drive, universal joints, axle shafts, final drive housing.
Suspension System:
Front and rear suspension components, shock absorbers, bushings, control arms.
Braking System:
Hydraulic brake system, brake fluid, master cylinder, brake calipers, brake pads, brake drums (rear), brake cables.
Steering System:
Steering column, tie rods, steering knuckle, steering linkage components.
Electrical System:
Battery, charging system (generator/alternator), starter motor, lighting (headlights, taillights, brake lights), ignition coil, wiring diagrams, fuses, switches.
Chassis And Body:
Frame inspection, body panels, seats, cargo bed, roll bar (ROPS), guards.
Procedures Included
Maintenance Tasks:
Oil and filter changes, air filter replacement, spark plug service, fuel filter replacement, coolant flush and replacement, brake pad/shoe replacement, lubrication points, tire pressure checks.
Diagnostic Procedures:
Troubleshooting common issues, symptom-based diagnostics, electrical circuit testing, engine performance diagnostics.
Repair Procedures:
Engine rebuild, carburetor adjustment/rebuild, CVT belt replacement, brake system repair, suspension component replacement, electrical component repair, radiator service.
Installation Procedures:
Component removal and installation for all major systems.
Technical Depth
Depth Of Coverage:
Comprehensive. Covers basic maintenance, routine servicing, troubleshooting, diagnostics, and complete mechanical and electrical component repair and overhaul.
📊 Manual Specifications
File Format
Required Software:
Adobe Reader (Free download).
Print Quality
Printability:
Printable (individual pages, chapters, or entire manual).
Binding Type
Digital Binding:
N/A (Downloadable PDF).
Paper Type
Digital Paper Simulation:
N/A (Digital document).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, air-cooled, single-cylinder gasoline engine.
Engine Displacement:
Approximately 391cc (23.8 cubic inches).
Bore X Stroke:
Specific values would be detailed in the manual, but typical for this class.
Performance
Horsepower Rating:
Typically around 11-13 HP (at crankshaft, dependent on specific tuning and year).
Torque Rating:
Specific values would be detailed in the manual.
Fuel System
Fuel Delivery:
Carburetor (Mikuni or similar).
Fuel Type:
Unleaded gasoline.
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition).
Lubrication System
Oil Type:
Kawasaki recommends specific motorcycle or small engine oil grades (e.g., SAE 10W-40 or 20W-50, API SG or higher).
Cooling System
Cooling Method:
Forced air cooling.
🔧 Transmission
Standard
Transmission Type:
CVT (Continuously Variable Transmission) with belt drive.
Drive Modes:
2WD (Rear Wheel Drive) typically, with some models potentially offering 4WD capabilities (manual would specify).
Features
Clutch Type:
Torque converter and centrifugal clutch assembly.
Gear Selection:
Typically High (H), Low (L), Neutral (N), and Reverse (R).
Fluid Requirements
Cvt Fluid Type:
Specific CVT fluid or recommended oil type as per Kawasaki's specifications (detailed in manual).
📐 Dimensions
Exterior
Overall Length:
Approximate: 95.5 - 100 inches (varies slightly by year/configuration).
Overall Width:
Approximate: 48.4 - 50 inches.
Overall Height:
Approximate: 70.3 - 71.7 inches.
Cargo
Cargo Bed Dimensions:
Approximate: 33.5 x 37.2 x 7.9 inches (Length x Width x Depth).
Cargo Bed Capacity:
Approximately 200-300 lbs (check manual for exact rating).
Weights
Curb Weight:
Approximate: 765 - 815 lbs (varies by configuration).
Towing Capacity:
Typically rated around 500-1100 lbs (check manual for exact rating).
Payload Capacity:
Approximately 350-450 lbs (includes rider and cargo).
🛡️ Safety Features
Ratings
Rollover Protection:
Equipped with a Kawasaki Genuine Roll Over Protective Structure (ROPS) meeting industry standards.
Active Features
Seatbelts:
Standard 3-point seat belts for driver and passenger.
Lighting:
Halogen headlights, taillights, and brake lights for visibility.
Passive Features
Construction:
Steel frame and body construction for chassis integrity.
💡 Technology Features
Infotainment
Audio System:
Base models typically do not include an integrated audio system; aftermarket installations are common.
Driver Assistance
Parking Brake:
Manual hand lever or foot-actuated parking brake.
Connectivity
Charging Ports:
Typically do not have built-in USB or 12V power outlets; often added as accessories.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 50-100 hours of operation or annually, whichever comes first (refer to manual for precise intervals).
Air Filter Inspection:
Regular inspection, cleaning, or replacement as needed, especially in dusty conditions (e.g., every 25-50 hours).
Spark Plug Replacement:
Recommended replacement every 100-200 hours or annually.
Cv Belt Inspection:
Periodic inspection for wear, cracks, and proper tension (e.g., every 50-100 hours or annually).
Fluid Specifications
Engine Oil Capacity:
Approximate: 1.5 - 1.8 liters (1.6 - 1.9 US qt).
Coolant Type:
Permanent type antifreeze/coolant, 50/50 mix with distilled water (specific Kawasaki recommendation should be followed).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Carburetor Fouling:
Common with infrequent use or poor fuel quality; requires cleaning and adjustment.
Cv Belt Wear:
Aggressive use or improper belt tension can lead to premature wear.
Starter Solenoid Issues:
Can sometimes develop wear or connection problems.
📚 Vehicle History
Brand Heritage
Kawasaki Motorsports:
Kawasaki Heavy Industries has a long and reputable history in motorcycle and powersports manufacturing, known for engineering and performance.
Model Evolution
Mule Series Origin:
The Mule utility vehicle line was introduced in the late 1980s, evolving into various configurations, with the Mule 600 series representing a more compact and entry-level offering.
Production
Manufacturing Origin:
Kawasaki powersports vehicles are typically manufactured in Japan or through their international assembly plants.
🏆 Awards & Recognition
Recognitions
Segment Popularity:
The Mule 600 series was popular as an affordable and functional utility vehicle for smaller properties and specific work applications.
Ratings
Industry Reviews:
Generally reviewed positively for its ruggedness and practicality in its class during its production run.

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