Kawasaki MULE 600 4×4 Service Manual ATV manuals in PDF

Factory Service Repair Manual For Kawasaki MULE 600 4×4 ATV. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Format: PDF
Language: English
Pages: 409
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: No

Model

Kawasaki ATV MULE 600, MULE 600 4X4
KAF400A1
KAF400B1
KAF400C1

Contents

– General Information
Before Servicing
Model Identification
Model Identification
General Specifications
Unit Conversion Table
– Periodic Maintenance
Periodic Maintenance Chart
Torque and Locking Agent
Periodic Maintenance Procedures
Fuel System
Throttle Pedal Free Play
Throttle Pedal Free Play
Idle Speed Inspection
Idle Speed Adjustment
Air Cleaner Element Cleaning
Fuel Hoses And Connections
Fuel Hoses Replacement
Fuel Filter Replacement
Fuel System Cleanliness
Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Spark Arrester Cleaning
Converter System
Drive Belt Inspection
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Converter Driven Pulley Shoe
Converter Air Cleaner Element
Converter Dust or Water Drain
Engine Lubrication System
Engine Oil Change
Oil Filter Replacement
Transmission
Transmission Oil Change
Wheels/Tires
Wheels Nuts Tightness
Inspection
Tire Wear Inspection
Final Drive
Front Final Gear Case Oil
Brakes
Brake Fluid Level Inspection
Brake Fluid Change
Brake Pedal Play Inspection
Brake Master Cylinder Cup and
Dust Seal Replacement
Brake Hose and Pipe Inspection
Brake Hose and Pipe
Brake Wear Inspection
Brake Wheel Cylinder Assembly
Parking Brake Lever Inspection
Steering
Steering Inspection
Steering Joint Dust Boot Frame
Seat Belt Inspection
Electrical System
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Electrolyte Level Inspection
Electrolyte Specific Gravity
Brake Light Switch Inspection
General Lubrication
Bolts, Nuts, and Fasteners
Tightness Inspection
– Fuel System
Throttle Pedal And Cable
Throttle Pedal Free Play
Throttle Pedal Free Play
Full Throttle Pedal Position
Throttle Cable Installation
Throttle Cable Lubrication
Throttle Cable Inspection
Governor Link Mechanism
Control Panel Assembly Removal
Control Panel Assembly
Governor Assembly Removal
Governor Assembly Installation
Governor Assembly Inspection
Choke Cable
Choke Knob Free Play Inspection
Choke Knob Free Play
Choke Cable Installation
Choke Cable Lubrication
Choke Cable Inspection
Carburetor
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness
Inspection
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning
Carburetor Inspection
Pilot Screw Setting
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Installation
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Air Cleaner Housing Dust And/Or
Water Installation
Fuel Pump
Fuel Pump Removal
Fuel Pump Installation
Fuel Pump Inspection
Fuel Filter
Fuel Filter Removal
Fuel Filter Installation
Fuel Filter Inspection
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning/Inspection
– Engine Top End
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Push Rod Inspection
Valve Mechanism Removal/Installation
Rocker Arm Inspection
Cylinder Head Warp
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Seat Inspection
Valve Seat Repair
Valve Spring Free Length
Valve Head Thickness
Valve Stem Bend
Valve Stem Diameter
Valve Guide Inside Diameter
Measuring Valve/Guide Clearance (Wobble Method)
Exhaust Pipe And Muffler
Exhaust Pipe Removal
Muffler Removal
Exhaust Pipe And Muffler Installation
Exhaust Pipe And Muffler Inspection
Spark Arrester Cleaning
– Converter System
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Cleaning/Inspection
Air Cleaner Housing Removal
Torque Converter
Torque Converter Removal
Torque Converter Installation
Torque Converter Case Removal
Torque Converter Case Installation
Drive Belt
Drive Belt Removal
Drive Belt Installation
Drive Belt Inspection
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Drive Pulley
Drive Pulley Removal
Drive Pulley Disassembly
Drive Pulley Inspection
Spider Shoe Side Clearance Adjustment
Bushing Installation
Drive Pulley Assembly
Drive Pulley Installation
Driven Pulley
Driven Pulley Removal
Driven Pulley Disassembly
Driven Pulley Inspection
Converter Driven Pulley Shoe Inspection
Bushing Installation
Driven Pulley Assembly
Driven Pulley Installation
– Engine Lubrication System
Engine Oil Flow Chart
Engine Oil And Oil Filter
Oil Level Inspection
Engine Oil Change
Oil Filter Replacement
Oil Pump, Relief Valve
Oil Pump Removal
Oil Pump Installation
Oil Pump Inspection
Relief Valve Removal
Relief Valve Installation
Relief Valve Inspection
Oil Screen
Oil Screen Removal
Oil Screen Installation
Oil Screen Cleaning/Inspection
Oil Temperature Sensor
Oil Temperature Sensor Removal
Oil Temperature Sensor Installation
– Engine Removal/Installation
– Engine Bottom End
Crankcase Cover
Crankcase Cover Removal
Crankcase Cover Assembly
Crankcase Cover Installation
Camshaft And Tappets
Camshaft, Tappet Removal
Camshaft, Tappet Installation
Camshaft Disassembly
Camshaft Assembly
Camshaft Inspection
Camshaft Bearing/Journal Wear
Cylinders And Pistons
Piston Removal
Piston Installation
Piston Cleaning
Piston Ring And Ring Groove Wear
Piston Ring End Gap
Piston Pin, Piston Pin Hole, And Connecting Rod Wear
Piston Diameter
Cylinder Inside Diameter
Crankshaft And Connecting Rods
Connecting Rod Removal
Connecting Rod Installation
Crankshaft Removal
Crankshaft Installation
Cleaning/Inspection
Connecting Rod Bend/Twist
Connecting Rod Big End/Crankpin Width Wear
Connecting Rod Big End Bearing/Crankpin Wear
Crankshaft Runout
Crankshaft Main Bearing/Journal Wear
Balancer Shaft
Balancer Shaft Removal
Balancer Shaft Installation
Balancer Shaft Bearing/Journal Wear
Breather
Breather Valve Removal
Breather Valve Installation
Breather Valve Inspection
– Transmission
Exploded View
Special Tools
Transmission Oil
Transmission Oil Level Inspection
Transmission Oil Change
Transmission Case
Transmission Case Removal
Transmission Case Installation
Transmission Case Disassembly
Transmission Case Assembly
Transmission And Shift Mechanism
Transmission Cable Installation
Transmission Shift Cable
Shift Rod Bending
Shift Fork Ear And Shifter Groove Wear
Transmission And Shift
Mechanism Inspection
Lubrication
Shift Cable Inspection
Shift Mechanism
Differential Gears And Shift
Differential Shift Cable
Differential Shift Cable Inspection
Differential Shift Mechanism Installation
Differential Shift Mechanism Inspection
Differential Gear Removal
Differential Gear Installation
Differential Gear Inspection
Bearings And Oil Seal
Bearing Replacement
Ball Bearing Inspection
Needle Bearing Inspection
Oil Seal Inspection
Transmission Sectional
– Wheels/Tires
Wheel Alignment
Toe In Adjustment
Wheels (Rims)
Wheel Removal
Wheel Installation
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tires
Tire Removal
Tire Installation
Tire Wear Inspection
– Final Drive
Front Final Gear Case (
Front Final Gear Case Oil Level Inspection
Front Final Gear Case Oil Change
Front Final Gear Case Removal
Front Final Gear Case Installation
Front Final Gear Case Disassembly
Front Final Gear Case Assembly
Differential Unit Disassembly
Differential Unit Assembly
Lsd Clutch Torque Inspection
Lsd Clutch Plate Inspection
Pinion Gear Unit Disassembly
Pinion Gear Unit Assembly
Front Final Bevel Gear Adjustment
Bevel Gear Inspection
Differential Gear Inspection
Ball Bearing Inspection
Oil Seal Inspection
Bevel Gear Case
Driven Bevel Gear Removal
Driven Bevel Gear Installation
Driven Bevel Gear Disassembly
Driven Bevel Gear Assembly
Drive Bevel Gear Removal
Drive Bevel Gear Installation
Bevel Gear Adjustment
Bevel Gear Inspection
Ball Bearing/Oil Seal Inspection
Propeller Shafts
Front Propeller Shaft Removal
Front Propeller Shaft Installation
Rear Propeller Shaft Removal
Rear Propeller Shaft Installation
Propeller Shaft Inspection
Axles
Front Axle Removal
Front Axle Installation
Rear Axle Removal
Rear Axle Installation
Axle Inspection
Dust Boot Inspection
Front Axle Joint Boot
Replacement
Ball Bearing Inspection
Grease Seal Inspection
– Brakes
Brake Fluid
Brake Fluid Recommendation
Brake Fluid Level Inspection
Brake Fluid Change
Brake Line Air Bleeding
Brake Pedal And Master Cylinder
Brake Pedal Play Inspection
Master Cylinder Removal
Master Cylinder Installation
Master Cylinder Disassembly/Assembly
Master Cylinder Inspection
Brake Hoses And Pipes
Brake Hose And Pipe Inspection
Brake Hose And Pipe Replacement
Brake Drums
Brake Drum Removal
Brake Drum Installation
Brake Drum Wear
Brake Panel Assemblies
Brake Panel Assy Removal
Brake Panel Assy Installation
Brake Panel Disassembly
Brake Panel Assembly
Wheel Cylinder Removal/Installation
Wheel Cylinder Assembly
Wheel Cylinder Inspection
Brake Shoe Lining Wear
Brake Shoe Spring Inspection
Grease Seal Replacement
Parking Brake Lever And Cables
Parking Brake Lever Travel Adjustment
Parking Brake Cable Lubrication/Inspection
– Suspension
Struts And Rear Shock Absorbers
Strut (Front Shock Absorber) Removal
Strut (Front Shock Absorber) Installation
Rear Shock Absorber Preload Adjustment
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Inspection
Front Suspension Arms
Front Suspension Arm Removal
Front Suspension Arm Installation
Front Suspension Arm Inspection
Swingarm
Swingarm Removal
Swingarm Installation
Swingarm Inspection
Swingarm Joint Replacement
– Steering
Steering Wheel And Main Shaft Assembly
Steering Wheel Free Play Inspection
Steering Wheel Centering
Steering Wheel And Steering Shaft Removal
Steering Wheel And Steering Shaft Installation
Steering Gear Assembly
Steering Gear Assembly Removal
Steering Gear Assembly Installation
Steering Gear Preload Adjustment
Tie Rod Length Adjustment
Dust Boot Inspection
Steering Knuckles
Steering Knuckle Removal
Steering Knuckle Installation
Knuckle Bearing Removal
Knuckle Bearing Installation
Knuckle Joint Removal
Knuckle Joint Installation
– Frame
Seat And Seat Belts
Seat Removal
Seat Installation
Seat Belt Removal
Seat Belt Installation
Control Panel
Control Panel Removal
Glove Compartment Removal
Front Cargo Compartment
Front Cargo Hood Removal
Front Cargo Compartment Removal
Front Cargo Compartment Installation
Cargo Bed
Cargo Bed Removal
Cargo Bed Assembly
Cargo Bed Installation
Cargo Bed Latch Position Inspection
Cargo Bed Latch Position Adjustment
Front And Rear Bars
Front Bar Removal
Front Bar Installation
Rear Bar Removal
Rear Bar Installation
Front Fender
Front Fender Installation
Guard And Cover
Front Guard Removal
Front Guard Installation
Floor Center Panel Removal
Floor Center Panel Installation
Front Final Gear Case Guard Removal
Front Final Gear Case Guard Installation
Bottom Guard Removal
Bottom Guard Installation
Transmission Case Guard Removal
Transmission Case Guard Installation
Center Cover Removal
Center Cover Installation
Side Covers Removal
Side Covers Installation
Guard Plate Removal
Guard Plate Installation
– Electrical System
Wiring Diagram
Parts Location
Precautions
Electrical Wiring
Wiring Inspection
Battery
Battery Removal
Battery Installation
Electrolyte Level Inspection
Electrolyte Specific Gravity
Charging Condition Inspection
Initial Charging
Ordinary Charging
Battery Test Charging
Charging System
Alternator Rotor And Stator
Alternator Rotor And Stator
Charging System Operational
Stator Coil Resistance
Regulator/Rectifier Inspection
Ignition System
Spark Plug Removal
Spark Plug Installation
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Solenoid Inspection
Starter Motor Inspection
Starter Motor Disassembly
Starter Motor Assembly
Starter Motor Brush Inspection
Brush Spring Inspection
Armature Inspection
Yoke Assembly Inspection
Pinion Clutch Inspection
Starter Circuit Relay Inspection
Lighting System
Headlight Beam Adjustment
Headlight Bulb Replacement
Tail/Brake Light Replacement
Light Switch Bulb Replacement
Indicator Light Bulb Replacement
Switches
Brake Light Switch Inspection
Oil Temperature Sensor
Oil Temperature Warning
Indicator Control Unit Inspection
Switch Inspection
Fuses
Fuse Removal
Fuse Installation
Fuse Inspection
– Appendix
Troubleshooting Guide
Cable, Wire, And Hose Routing

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