Kawasaki MULE 600 SERIES Assembly & Preparation Manual

Brand: Kawasaki

Model: MULE 600 SERIES

Type: Assembly & Preparation Manual

This manual is also suitable for

MULE 610 4×4

MULE 600

Utility Vehicle

Assembly & Preparation

Manual

Foreword

In order to ship Kawasaki vehicles as effi-

ciently as possible, they are partially disassem-

bled before crating. Since some of the most

commonly removed parts have a direct bear-

ing on a vehicle’s reliability and safety, consci-

entious pre-sale assembly and preparation be-

comes extremely important. Good setup pro-

cedures can prevent needless warranty claims

and give customers a greater sense of c onfi-

dence in Kawasaki and their Kawasaki Dealers.

This Assembly and Preparation Manual ex-

plains step by step procedures of the following

items for all Kawasaki utility vehicles.

1. Crate Handling

2. Uncrating

3. Assembly

4. Preparation

The selling dealer assumes sole responsibil-

ity for any unauthorized modifications prior to

sale. Refer to your Service Binder for any Ser-

vice Bulletins specifying Factory Directed Mod-

ifications (Special Claims) which must be per-

formed before the vehicle is ready for sale.

Whenever you see the following symbols

heed their instructions! Always follow safe

operating and maintenance practices.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or less of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

correctly followed, could result in dam-

age to, or destruction of equipment.

NOTE

○This note symbol indicates points of particular

interest for m ore efficient and convenient op-

eration.

Kawasaki Heavy Industries, Ltd. accepts no

liability for any inaccuracies or omissions in this

publication, although every possible m easure

has been taken to make it as complete and ac-

curate as possible. All procedures and specifi-

cations subject to change without notice.

Table of Contents

ate Handling..............................................................................

Crate Handling Precautions ........................................................ 3

Uncrating ...................................................................................... 3

ening Crate .............................................................................

Parts C heck ................................................................................. 8

Assembly ...................................................................................... 10

teering Wheel............................................................................

Rear Bar ...................................................................................... 11

Front Bar ..................................................................................... 12

rench Labels for Canadian Models (KAF400A/B) .....................

Cargo Bed ................................................................................... 14

Preparation ................................................................................... 14

Battery Service ............................................................................ 14

Transmission Oil.......................................................................... 17

Front Final Gear Case Oil (KAF400A/C) ..................................... 17

Brake Fluid .................................................................................. 18

Brake Pedal................................................................................. 19

Parking Brake Lever .................................................................... 20

Steering Wheel............................................................................ 20

Tire Air Pressure.......................................................................... 20

Fuel ............................................................................................. 21

Engine Oil.................................................................................... 22

Throttle Pedal .............................................................................. 24

Choke Knob................................................................................. 25

Idle Speed Adjustment ................................................................ 25

Brake Light Switch....................................................................... 27

Headlight Beam........................................................................... 27

Wheel Alignment ......................................................................... 27

Fastener Check ........................................................................... 30

Standard Torque Table ................................................................ 32

Test Ride ..................................................................................... 32

A & P Check List ......................................................................... 32

UNCRATI

NG 3

Crate Handling

Crate Handling Precautions

Crate Position:

Always place the crate upright on its base.

The crate has been designed to carry the w eight

of the vehicle only in that position. The sides

and top of the crate are not strong enough to

act as the base of the crate. If the crate is tilted

very far or set on its end or side, loose parts

may be dislodged and fall inside the crate.

Mov

ing Crated Vehicle:

WARNING

Do n

ot move or lift the crate by pulling

on the crate bands. They are designed

to keep the cardboard cover on, and if

ed as handles they can snap, causing

you or the crate to fall unexpectedly.

Whenever moving the crate from one place to

another, use a fork lift or flat bed hand truck. Ve-

hicle crates are too big and heavy to be moved

by hand. While moving a crate, never stand it

on end or tip it over on its side. DO NOT DROP

crated vehicles.

Loading and Unloading Trucks:

To load or unload crates, use a fork lift, a lift

-type tail gate, or a ramp. Never unload crates

by hand. NEVER DROP crates off a truck.

Tyin

gDownCrates:

Always tie down crates when transporting

them. Put the tie downs across the crate at the

crat

e’s internal vertical braces. Do not use any

hooks on the crate.

Stacking Crates:

The number of crates that may be stacked on

top of one another depends on the condition of

the crates more than any other single factor.

Also, take into consideration the weight of the

upper crate(s), the sizes of all the crates in a

stack, and the strength of the bottom crate(s)

base on the type of crate construction (steel,

wood, bracing, etc.).

In any case, do not stack crates more than two

high for trucking, and three high for storage.

Uncrating

Opening Crate

•

Clear a space about 6 m (20 ft.) square to

give yourself plenty of space to work.

•

Place the crate upright on its base.

•

Remove the outer cover and inspect the unit

for concealed damage. If concealed damage

is evident, document the damage as outlined

in the Kawasaki Warranty Policies and Pro-

cedures Manual before proceeding to uncrate

the unit.

4 UNCRAT

ING

Top Panel Removal

•

Remove the screws from the crate brackets

on the top crate.

A. C

rate Screws

B. Top Crate

•

Using a BPS3 square drive bit (ex. IM-

PORT APEX Square Recess “Power Bits-

1/4 Hex-size #3” or MAGNA “Insert Bits-size

#3” with quick change holder), remove the

screws from the sides and ends into the top.

A. “Power Bit (APEX)”

WARNING

Be careful of staples and other sharp

fasteners. Remove or bend over all nails

in the crate base to prevent injure.

•

There are two screws in every corner.

•

Remove two screws in every cross member.

•

Top panel can be lifted from the unit. Have

ase

cond person help to remove t his piece

as it can be awkward to handle. Discard this

assembly. Take care when letting the rear bar

ass

embly down from the top, it is heavy and

may fall.

Side Panel Removal

•

Remove the (16) screws shown below. The

panel should come loose without excess

force; check for any screws missed if the

panel will not come off easily.

NOTE

○Trying to break the panels off can result in

mage to the unit.

•

Repeat procedure for the other side of the

unit. Discard these panels.

End Panel Removal

•

Remove the (5) screws shown below. The

panel should come loose without excess

force, check for any screws missed if panel

will not come off easily.

NOTE

○Trying to break the panels off can result in

damage to the unit.

UNCRATI

NG 5

•

Rep

eat as above for the rear panel. Discard

these panels.

Front Tie-down Removal

•

Remove front tie-downs by opening fully and

disengaging latch. Take care to undo these

evenly as there is heavy tension in the tie

-down.

A. Tie-downs (Front)

NOTE

○It is important to remove the top panel as the

unit will rise when the tie-downs are undone.

Failure to do so will result in damage to the

unit.

Rear Tie-down Removal

•

Remove rear tie-downs by opening fully and

disengaging latch. Take care to undo these

evenly as there is heavy tension in the tie

-down.

A. Tie-downs (Rear)

NOTE

○It is important to remove the top panel as the

unit will rise when the tie-downs are undone.

Failure to do so will result in damage to the

unit.

Removing The Bars From The Unit

•

Cut the tie bands that retain the steering

wheel and remove.

•

Remove the strap that holds the front bar and

rear bar assembly together.

A. Strap

B. Front Bar

C. Steering Wheel

•

Remove the rear bar assembly from the unit.

Have a second person help to remove this

piece as it can be awkward to handle. Take

care when letting the rear bar assembly down

from the unit, it is heavy and may fall.

•

Remove the crate bolts on floor of crate base.

•

Remove the bolts, nuts, and washers. Dis-

card them.

•

Remove the front bar from the unit.

6 UNCRAT

ING

A. Crate Bracket

B. Bolt

C. Fr

ont Bar (Right)

D. Nut, Bolt, and Washer

UNCRATI

NG 7

Dummy Page

8 UNCRAT

ING

Parts Check

NOTE

○There may be minor differences in appearance between these illustrations and the actual vehicle

parts.

•

Remove the parts and check the crate base and packaging materials carefully for loose parts. Check

the parts against the illustration. Order any parts that are missing from the crate. Part numbers are

provided in the following charts.

In the following charts under Remarks, D = diameter in millimeters, and L = length in millimeters.

UNCRATI

NG 9

No. Part Name

Qty

Remarks Part Number

Steering Wheel

1 46003-1265

Spring Washer (1) 461F1200

Nut, Steering Wheel (1) 92210-1249

Cover, Steering Wheel 1 14024-1574

2 Front Bar with 1 55047-0006

Bolt, Upper (2) D = 10, L = 70 92001-1618

Nut, Upper (2) D=10 92210-1204

Flat Washer (4) D=12 92022-1396

Bolt, Lower 4 D = 14, L = 36 92153-1282

3 Rear Bar with 1 55047-0008

Bolt, Lower, Rear Bar (2) D = 10, L = 20 130J1020

Nut, Lower, Rear Bar (2) D=10 92210-1204

Bolt, Lower, Rear Bar (4) D = 10, L = 16 130J1016

Screen (1) 14037-0035

Bolt

, Screen

(5)

D = 8, L = 20 130J0820

Nut, Screen (5)

D=8 92210-0005

Guard, Screen (1) 13271-0560

Seat Assy, Back (1) 53066-0078

Nut, Seat Assy, Back (4) D=8 92210-0005

Seat Belt (2) 53061-1012

Fre

nch Labels and Instruction for

KAF400A Canadian Models only

Instruction, Label 1 56030-0087

Label, Cargo Bed Information 1 56053-0066

Label, Tire/Max. Load 1 56053-0067

Label, Warning, Cargo Bed 1 56070-0054

bel, Warning, Off Highway Utility

Vehicle

1 56070-0055

Label, Warning, Refueling 1 56070-0057

abel, Warning, General

1 56070-1206

Label, Warning, Hot Surfaces

1 56070-1234

French Labels and Instruction for

AF400B Canadian Models only

Instruction, Label 1 56030-0090

Label, Cargo Bed Information 1 56053-0066

Label, Tire/Max. Load 1 56053-0105

Label, Warning, Cargo Bed

1 56070-0054

Label, Warning, Off Highway Utility

Vehicle

1 56070-0055

Label, Warning, Refueling

1 56070-0057

Label, Warning, General 1 56070-1206

Label, Warning, Hot Surfaces 1 56070-1234

6 Battery Vent Hose 1 L = 229 92190-1261

7 Owner’s Manual 1 –

10 ASSEM

BLY

Assembly

Steering Wheel

•

Remove the engine emission related hangtag

(Index

Card: P/No. 49007-2085) for Califor-

nia from the steering shaft.

A. S

teering Shaft

B. Hangtag

•

Hang it to the shift lever.

A. Shift Lever

B. Hangtag

NOTE

○This hangtag is not to be removed before sale.

Steering Wheel Installation

•

Remove the steering wheel nut (D = 12) and

the spring washer. Do not remove the black

washer (D = 45).

•

Set the front wheels s traight ahead.

A. Nut (D = 12)

B. Spring Washer

C. Steering Shaft

D. Black Washer (D = 45)

•

Mount the steering wheel on the steering

shaft so that it is straight ahead, and install

the spring washer and plated nut (D = 12).

•

Tighten the steering wheel nut to the specified

torque.

Torque : 54 N·m (5.5 kgf·m, 40 ft·lb)

A. Nut

B. Spring Washer

C. Cover

•

Install the steering wheel cover on the steer-

ing wheel by fitting the projections of the cover

into the notches of the wheel.

ASSEMBL

Y11

A. Cover

CAUTION

Be careful not to puncture a tire with

sharp fasteners. Remove or bend over

all nails in the crate base to prevent in-

jury.

•

Roll off the vehicle from the crate base.

•

Discard the crate base.

Rear Bar

Rear Bar Installation

•

Loosen the four mounting bolts (D = 8, L = 20)

and nuts to remove the crate brackets from

the screen.

A. Crate Bracket(s)

B. Bolt (D = 8, L = 20)

C. Nut

•

Discard the brackets, and reinstall the screen

on the rear bar with the bolts (4) and nuts

removed.

A. Bolts (D = 8, L = 20)

B. Screen

C. Nuts

•

Remove the two mounting bolts (D = 10, L =

20) and nuts from the lower end of the rear

bar.

A. Rear Bar

B. Bolt

C. Nut

•

Lift the seat up, and release the cargo bed

latch.

•

Lift the cargo bed and support it with the rod.

A. Rod

B. Cargo Bed

•

Remove the rear bar mounting bolts (D = 10,

L = 16)(4) from the chassis.

12 ASSEM

BLY

A. Bolts (D = 10, L = 16)

B. Chassis

•

To remove the guard plate, pull out the up-

per rivets by inserting the screwdriver into the

notch and remove the lower rivets. Remove

the guard plate.

A. Guard Plate

B. Rivets (6)

C. Notch

D. Upper Rivet

E. Lower Rivet

•

With the help of a second person, locate the

rear bar assembly on the frame with the rear

bar mounting bolts (6) from the outside and

nuts (2), and tighten the bolts finger tight.

A. Rear Bar (Right)

B. Bolt (D = 10, L = 20)

C. Bolts (D = 10, L =16)

D. Nut

NOTE

○Install the air ducts and guard plate after “Idle

Speed Adjustment” section on page 25 in the

Preparation chpater.

Front Bar

Front Bar Installation

•

Remove the bolts (D = 10, L = 70)(2), flat

washers (4), and nuts (D = 10)(2) from the

upper end of the rear bar.

A. Bolt (D = 10, L = 70) and Flat Washer

B. Nut (D = 10) and Flat Washer

C. Rear Bar (Left)

•

With the help of a second person, install the

lower ends of the front bar onto the frame with

the lower mounting bolts (D = 14, L = 36)(4),

and tighten the bolts finger tight.

ASSEMBL

Y13

A. Front Bar

B. Bolts (D = 14, L = 36)

•

Join the rear ends of the front bar and the

rear bar with the bolts (2), flat washers (4),

and nuts (2) removed, and tighten them finger

tight.

A. Rear Bar (Left)

B. Nut and Flat Washer

C. Bolt (D = 10, L = 70) and Flat Washer

D. Front Bar

•

Tighten the front bar lower mounting bolts to

the specified torque.

Front Bar Lower Mounting Bolt Torque:

98 N·m (10 kgf·m, 72 ft·lb)

•

Tighten the front and rear bar mounting bolts

and nuts to the specified torque.

Rear Bar Mounting Bolt and Nut Torque:

44 N·m (4.5 kgf·m, 33 ft·lb)

Front Bar Upper Mounting Bolt and Nut

Torque:

44 N·m (4.5 kgf·m, 33 ft·lb)

French Labels for Canadian

Models (KAF400A/B)

NOTE

○Apply the French labels over the English

labels

on the hood, control panel, rear bar,

cargo bed, guard plate, or right side cover

only when required.

•

Wipe off any oil or grease from the English

labels. Refer to the following photographs in

the label locations.

•

Peel each French label off the backing sheet

and apply it over the English label.

1. Off-Highway Utility Vehicle Warning

(56070-0055)

2. Shifting Caution

3. General Warning (56070-1206)

4. Front Cargo Hood Wa rning

5. Carg o Bed Information (56053-0066)

6. Cargo Bed Warning (56070-0054)

14 PREPA

RATION

7. Ti

re Pressure & Maximum Loading

Warning (for KAF400A: 56053-0067) (for

KAF400B: 56053-0105)

8. Carrier Hook Operation

10. Refueling Warning (56070-0057)

11. Hot Surfaces Warning (56070-1234)

Cargo Bed

Cargo Bed Latch Position Inspection

The cargo bed must be latched securely on

the cargo bed hook without rattling.

•

If there is rattling or not snug enough, adjust

the latch position.

A. Cargo Bed Latch

B. Cargo Bed Hook

C. Mounting Bolts

Cargo Bed Latch Position Adjustment

•

Lift the seat up.

•

Release the latch and loosen the mounting

bolts.

•

Reposition the latch to the suitable place by

sliding within the ellipse bolt holes.

•

Retighten the mounting bolts.

Prepa

ration

Battery Service

Conve

ntional Battery

The battery used in this vehicle is conven-

tional type. Follow the procedure for activating

anewb

attery to ensure the best possible bat-

tery performance.

Activating the battery requires two steps,

fill

ing the battery with electrolyte, and charging.

Read the Battery Safety label shown below and

following procedures carefully before battery

acti

vation.

CAUTION

Incorrect Battery Activation w ill reduce

battery performance and service life. Be

sure to strictly follow the Battery Service

instructions in this Manual.

WARNING

Heed the battery safety label shown

here.

ttery Removal

•

Lift the seat up. Battery is located under the

left end of the seat.

•

emove the two fuse case from the holders.

•

Remove the battery holder nuts and the

holder with damper.

•

ift the battery out of the battery case. Be

careful that the rubber damper is not pulled

out of the position.

PREPARA

TION 15

A. Fuse Case(s)

B. Fuse Case Holder(s)

C. Nuts

D. Battery Holder

E. Damper

F. Battery

Battery Activation

•

Place the battery on a level surface. Just prior

to adding electrolyte, remove the filling plugs

and red sealing tube. Throw the red tube

away.

A. Battery (YB14A-A2)

B. Red Sealing Tube

C. Terminals

WARNING

Installing the red tube after the battery is

filled with acid can cause an explosion.

Discard the tube as soon as it removed.

•

Install the battery vent hose.

•

Fill the battery with electrolyte (a sulfuric acid

dilution with a specific gravity of 1.270). Do

not use water or any other liquid to activate.

NOTE

○Electrolyte should be between 16 °C (60°F)

and 30 °C (86°F) before filling. Fill to upper

level as indicated on battery.

•

Let the battery stand for at least 30 minutes.

Move the battery or gently tap so that any

bubbles between the plates will be expelled.

If the electrolyte level drops below the upper

line, refill the battery with more electrolyte be-

fore charging.

•

During charging, batteries can spit electrolyte

out an open vent.

NOTE

○Neve

r charge a battery in the vehicle. Elec-

trolyte spillage can cause damage.

•

A battery must be completely charged before

installation. Charge for three to five hours at

the current equivalent of 1/10 of its rated ca-

pacity (Amp Hours). For example, the charge

rate for a 14 ampere-hour battery is 1.4 am-

peres.

•

Check during charging to see if the electrolyte

level has fallen, and if so, fill with distilled or

clean water to the upper level. After adding

water, charge for another hour at the same

rate as before to mix the water and acid.

. Filling Plugs

B. Upper Level Line

C. Lower Level Line

D. Vent Hose

•

When charging is complete, always turn off

the charger before disconnecting the battery.

WARNING

Keep the battery away from sparks and

open flames during charging, since the

battery gives off an explosive gas mix-

ture of hydrogen and oxygen. When

using a battery charger, connect the

battery to the charger before turning on

the charger. This procedure prevents

sparks at the battery terminals which

could ignite any battery gases.

16 PREPA

RATION

CAUTION

If the temperature of the electrolyte

rises above 47 °C (115°F) during charg-

ing, reduce charging rate to bring down

the temperature, and increase charg-

ing time proportionately. Charging the

battery at a rate higher than specified

could ruin the battery. Charging at a

higher rate causes excess heat, which

can warp the plates and cause internal

shorting. Higher than normal charging

rates also cause the plates to shed ac-

tive material. Deposits will accumulate,

and can cause internal shorting.

•

Install the plugs and finger tighten firmly.

CAUTION

Do not over-tighten the plugs, finger

tighten only.

•

Wash off any spilled acid with a water and

king soda solution, paying particular atten-

tion that any acid is washed off the terminals.

Dry the battery case.

NOTE

○Charging rates will vary depending on how

long the battery has been stored, tempera-

ture, and the type of charger used. Check

voltage after initial charge using a voltmeter,

if it is not at least 12.8 volts repeat charging

cycle.

Battery Installation

•

Turn the ignition switch OFF.

•

Check that the rubber damper on the battery

holder and the battery case are properly in

place.

•

Put the battery in place, and route the battery

vent hose through the hole in the floorboard.

•

First, connect the red capped lead to the pos-

itive (+) terminal, and then connect the black

negative lead to the negative terminal (–).

A. Battery

B. Positive Terminal (+)

C. Ne

gative Terminal (–)

D. Vent Hose

•

Reinstall the fuse cases to the holders.

•

Apply a light coat of grease to the terminals to

prevent corrosion.

•

Cover the positive terminal (+) with its protec-

tive cap.

•

Reinstall the battery holder and damper with

the nuts.

A. Fuse Case(s)

B. Fuse Case Holders

C. Nuts

D. Battery Holder

E. Damper

CAUTION

Keep the battery vent hose outlet away

from the frame and drive system com-

ponents. Battery electrolyte will corrode

and weaken them. Do not let the vent

hose become folded, pinched, or melted

by the exhaust system. An unvented

battery will not keep a charge and it may

crack from built-up gas pressure.

PREPARA

TION 17

Transmission Oil

Transm

ission Oil Level Inspection

•

Check oil level and drain plug tightening.

Transmission Oil Drain Plug Torque

15 N·m (

1.5 kgf·m, 11 ft·lb)

A. Transmission Case

B. Drain Plug

C. Gu

ard Plate

•

Park the vehicle so that it is level, both side-to

-side and front-to-rear.

•

Lift the seat up, and release the cargo bed

latch.

•

Lift the cargo bed and support it with the rod.

•

Unscrew the oil level gauge, wipe its dipstick

dry, and insert it into the gauge hole but DO

NOT SCREW IT IN.

A. Transmission Case

B. Oil Level Gauge

C. Oil Filler Cap

•

Pull out the oil level gauge and check the oil

level. The oil level should be between the “H”

(High) and “L” (Low) lines on the dipstick.

A. Oil Level Gauge

B. O-ring

C. "H" (High) Line

D. "L" (Low) Line

•

If the oil level is too high, remove the oil filler

cap, remove the excess oil, using a syringe

or other suitable device, through the oil filler

opening.

•

If the oil level is too low, remove the oil filler

cap, add the oil to reach the correct level.

•

When replacing the oil level gauge and oil

filler cap, be sure the O-ring is in place, and

screw them in finger tight.

•

Install the oil level gauge and oil filler cap.

NOTE

○Use the same type of oil that is already in the

transmission case.

Transmission Oil

Type: API GL-5 hypoid gear oil

Viscosity: SAE 90 [above 5°C (41°F)]

SAE 80 [below 5°C (41°F)]

Capacity: KAF400A/C: 2.4 L (2.5 US qt)

KAF400B: 2.2 L (2.3 US qt)

Front Final Gear Case Oil

(KAF400A/C)

Front Final Gear Case Oil Level Inspec-

tion

•

Park the vehicle so that it is level, both side-to

-side and front-to-rear.

•

Remove the filler cap from the front final gear

case.

18 PREPA

RATION

A. Front Final Gear Case

B. Filler Cap (on the left side)

•

Check the oil level. The oil level should come

to the bottom thread of the filler opening. If it

is low, add oil through the oil filler opening as

necessary.

A. Front Final Gear Case

B. Filler Opening

C. Bottom Thread

•

Reinstall the filler cap.

NOTE

○Use the same type of oil that is already in the

gear case.

Front Final Gear Case Oil

Type:

API GL-5 or GL-6

hypoid gear oil for LSD

(Limited Slip Differential

gears)

Viscosity:

SAE 90 (GL-6) or SAE 140

(GL-5)

Capacity: 0.2 L (0.2 US qt)

Front Final Gear Case Oil Drain Plug

Torque:

20 N·m

(2.0 kgf·m, 14 ft·lb)

Oil Filler Cap Torque:

29 N·m (3.0 kgf·m, 22 ft·lb)

Brake Fluid

Brake Fluid Level Inspection

WARNING

Never reuse old brake fluid.

Do not use fluid from a container that

has been left unsealed or that has been

open for a long time.

Do not mix two types of fluid for use in

the brakes. This lowers the brake fluid

boiling point and could reduce brake ef-

fectiveness. It may also cause the rub-

ber brake parts to deteriorate.

Don’t leave the reservoir cap off for any

length of time to avoid moisture contam-

ination of the fluid.

Don’t add or change brake fluid in the

rain or during conditions of blowing dust

or debris.

CAUTION

Brake fluid quickly ruins painted sur-

faces. Wipe up any spilled fluid immedi-

ately.

•

With the vehicle on level ground, check that,

through the inspection hole in the dashboard,

the fluid level in the reservoir is between the

upper (marked MAX) and lower (marked MIN)

level lines.

A. Inspection Hole

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Kawasaki MULE 600 SERIES Assembly & Preparation Manual

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Model: MULE 600 SERIES

Type: Assembly & Preparation Manual

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