2005-2016 Kawasaki KAF400 UTV Mule 610 4×4 600 UTV Service Manual

Description

This 2005-2016 Kawasaki KAF400 UTV Mule 610 4×4 and Mule 600 Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015 2016 Kawasaki KAF400 Mule 610 4×4 and Mule 600 utility side by side vehicles.

Service Manual Coverage

2005 KAF400-A1
2005 KAF400-B1
2005 KAF400-C1
2006 KAF400A6
2006 KAF400B6
2006 KAF400C6
2007 KAF400A7
2007 KAF400B7
2007 KAF400C7
2008 KAF400A8
2008 KAF400B8
2008 KAF400C8
2009 KAF400A9
2009 KAF400B9
2009 KAF400C9
2010 KAF400AA
2010 KAF400BA
2010 KAF400CA
2011 KAF400AB
2011 KAF400BB
2012 KAF400AC
2012 KAF400BC
2013 KAF400AD
2013 KAF400BD
2014 KAF400AE
2014 KAF400BE
2015 KAF400AF
2015 KAF400DBF
2016 KAF400

Table of Contents

Periodic Maintenance
Fuel System
Engine Top End
Converter System
Engine Lubrication System
Engine Removal/Installation
Engine Bottom End
Transmission
Wheels/Tires
Final Drive
Brakes
Suspension
Steering
Frame
Electrical System
Appendix

Index of Topics

SECTION 1 – General Information
General Information
Before Servicing
Model Identification
Model Identification
General Specifications
Unit Conversion Table

SECTION 2 – Periodic Maintenance
Periodic Maintenance Chart
Torque and Locking Agent
Specifications
Special Tools
Periodic Maintenance Procedures

SECTION 3 – Fuel System
Fuel System
Throttle Pedal Free Play
Inspection
Throttle Pedal Free Play
Adjustment
Fuel Hoses And Connections
Inspection
Fuel Hoses Replacement
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness
Inspection
Air Cleaner Element Cleaning
Fuel Filter Replacement
Evaporative Emission Control System Inspection (CAL Model, US and CA Models of the
KAF400AB ~/BB ~)

SECTION 4 – Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Spark Arrester Cleaning

SECTION 5 – Converter System
Converter Air Cleaner Element
Cleaning/Inspection
Converter Dust or Water Drain
Cleaning
Converter Drive Belt Inspection Converter Drive Belt Deflection
Inspection
Converter Drive Belt Deflection
Adjustment
Converter Driven Pulley Shoe
Inspection

SECTION 6 – Engine Lubrication System
Engine Oil Change
Oil Filter Replacement
Transmission
Transmission Oil Change
Electrical System
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Wheels/Tires
Wheels Nuts Tightness
Inspection
Tire Wear Inspection
Final Drive (KAF400-A/C)
Front Final Gear Case Oil
Change
Brakes
Brake Fluid Level Inspection
Brake Fluid Change
Brake Pedal Play Inspection
Brake Master Cylinder Cup and
Dust Cover Replacement
Brake Hose and Pipe Inspection Brake Hose and Pipe
Replacement
Brake Wheel Cylinder Assembly
Replacement
Brake Wear Inspection
Parking Brake Lever Inspection
Steering
Steering Inspection
Steering Joint Dust Boot
Inspection
Frame
Seat Belt Inspection
Electrical System
Battery Inspection
Brake Light Switch Inspection
General Lubrication
Bolts, Nuts, and Fasteners
Tightness Inspection
Fuel System
Exploded View
Specifications
Throttle Pedal and Cable
Throttle Pedal Free Play
Inspection
Throttle Pedal Free Play
Adjustment
Full Throttle Pedal Position
Adjustment
Throttle Cable Installation
Throttle Cable Lubrication
Throttle Cable Inspection
Governor Link Mechanism
Control Panel Assembly Removal Control Panel Assembly
Installation
Governor Assembly Removal
Governor Assembly Installation Governor Assembly Inspection
Choke Cable
Choke Knob Free Play Inspection Choke Knob Free Play
Adjustment
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 Element Cleaning
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
Evaporative Emission Control System (CAL Model, US and CA Models of
the KAF400AB ~/BB ~)
Parts Removal/Installation
Hose Inspection
Canister Inspection
Engine Top End
Table of Contents
Exploded View
Exhaust System
Specifications
Special Tools
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Push Rod Inspection
Valve Mechanism Removal/Installation
Rocker Arm Inspection
Cylinder Head Warp Inspection
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Seat Inspection
Valve Seat Repair
Valve Spring Free Length Inspection
Valve Head Thickness Inspection
Valve Stem Bend Inspection
Valve Stem Diameter Inspection
Valve Guide Inside Diameter Inspection
Valve to Guide Clearance Measurement (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
Table of Contents
Exploded View
Specifications
Special Tools and Sealant
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
High Altitude Setting Information
Specifications
Engine Lubrication System
Table of Contents
Exploded View
Specifications
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 (KAF400-A/C)
Oil Temperature Sensor Removal
Oil Temperature Sensor Installation

SECTION 7 – Engine Removal/Installation
Table of Contents
Exploded View
Special Tool
Engine Removal/Installation
Engine Removal
Engine Installation

SECTION 8 – Engine Bottom End
Table of Contents
Exploded View
Specifications
Special Tools
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 Inspection
Cylinders and Pistons
Piston Removal
Piston Installation
Piston Cleaning
Piston Ring and Ring Groove Wear Inspection
Piston Ring End Gap Inspection
Piston Pin, Piston Pin Hole, and Connecting Rod Wear Inspection
Piston Diameter Inspection
Cylinder Inside Diameter Inspection
Crankshaft and Connecting Rods
Connecting Rod Removal
Connecting Rod Installation
Crankshaft Removal
Crankshaft Installation
Cleaning/Inspection
Connecting Rod Bend/Twist Inspection
Connecting Rod Big End/Crankpin Width Wear Inspection
Connecting Rod Big End Bearing/Crankpin Wear Inspection
Crankshaft Runout Inspection
Crankshaft Main Bearing/Journal Wear Inspection
Balancer Shaft
Balancer Shaft Removal
Balancer Shaft Installation
Balancer Shaft Bearing/Journal Wear Inspection
Breather
Breather Valve Removal
Breather Valve Installation
Breather Valve Inspection

SECTION 9 – Transmission
Exploded View
Specifications
Special Tools and Sealant
Transmission Oil
Transmission Oil Level Inspection
Transmission Oil Change
Transmission Case
Transmission Case Removal
Transmission Case Installation Drive Shaft Nut Removal (KAF400-B)
Drive Shaft Nut Installation (KAF400-B)
Transmission Case Disassembly
Transmission Case Assembly
Transmission and Shift Mechanism Transmission Cable Installation Transmission Shift Cable Inspection
Shift Rod Bending Inspection
Shift Fork Ear and Shifter Groove
Wear Inspection
Transmission and Shift
Mechanism Inspection
2WD/4WD Shift Mechanism (KAF400-A/C)
2WD/4WD Shift Cable Adjustment
2WD/4WD Shift Cable Lubrication
2WD/4WD Shift Cable Inspection 2WD/4WD Shift Mechanism Removal
2WD/4WD Shift Mechanism Inspection
Differential Gears and Shift Mechanism
Differential Shift Cable Adjustment
Differential Shift Cable Lubrication
Differential Shift Cable Inspection Differential Shift Mechanism Removal
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 Figure

SECTION 10 – Wheels/Tires
Table of Contents
Exploded View
Specifications
Special Tool
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

SECTION 11- Final Drive
Exploded View (KAF400-A/C)
Exploded View (KAF400-B)
Specifications
Special Tools and Sealants
Front Final Gear Case (KAF400-A/C) 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 (KAF400-A/C)
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 (KAF400-A/C)
Front Propeller Shaft Removal
Front Propeller Shaft Installation
Rear Propeller Shaft Removal
Rear Propeller Shaft Installation
Propeller Shaft Inspection Axles
Front Axle Removal (KAF400-A/C)
Front Axle Installation (KAF400-A/C)
Front Axle Removal (KAF400-B) Front Axle Installation (KAF400-B)
Rear Axle Removal
Rear Axle Installation
Axle Inspection
Dust Boot Inspection (KAF400-A/C)
Front Axle Joint Boot
Replacement (KAF400-A/C)
Ball Bearing Inspection
Grease Seal Inspection

SECTION 12 – Brakes
Exploded View
Specifications
Special Tools
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 Inspection
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 Inspection
Brake Shoe Spring Inspection
Grease Seal Replacement (KAF400-A/C)
Parking Brake Lever and Cables
Parking Brake Lever Travel Adjustment
Parking Brake Cable Lubrication/Inspection
Parking Brake Lever Removal
Parking Brake Lever Installation

SECTION 13 – Suspension
Table of Contents
Exploded View
Specifications
Special Tools
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

SECTION 14 – Steering
Exploded View
Specifications
Special Tools
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

SECTION 15 – Frame
Exploded View
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
Cooling Fan Guard Removal (KAF400A9 ~ AA/B9~ BA/C9- CA)
Cooling Fan Guard Removal (KAF400AB ~/BB ~)
Cooling Fan Guard Installation (KAF400A9 ~ AA/B9 ~ BA/C9 ~ CA)
Cooling Fan Guard Installation (KAF400AB ~/BB ~)
Guard Plate Removal
Guard Plate Installation

SECTION 16 – Electrical System
Exploded View
Wiring Diagram (KAF400-A/C)
Wiring Diagram (KAF400-B)
Specifications
Special Tools
Parts Location
Precautions
Electrical Wiring
Wiring Inspection
Battery
Battery Removal
Battery Installation
Electrolyte Level Inspection
Electrolyte Specific Gravity Inspection
Charging Condition Inspection
Initial Charging
Ordinary Charging
Battery Test Charging
Charging System
Alternator Rotor and Stator Removal
Alternator Rotor and Stator Installation
Charging System Operational Inspection
Stator Coil Resistance Inspection Regulator/Rectifier Inspection (KAF400-A1/B1/C1, A6 ~ A8/B6 ~ B8/C6 ~ C8)
Regulator/Rectifier Inspection (KAF400A9 ~/B9 ~/C9 ~ CA)
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 Inspection (KAF400-A/C)
Oil Temperature Warning Indicator Control Unit Inspection (KAF400-A/C)
Switch Inspection
Fuses
Fuse Removal
Fuse Installation
Fuse Inspection

SECTION 17 – Appendix
Table of Contents
Troubleshooting Guide
Cable, Wire, and Hose Routing