2012 Kawasaki Mule 4000 Hood release latch cable replaced
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By Travis
View File Kawasaki Mule 550,520,500 Complete service manual
This is a complete service manual for the Kawasaki Mule 500,520 and 550 models.
Topics covered include Brakes, Steering, Electrical system, suspension and fuel system. As well as engine repair procedures and Transmission/Final Drive procedures.
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If you need more information about the engine this manual linked below is chock full of information.
Thanks goes to @cliffyk for getting these files all into one PDF format for uploading.
Submitter Travis Submitted 04/18/2021 Category Kawasaki
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By FloridaMan
I have a 2012 Massimo MSU 500 that died. I found that it didn't have spark and the fuel pump wouldn't run. Checked all fuses and none were blown.
Went through and replaced the ignition coil, HT lead and spark plug. Still no spark.
Thought it could be the fuse/relay box because I didnt' know much about the machine at that point so I replaced it. No spark.
Then I replaced the ECM just because I was running out of ideas. No spark.
I removed the 9 pin connector and hardwired it making sure that they were no wires got swapped. Still no spark.
Then I replaced the wiring hardness. In doing so, I replaced the 9 pin connector with new ones. I made sure all wires were matched up between the engine harness side and the other harness assembly. Still no spark.
I have no other ideas what to do. My fuel pump doesn't kick on and I have no spark. I have 12V on the fuel pump, ignition coil and fuel injector, but no ground from the ECM control. I unplugged the fuel injector and waited for a diagnostic code but nothing ever came in. It makes me think that the ECM isn't powering up. I've checked for 12V on pins 18 (purple wire) and 15 (white and black wire). I also checked for ground on pin 2 (black wire). All are good.
I am out of options here and I have no idea what else it could be. I have all connections redone and are coated with dielectric grease. I've checked all easy things like fuses and making sure I have 12V in the right placed. I would appreciate any help.
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By Moos
I replaced the fuel pump, ended up with a couple bad ones. This last one now worked fine for about 150 miles, now only works when its cool outside. (30-40). As soon as we hit 55 degrees, It will not run. Barely starts, runs rough, will not move. Any ideas? Another bad pump? Something else going on? Any help would be appreciated. Thanks.
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