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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 lonerider98
At the end of last year my Coleman UT 500 will not go into reverse. I can hold it over toward the reverse to move it nut it won't lock into reverse. Anyone have this problem? Winter is just about over and going to have to get this resolved. Thank You!
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By Rizzguy
Don’t waste your time everybody with rpm motorsports, Omaha. They are people that don’t even work on sxs’s. Trying to tell you how to install things.
Completely uneducated guy tried to tell me I did not install a mid pipe correctly when it won’t install correctly; that was the reason for the video and the complaint that I called him about.
This mid pipe has a 1 inch gap at the rear, and the only way to close it up is with a longer bolt, and to stretch the flex at the Exhaust
After one ride, the rear bolts have disappeared, because how much tension there is on the flex
And the bolts does not line up at the flange
Have a video before and after. And they are telling me that it’s my fault because it does not fit
wtf.!
What kind of idiotic people are even answering the phones these days.?
This guy has probably only read a book and never even driven a motorcycle in his life
Don’t waste your time with this bullshit products
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By Irons
Hopefully this helps somebody because I couldn't find any info on this runaway condition.
Drove 1/2 mile to the gas station and when I started up to leave the starter stuck on. Turn key off starter is still running~! Limp it home wondering what the heck to do, get it in the garage and pull the negative battery terminal to get it to stop. Whew, WTF?
Calm down and start checking things, starter is hot of course but nothing is smoking and nothing smells burnt. Pull battery cover off and start checking wires from battery to relay and relay to the starter. OK good nothing is hot, nothing is crispy and nothing is melted. Probably smoked the starter though. If this had happened to my wife and I wasn't around the machine would have run until the battery died and probably melted down/burned.
I'll get to the point to save you folks some time and trouble. Because this is a kymco machine you need 2 different Kawasaki parts to make this repair, and information is scarce to say the least. The switch and a sub harness to connect it to the machine's plug.
Everything works now, but the starter sounds horrible so I'll be changing that too before spring.
Good luck out there and hopefully this is just a freak occurrence, but if I were you I'd get rid of this kymco part and put the Kawasaki replacement in now.
Switch, Magnetic is part number 27010-0767
Sub Harness Start Relay is part number 26031-Y034
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By ILoveOldJunk
Recently acquired a 21 year old Mule. The previous owner let the brake master cylinder run dry, and when I flushed the brakes, one wheel's brakes locked up. I took the wheel off, but cannot get the axle nut off, and there is not enough space to get my gear puller behind the drum anyway. Anybody had an issue with seized brakes? How can I get this thing off to replace it or rebuild it?
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