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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 buckrub
Hey guys! Newbie here. I'm an old man who's better with plowing a mule (4-legged kind) than these newfangled beasts. I, and a friend of mine, just bought new Coleman sxs and are having to finish the assembly. I've been reading on this site and I'm falling on the mercy of you experts. The only way I'm an expert is that an "ex" is a has been, and a spurt is a drip under pressure. LOL First off, the 2 buggies have no ignition switches. They seem to mount on the dash, not the opening in the steering wheel shaft cover, so we ordered new ones that are supposed to fit. They are 8 inches long, and have a 4-wired white plugin which is slightly rectangled when looking at the end of the plug. The trouble is there's nothing to plug into. There is a three-wire grey plug close enough to reach the four-wire plug, but of course, they are not compatible.
Secondly, the blinker, light, ect. unit on steering wheel just spins around when touched. I see no way in heaven or earth to secure it. I've looked at a diagram on the Powersports site, but can't detect how it mounted. Fellows I'd be so grateful for any help with this. Me and my mule will even plow your garden for free, for your help. LOL
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By AlaskaTrail
Hi All,
New to UTVs and recently accuired a ut400 from our local Alaska Commercial Co. and had a questions regarding the transmission fluid. I have had a squeeling noise, sounds like a teapot, that recently started after being driven for a few minutes. The manual says to change the fluid at 500 miles, so I was thinking maybe its just time for this to be changed. Other then that I cannot find any information regarding the type used. While reading through these forums, I seen someone put that the transmission is lubricated with the engine oil. Is this true? If not what should I be using and where can I find the information to change it out? Any input on this would be greatly appretiated!
Thanks in advance
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By moonrover
Mine is overheated/burned/melt at connection with its wire connector, parts are ordered to replace both them. This seems to be a common issue, and some of you already replaced it. I right now just connect the wires, so the fan runs all the time whenever the initiation is on, but it's better let fan runs as needed with a working temperature sensor/switch.
Question: Does some coolant come out by removing the switch/sensor from radiator? Or, is the threaded hole all the way inside radiator? If the answer is yes, I want to drain or extract some coolant to make its level below the sensor before replacing it, so I don't make a mess with coolant spilled out
Thank you.
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