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By great8redsfan
Okay folks. I have a low power issue. Been like this for a few years. Place I work at bought 3 and all have lost most of the pulling power. They gave them away after local shop worked on one for 3 months and it had great power for about 1 month and then crap. They replaced throttle body, fuel injector, spark plug and IAC motor. Seat belt switches have wires cut and left open so no seat belt warning light anymore. It revs to 6k rpm in neutral but when put in gear and take off in low it just doesn’t seem to want to go anymore. Running 93 octane fuel with Stabil. Any ideas greatly appreciated. I dont have a scan tool but no codes on dash. If held to floor it pops a little and runs almost 5K rpm but if I let off pedal about an inch it smoothed out and revs up to 6k rpm.
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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.
********************************************************************************************************************************************************************************************
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 Robert B
Going down a 20 deg hill engine is holding UTV back. Then something releases like going into Neutral and makes a loud clacking noise. Have to use brake to slow UTV down. Then once level it shifts back into gear. Have done shift extension does not pop out of gear.
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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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