Suzuki Mule..........
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By Travis
Many people have issues with the kawasaki FJ400 engine fouling out spark plugs, after working on a few FJ engines and 600 series Mule's with this issue, i can say the fix for this issue is using a slightly hotter spark plug... the factory recommends a BPR6ES NGK plug.... the Number in NGK plugs represents its heat range and somewhat odd, the lower the number the hotter the plug, at least as far as NGK is concerned. If you have a Mule fouling spark plugs try installing a NGK BPR4ES spark plug.
FROM NGK
A hotter heat range spark plug has an insulator design with a longer heat flow path to the metal shell of the plug. As a result, more heat stays in the ceramic firing end and less is dissipated to the engine. A colder heat range spark plug has an insulator design with a shorter heat flow path to the metal shell of the plug. As a result, less heat stays in the ceramic firing end and more is dissipated to the engine. For a spark plug to function properly, it must have a tip temperature high enough to burn off carbon deposits (self-cleaning) and avoid fouling, while remaining low enough to avoid overheating the ceramic firing end and pre-ignition.
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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 nods
Less than 40 miles can barely start. Dealer is working with Hisun on a number of other issues on this UTV. Can not get clear info on the meaning of these E codes this is getting. Anybody have some clear info for me?
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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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