Kawasaki Mule 2500, 2510, 2520 (KAF620) Service Manual (incl. Wiring)

$29.99

Model: Mule 2500 | Mule 2510 | Mule 2520 | KAF620-A1 | KAF620-A2 | KAF620-B1 | KAF620-B2 | KAF620-C1 | KAF620A | KAF620B | KAF620C
Type: Utility Vehicle
Serial: JK1AFCC1RB500001
269 Pages·68 MB·Searchable PDF·English·Print-Ready
  • ✓ Wiring Diagrams
  • ✓ Torque Specs
  • ✓ Bookmarks
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Kawasaki Mule 2500, 2510, 2520 (KAF620): Exploded view of fuel system, air cleaner assembly, and throttle linkage components.
Kawasaki Mule 2500, 2510, 2520 (KAF620) Service Manual (incl. Wiring)
$29.99

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Wrenching on a Mule 2500, 2510, or 2520? This 269-page Kawasaki Mule 2500 service manual PDF (OEM #99924-1163-02) covers the entire KAF620 family: A1, A2, B1, B2, and C1 utility vehicles. You get complete wiring diagrams for the charging, ignition, and starter systems, exploded views of the brakes, steering, and final drive, plus factory torque tables and a full troubleshooting guide. Inside: step-by-step procedures for the torque converter, drive belt, transmission, and differential, the jobs that actually put these machines on jack stands. Set idle on the Mikuni BV26-18 carb at 900 to 950 rpm, and check water pump shaft diameter against the 9.975 to 9.990 mm spec before you blame the thermostat. Electrical gremlins hate a real wiring diagram. Bookmarked and keyword-searchable; pull it up on your phone and get back to work.

What's Inside This Kawasaki Mule 2500, 2510, 2520 (KAF620) Manual

SystemPagesKey Topics
Quick Reference Guide2-3
General Information6-25Model Identification, Cable, Wire, Hose, And Pipe Routing
Fuel System26-41Throttle Pedal and Cable, Choke Cable, Carburetor, Air Cleaner, Fuel Pump and Fuel Filter, Fuel Tank
Cooling System42-53Coolant, Water Pump, Radiator and Radiator Fan, Radiator Cap, Thermostat, Hoses and Pipes
Engine Top End54-69Cylinder Head, Valves, Rocker Arm/Shaft Wear, Rocker Arm Push Rod Inspection, Exhaust Pipe and Muffler, Spark Arrester Cleaning
Converter System70-83Torque Converter, Drive Belt, Drive Pulley, Driven Pulley
Engine Lubrication System84-91Engine Oil and Oil Filter, Oil Pump and Relief Valve, Oil Screen
Engine Removal/Installation92-97Engine Removal, Engine Installation
Engine Bottom End98-113Crankcase Cover, Camshaft and Tappets, Cylinders and Pistons, Crankshaft and Connecting Rods, Breather Valve
Transmission114-137Transmission Oil, Transmission Case, Transmission and Shift Mechanism, Hi/Low Gears and Shift Mechanism, Differential Gears and Shift Mechanism, Bearings and Oil Seal
Wheels / Tires138-145Wheel Alignment, Wheels (Rims), Tires
Final Drive146-171Front Final Gear Case, Differential Unit and Ring Gear Disassembly, Pinion Gear Unit Disassembly, Bevel Gear Inspection, Propeller Shafts, Drive Shafts and Axles
Brakes172-189
Suspension190-195Struts and Rear Shock Absorbers, Front Suspension Arms, Leaf Springs and Dampers
Steering196-203
Frame204-215Seat and Seat Belts, Cargo Bed, Front and Rear Bars, Front Fender Assembly, Radiator Side Cover Removal, Rear End Sub-Frame
Electrical System216-241Battery, Charging System, Ignition System, Electric Starter System, Lighting System, Switches
Appendix242-269Troubleshooting Guide, General Lubrication, Nut, Bolt, And Fastener Tightness, Unit Conversion Table

Quick Reference Specifications

SpecificationValuePage
Fuel hose--replace4 yearsp. 5
Carburetor: Idle speed900 ~ 950 r/min (rpm)p. 29
Water pump shaft diameter9.975 mm ~ 9.990 mmp. 44
Water pump shaft bearing inside diameter10.020 ~ 10.038 mmp. 44
Thermostat Valve full opening lift7 mm or more @90°C (194°F)p. 44
Battery12V 19 Ahp. 11
Fuel tank capacity20 Lp. 10
Engine oil capacity (when filter is removed)1.8 Lp. 10
Maximum vehicle load603 kgp. 11
Throttle pedal free play5 - 10 mmp. 29
Radiator Cap Relief Pressure93 - 123 kPap. 44
Cylinder compression (Usable Range)1000 - 1520 kPap. 56
BrandKawasaki
ModelMule 2500, Mule 2510, Mule 2520, KAF620-A1, KAF620-A2, KAF620-B1, KAF620-B2, KAF620-C1, KAF620A, KAF620B, KAF620C
Machine TypeUtility Vehicle
Manual TypeService Manual
LanguageEnglish
FormatSearchable PDF (Digital Download)
Pages269
File Size68 MB
Manual No.99924-1163-02
Serial RangeJK1AFCC1RB500001
Wiring DiagramsYes
Hydraulic SchematicsNo
Torque SpecificationsYes
Bookmarked / IndexedYes