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
| System | Pages | Key Topics |
|---|---|---|
| Quick Reference Guide | 2-3 | - |
| General Information | 6-25 | Model Identification, Cable, Wire, Hose, And Pipe Routing |
| Fuel System | 26-41 | Throttle Pedal and Cable, Choke Cable, Carburetor, Air Cleaner, Fuel Pump and Fuel Filter, Fuel Tank |
| Cooling System | 42-53 | Coolant, Water Pump, Radiator and Radiator Fan, Radiator Cap, Thermostat, Hoses and Pipes |
| Engine Top End | 54-69 | Cylinder Head, Valves, Rocker Arm/Shaft Wear, Rocker Arm Push Rod Inspection, Exhaust Pipe and Muffler, Spark Arrester Cleaning |
| Converter System | 70-83 | Torque Converter, Drive Belt, Drive Pulley, Driven Pulley |
| Engine Lubrication System | 84-91 | Engine Oil and Oil Filter, Oil Pump and Relief Valve, Oil Screen |
| Engine Removal/Installation | 92-97 | Engine Removal, Engine Installation |
| Engine Bottom End | 98-113 | Crankcase Cover, Camshaft and Tappets, Cylinders and Pistons, Crankshaft and Connecting Rods, Breather Valve |
| Transmission | 114-137 | Transmission Oil, Transmission Case, Transmission and Shift Mechanism, Hi/Low Gears and Shift Mechanism, Differential Gears and Shift Mechanism, Bearings and Oil Seal |
| Wheels / Tires | 138-145 | Wheel Alignment, Wheels (Rims), Tires |
| Final Drive | 146-171 | Front Final Gear Case, Differential Unit and Ring Gear Disassembly, Pinion Gear Unit Disassembly, Bevel Gear Inspection, Propeller Shafts, Drive Shafts and Axles |
| Brakes | 172-189 | - |
| Suspension | 190-195 | Struts and Rear Shock Absorbers, Front Suspension Arms, Leaf Springs and Dampers |
| Steering | 196-203 | - |
| Frame | 204-215 | Seat and Seat Belts, Cargo Bed, Front and Rear Bars, Front Fender Assembly, Radiator Side Cover Removal, Rear End Sub-Frame |
| Electrical System | 216-241 | Battery, Charging System, Ignition System, Electric Starter System, Lighting System, Switches |
| Appendix | 242-269 | Troubleshooting Guide, General Lubrication, Nut, Bolt, And Fastener Tightness, Unit Conversion Table |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Spark Plug | clean and gap | p. 4 |
| Fuel hose--replace | 4 years | p. 5 |
| Carburetor: Idle speed | 900 ~ 950 r/min (rpm) | p. 29 |
| Carburetor specifications: Make/type | Mikuni/BV26-18 | p. 29 |
| Water pump shaft diameter | 9.975 mm ~ 9.990 mm | p. 44 |
| Water pump shaft bearing inside diameter | 10.020 ~ 10.038 mm | p. 44 |
| Thermostat Valve opening temperature | 63 ~ 67°C (145 ~ 153°F) | p. 44 |
| Thermostat Valve full opening lift | 7 mm or more @90°C (194°F) | p. 44 |
| Spark Arrester Cleaning | 4-15 | p. 54 |
| Remove the starter motor | Remove | p. 7 |
| Battery | 12 V 19 Ah | p. 258 |
| Fuel tank capacity | 20 L | p. 10 |
Kawasaki Mule 2500, 2510, 2520 (KAF620) Common Problems This Manual Covers
Kawasaki Mule 2510 engine cranks slowly or won't turn over after sitting in cold weather
Test the battery first: the spec table on page 11 calls for a 12V 19 Ah unit, and a weak one drags cranking speed fast. Clean and tighten both terminals, then load test the battery. If cranking stays slow with a full charge, work through the electric starter checks in the troubleshooting chart on page 243.
Manual Section: Troubleshooting Guide (Engine) p. 243Engine overheats and pushes coolant out of the radiator overflow on long grades
Test the radiator cap first; it must hold 93 to 123 kPa (14 to 18 psi) or it dumps coolant early. Check the thermostat in heated water, the specs on page 44 call for valve opening at 63 to 67 degrees C (145 to 153 F). Clean packed mud and chaff out of the radiator fins before condemning the water pump.
Manual Section: Cooling System p. 44Engine starts hard, idles rough, and stalls after fuel sat in the tank over winter
Drain the float bowl and check for water or varnish. Pull the carburetor and clean the jets; page 29 lists the stock Mikuni setup with a #115 main jet, #40 pilot jet, and pilot screw at 1.5 turns out. After reassembly, set idle to 900 to 950 rpm and replace any fuel hose older than 4 years.
Manual Section: Fuel System p. 29Oil residue in the coolant reservoir and white exhaust smoke at operating temperature
Measure cylinder compression on both cylinders before tearing anything down; usable range is 1000 to 1520 kPa per page 56. A low or uneven reading alongside oil in the coolant points to a failed head gasket. Pressure test the cooling system to confirm, then pull the cylinder head using the engine top end chapter starting on page 54.
Manual Section: Engine Top End p. 56Sluggish takeoff, drive belt squeal, and top speed falling off when hauling a load
Inspect the drive belt for glazing, cracks, and narrowed width; the converter system chapter starting on page 70 covers belt and pulley checks. Clean dust out of both pulley sheaves and confirm the driven pulley slides freely. Verify you are not exceeding the 603 kg maximum vehicle load, since chronic overloading glazes belts fast.
Manual Section: Converter System p. 70Frequently Asked Questions
How to adjust the full throttle pedal position on Kawasaki Mule 2510?
To adjust the full throttle pedal position, first loosen the locknut. Then, depress the throttle pedal until the throttle lever on the carburetor is in the fully opened position, and keep it there. Turn the throttle pedal stop bolt until its head lightly touches the bottom of the throttle pedal, and finally, tighten the locknut securely. p. 30
What are the torque specifications for the carburetor mounting bolts on a Kawasaki Mule 2500?
The torque specification for the carburetor mounting bolts is 15 N-m (1.5 kg-m, 11.0 ft-lb). This applies to the Mule 2500 as its procedures are the same as the Mule 2520, which is covered in the base manual. p. 36
What are the torque specifications for the wheel lug nuts on a Kawasaki Mule 2500?
The torque specification for the wheel nuts is 98 N-m (10.0 kg-m, 72 ft-lb). This specification is applicable to the Mule 2500, as its procedures are consistent with the Mule 2520 model. p. 142
What are the replacement specifications for the battery in a Kawasaki Mule 2510?
The battery replacement specification for the Kawasaki Mule 2510 is 12 V 19 Ah. This ensures proper electrical system function and compatibility. p. 11
What is the engine oil capacity for the Kawasaki Mule 2510 when the oil filter is removed?
When the oil filter is removed, the engine oil capacity for the Kawasaki Mule 2510 is 1.8 L. It is 1.5 L when the filter is not removed. p. 86
How quickly can I access this Kawasaki Mule 2500 & variants manual after buying?
Instant PDF download. You get the full 269-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print this Kawasaki Mule 2500 & variants manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Reviews
There are no reviews yet.