Kawasaki Mule 2510/2520/2500 UTV Service Manual Set 1993–1997 (P/N 99924-1163-02)

Use the supplement with the base manual's Mule 2520 procedures; it covers only Mule 2500 differences. The supplement references the first-edition base manual; this set includes the later second edition.

PDF Reading and File Contents

Search, navigation, and wiring detail: Neither PDF has text search or embedded bookmarks. Small wiring labels require zooming and page rotation; some connector and wire-color markings in the base manual remain blurred when enlarged.

ZIP download containing two printable PDFs, 269 pages total. That total includes six cover/front-matter pages and four blank pages in the base manual, four cover/front-matter pages in the supplement, and one Model Application page in each file.

Engine, Converter, and Driveline Workshop Coverage

The following selected repair and diagnostic topics are part of the publications' wider contents. Other covered work includes exhaust-system service and spark-arrester cleaning.

• Engine repair: Step-by-step cylinder-head removal and disassembly, valve service, and piston, crankshaft, and lubrication-system inspection and repair procedures.

• Fuel and cooling: Mikuni BV26-18 carburetor disassembly, governor linkage service, fuel-pump and tank work, coolant replacement, and cooling-system pressure testing.

• Converter and transmission: Torque-converter removal, drive- and driven-pulley teardown and reassembly, belt inspection, transmission removal and case splitting, and internal gear and chain service.

• KAF620A 4WD: High/low and 2WD/4WD shift-system service, limited-slip front differential inspection, bevel-gear setup, and propeller-shaft and drive-axle work.

• Brakes and chassis: Hydraulic drum-brake service, master-cylinder overhaul, wheel-cylinder inspection, line bleeding, parking-brake adjustment, wheel alignment, suspension, and rack-and-pinion steering.

• Electrical diagnosis: Starting, ignition, charging, fuel-pump-relay, and radiator-fan tests, with wiring diagrams, electrical parts-location views, and a symptom-based troubleshooting guide.

Kawasaki wrote the base manual primarily for trained mechanics in a properly equipped shop; owners with basic mechanical knowledge and the proper tools can use it for basic maintenance and repair.

Engine Inspection, Fuel Controls, and Cooling Tests

Engine coverage extends to compression testing, valve-seat repair, camshaft and tappet inspection, piston and ring service, cylinder boring and honing, and connecting-rod and crankshaft checks. The lubrication chapter adds oil-pump and relief-valve inspection, oil-screen service, and an Engine Oil Flow Chart.

Engine removal and installation include converter alignment using assembly jig 57001-1365. Fuel-control procedures cover throttle and choke setup; cooling coverage adds water-pump service, radiator and cap inspection, thermostat testing, hose and pipe checks, and a Coolant Flow Chart.

Pulley Wear and Model-Specific Driveline Work

Converter inspections address bushings, springs, rollers, and wear shoes. The clutch-holder 57001-1243 instructions warn that placing the holder on the spider assembly can break it.

Transmission specifications and capacities distinguish KAF620A from KAF620B, with internal checks for shifters and differential gears. Adjustment procedures cover the transmission, differential-lock, high/low, and 2WD/4WD cables; the high/low unit and front-drive hardware are specific to the 2510.

Front final-drive work includes LSD clutch-torque and clutch-plate checks, bearing preload, bevel-gear backlash, and tooth-contact adjustment illustrations. Tool references include pinion gear holder 57001-1281 and dial-gauge holder 57001-1049. The setup section warns that excessive tapered-bearing preload can damage the bearings.

Brake Drums, Suspension, and Steering

Brake coverage includes fluid replacement and shoe-wear checks, with drum remover 57001-1260 and holder 57001-1325 identified for press-fit drum service. The front drums on KAF620B are excepted from the press-fit procedure.

Chassis sections cover MacPherson struts, front suspension arms, leaf springs, rear dampers, and the De Dion rear axle. Steering work includes gear preload, tie-rod length, and steering-wheel centering. Body-panel, cargo-bed, and rear-subframe removal are also documented.

Electrical Tests and Mule 2500 Differences

Separate wiring diagrams and resistance tables cover igniters with 4-pin and 6-pin connectors. Fuel-pump diagnosis accounts for the pump operating with the engine running, rather than with the key on alone—a useful distinction before treating a lack of key-on pump activity as a fault.

The supplement adds KAF620C specifications, cable/wire/hose/pipe routing, wheels and tires, brake and steering exploded views, electrical parts locations, and its own wiring diagram. It identifies the C1 as a no-horn configuration.

Across the publications, exploded views carry assembly callouts for torque, grease, locking agent, sealant, and replacement parts. Component-specific torque tables, fluid-capacity data, wear limits, and electrical test specifications accompany the procedures.

Engine, brake, fuel, and converter work involves heavy parts, hot fluid, pressure, flammable fuel, and stored spring energy. Follow the factory precautions and use proper lifting and support equipment.

Valve Clearance and Belt-Wear Data: A Preview

For the KAF620A/B engine, the valve-clearance inspection and adjustment section specifies 0.25 mm with the engine cold.

The converter specifications list a standard drive-belt width of 31.2 mm and a 29 mm service limit, alongside the belt measurement and inspection procedure.