Kawasaki KAF620 Mule 2510/2520 1993–1997 Utility Vehicle Service Manual OEM (P/N 99924-1163-02)

• Document set: a 269-page PDF containing the 251-page Mule 2510/2520 Service Manual, P/N 99924-1163-02, Second Edition dated June 5, 1997, plus the 18-page Mule 2500 Supplement, P/N 99924-1169-51, First Edition dated July 9, 1993.
• Model coverage: Mule 2510 KAF620A 4WD (A1/A2), Mule 2520 KAF620B 2WD (B1/B2), and Mule 2500 KAF620C 2WD (C1), with factory Model Application charts and beginning frame numbers.
• Engine repair: covers the liquid-cooled OHV V2 engine, Mikuni BV26-18 carburetor and governor, cylinder head and valve service, piston and crankshaft work, lubrication-system inspection, and engine removal and alignment.
• Converter and transmission work: includes torque-converter removal, drive- and driven-pulley disassembly, belt and wear-part inspection, transmission-case splitting, internal gear and chain service, and shift-cable adjustment.
• KAF620A driveline and chassis: details the hi/low and 2WD/4WD shift systems, limited-slip front final gear, bevel-gear setup, propeller shafts, drive axles, hydraulic drum brakes, MacPherson-strut front suspension, De Dion rear axle, and rack-and-pinion steering.
• Diagnostic support: provides exploded assembly views, component-specific torque tables, fluid capacities, wear limits, electrical test specifications, a troubleshooting guide, cable and hose routing, and model-specific wiring diagrams.

Kawasaki states that the base manual was prepared primarily for trained mechanics working in a properly equipped shop, while owners with basic mechanical knowledge and the correct tools can use it for basic maintenance and repair. It is a factory service publication, not an operator-only handbook.

KAF620A/B Base Manual and KAF620C Differences

The Model Application pages identify KAF620-A1 from JK1AFCA1*PB500001, KAF620-B1 from JK1AFCB1*PB500001, KAF620-A2 from JK1AFCA1*TB501351, KAF620-B2 from JK1AFCB1*TB501351, and KAF620-C1 from JK1AFCC1*RB500001; the asterisk represents the digit that changes from one machine to another.

The 2510-specific sections document the 4WD hardware that is not used on the 2520, including the high/low range unit, 2WD/4WD selector, front limited-slip differential, bevel-gear case, and propeller shafts. Transmission specifications and capacities are separated by KAF620A and KAF620B rather than presented as one universal value.

The Mule 2500 supplement is not a standalone manual. Kawasaki directs the reader to use the KAF620B Mule 2520 as the base model and supplies only KAF620C-specific differences: general specifications, routing views, wheels and tires, brake and steering exploded views, electrical parts locations, and a separate wiring diagram. It also identifies the C1 as a no-horn configuration. Both required publications are included here.

Powertrain and Chassis Workshop Coverage

The engine chapters go beyond tune-up data. They cover compression testing, cylinder-head removal and disassembly, valve-clearance inspection and adjustment, valve-seat repair, camshaft and tappet inspection, piston and ring service, cylinder boring and honing, connecting-rod and crankshaft checks, oil-pump and relief-valve inspection, and oil-screen service. Fuel and cooling sections add throttle and choke setup, carburetor disassembly, fuel-pump and tank service, coolant draining and filling, cooling-system pressure testing, and water-pump, radiator, cap, thermostat, hose, and pipe inspection.

Drivetrain repair includes drive-belt measurement; drive- and driven-pulley teardown, reassembly, and wear checks; transmission removal and case splitting; chain, gear, shifter, and differential inspection; and adjustment of the transmission, differential-lock, high/low, and 2WD/4WD cables. The KAF620A final-drive chapter adds LSD clutch-torque checks, clutch-plate inspection, bearing preload, bevel-gear backlash and tooth-contact adjustment, and axle and propeller-shaft service.

Brake coverage includes fluid replacement, line bleeding, master-cylinder overhaul, press-fit drum removal and installation, wheel-cylinder inspection, shoe wear checks, and parking-brake adjustment. The chassis chapters document wheel alignment, tire service, struts, front suspension arms, leaf springs, rear dampers, steering-gear preload, tie-rod length, steering-wheel centering, body-panel removal, the cargo bed, and the rear subframe.

Factory Test Material and Repair Cautions

Named tool references include the clutch holder 57001-1243, engine/transmission alignment jig 57001-1365, brake drum remover 57001-1260, brake drum holder 57001-1325, pinion gear holder 57001-1281, and dial-gauge holder 57001-1049.

Useful visual references include the Coolant Flow Chart, Engine Oil Flow Chart, cable/wire/hose/pipe routing views, front final-gear tooth-contact illustrations, electrical parts-location views, separate 4-pin and 6-pin igniter wiring diagrams, and the KAF620C wiring diagram. Exploded views carry assembly callouts for torque, grease, locking agent, sealant, and replacement parts.

The converter section warns that placing the clutch holder on the spider assembly can break it. The front final-drive setup section also warns that excessive tapered-bearing preload can damage the bearings.

Engine removal, brake service, cooling pressure tests, fuel-system work, and spring-loaded converter repair involve heavy parts, pressure, hot fluid, flammable fuel, or stored energy. Use proper lifting and support equipment and follow the factory safety instructions before starting work.