Kawasaki Mule 2500 Died Twice on Hot Day

PhilG327 · Jun 22, 2020

Checked the fuel filter today, and it is full of crud. Looks like it may be the original. Also, air filter looks like somebody made a nest in there! Need to pick up one of each and give her a go. Thanks for all the suggestions, will update when it stops raining here.

PhilG327 · Jun 24, 2020

now that I think about it, I don't think the fan came on at all that day. probably should have. temp warning light apparently does not work - will check tomorrow when I am at the farm again. fingers crossed

Industrial Toys · Jun 24, 2020

So, it's GAS, not Diesel?

radios1 · Jun 24, 2020

Industrial Toys said:
So, it's GAS, not Diesel?

Diesels don't have an ignition system..

Industrial Toys · Jun 24, 2020

Yes they do. A system of high compression and injectors/pump. :laughing:

I looked, but evidently missed the ignition reference.

Seems the machine requires a little much needed maintenance.

I have always been meaning to put a Temperature Gauge on my 2510 Diesel. That could save a lot of money and grief down the road.

PhilG327 · Jul 3, 2020

Well, new fuel and air filters were not the fix, though both did need replacing. In fact it may even run worse now. Barely got out of the barn and it started stalling out. Like it was starved for fuel. Helped to pull the choke. After several starts I noticed that it was cranking slowly so I'm suspecting it's a battery problem. Charged the battery all night (green light on charger says it's full) and it only shows 12.1 volts. Should be 13-14volts with a full charge. Will see if I can get the battery tested by local auto repair shop I trust. Anyone think a weak battery could cause constant stalling? Otherwise I'm thinking fuel pump next.

Note: it is a gas Kawasaki

LouNY · Jul 3, 2020

Look at post #7,
also a low battery will effect the ignition module which controls the fuel pump relay.
The relay and ignition module are under the drivers side of the seat.

You could also run a separate switched power wire to the fuel pump.

radios1 · Jul 3, 2020

have you looked at the fuel level in the carburetor?. it could be low due to a stuck needle valve. if it's plastic, change it for a stainless steel needle valve..

Zebrafive · Jul 3, 2020

LouNY said:
The older mules used a solid state relay with a signal from the ignition box to control the relay which controls the fuel pump.
The fuel pump is external in the right rear of the vehicle with the bed up it's easy to access it, also the fuel filter is a simple inline filter right in front of the pump.

I found a thread on a utv site which detailed the issue and trouble shooting and how to bypass the relay if desired.

An easy way to trouble shoot it is to splice in a small light in parallel with the fuel pump if the light goes out when it quits no power to the pump.

Do you know what year Mules have the solid state fuel pump relay? I have 1996 2510 Mule.
Can you direct me to the site with trouble shooting directions?

When I have trouble with my Mule it's failure to start. My last "fix" was to hit the fuel pump (maybe jar the brushes)? My trouble shooting showed power to the fuel pump. but no output (before hitting it)
It has been working fine since, but I don't know how long it will stay working.

LouNY · Jul 3, 2020

Zebrafive said:
Do you know what year Mules have the solid state fuel pump relay? I have 1996 2510 Mule.
Can you direct me to the site with trouble shooting directions?

When I have trouble with my Mule it's failure to start. My last "fix" was to hit the fuel pump (maybe jar the brushes)? My trouble shooting showed power to the fuel pump. but no output (before hitting it)
It has been working fine since, but I don't know how long it will stay working.

I will see if I can find it again;

here's one; Mule 251 Fuel Delivery Problem | Kawasaki Motorcycle Forums