Kawasaki Mule 2500 Died Twice on Hot Day

PhilG327 · Jul 13, 2020

Thank you. That explains why I could not find it. I was looking for an old fashioned relay like the ones I used to replace back in the OLD days of clacking relays, vacuum tubes and resistors & capacitors. Antique stuff. I found some information on how to test the relay in a later model and will see if that shows the relay has failed. I can at least see if the relay is getting any power first. Would like to be sure it's bad before I buy a new one. Thanks again!

LouNY · Jul 13, 2020

It is a solid state relay with the signal coming from the front cylinders ignition system.
Welcome

PhilG327 · Jul 16, 2020

Thank you. I found two relays under the seat. One larger relay is mounted inside of the frame rails, while the smaller relay is on the outside of the frame rail behind the emergency brake. Both are intact and all wires are tight. Rather than keep throwing parts at it without a service manual I've decided to borrow a trailer and try to find a repair shop that I can trust. Some place with some experiences with Mules.

Thanks to all for all of your help and suggestions !

PhilG327 · Jul 23, 2020

Did a little more troubleshooting today. Put 12volts directly to fuel pump and found it did not pump and the only noise it makes is one click and nothing else. Dead quiet, no whirring, no nothing. Certainly nothing like any electric fuel pump I dealt with long ago in various imported sports cars (those were loud). Must be bad. Also found that when the pump is connected up again to the Mule wiring the voltage across the pump drops from 12v to only 9 1/2v. Only guessing now, but it must be loading down the circuit and causing a major drop in voltage. Will order a new pump tomorrow.

PhilG327 · Jul 25, 2020

Anybody have flow specs and/or psi specs for the OEM fuel pump ? I'm going to have to buy something off ebay or amazon as real OEM is more than I can afford. Especially, as I'm still really not absolutely positive that is the fix

Zebrafive · Jul 26, 2020

eBay has multiple choices for about $20

PhilG327 · Jul 30, 2020

FYI - after a few days of trying to find someone to repair my Mule with no luck at all, I rolled the dice and ordered a fuel pump and fuel pump relay off Amazon. Didn't pick the most expensive offerings or the cheapest, but went by (probably fake) reviews and said, "oh well what the heck". Will be interesting to see what arrives. Really need to get the old Mule running again

Kyle_in_Tex · Aug 1, 2020

PhilG327 said:
FYI - after a few days of trying to find someone to repair my Mule with no luck at all, I rolled the dice and ordered a fuel pump and fuel pump relay off Amazon. Didn't pick the most expensive offerings or the cheapest, but went by (probably fake) reviews and said, "oh well what the heck". Will be interesting to see what arrives. Really need to get the old Mule running again

I believe all the off brand pumps are made by the same place in china. Sometimes they last a month, sometimes they last 2 years. The OEM lasted about 10-12 years or so.

Zebrafive · Aug 1, 2020

PhilG327 said:
FYI - after a few days of trying to find someone to repair my Mule with no luck at all, I rolled the dice and ordered a fuel pump and fuel pump relay off Amazon. Didn't pick the most expensive offerings or the cheapest, but went by (probably fake) reviews and said, "oh well what the heck". Will be interesting to see what arrives. Really need to get the old Mule running again

Did you try the "hit it with a hammer" sometimes fix?

PhilG327 · Aug 2, 2020

Zebrafive said:
Did you try the "hit it with a hammer" sometimes fix?

I did try the hammer! We had a FIAT station wagon back in the late 70's that required a sharp rap with a long socket wrench handle until a replacement arrived from Italy some weeks later. I still get grief from my wife about that one