No Fan - Kawasaki Mule 2500

[PhilG327]

I own an ancient Kawasaki Mule 2500 (2WD) and the fan does not run. Even on these hot, hot days (90F and above) the fan no longer comes on. It did last year but I have to admit I just noticed this last week. Where do I start? I checked the fuse under the seat for the fan and I can turn the fan by hand so it is not frozen up. I assume it could be the thermostat but have no idea where it is on the engine or radiator. Can someone provide a picture, diagram or map? Can the thermostat be checked with a volt meter like I could years ago on some cars?

I'd like to try putting 12V DC directly to the fan, but cannot figure out how to access it. I assume there must be wires to it, but is there an access panel or secret way to get to it? Perhaps the power to the fan has just gotten disconnected? Getting it to the closest repair shop is a big deal so I'd like to at least give fixing it a try first. If there's something else that might be broken, dead or disconnected, please let me know.


Any and all advice is very welcome!

 

[RustyA]

Typically the fan is mounted to blow through the radiator for cooling. It is usually controlled by a temp sensor mounted near the thermostat housing. Sensor closes circuit to feed power to fan. Should be two wire connector on fan, one ground and the other power if sensor is closed. First question is there enough coolant in system for sensor to read temp? If so put 12v to fan, if it runs sensor is open either due to defect or lack of antifreeze and it can't tell it's hot.

 

[RustyA]

Maybe this might help, it's for a 2510...

kawasaki mule 2500 fan wiring - Google Search

 

[jaxs]

STOP Do not operate the engine until you check for water pump operation. Feeling lines,radiator and coolant in radiator is a good indicator of heated water not reaching radiator. Replacing water pump is listed under routine maintenance along with oil changes and tire pressures. #1 reason for engine falure is neglecting to replace pumps. The fan sensor is on a water line near radiator so if pump isn't circulating water the sensor never see's overheated water. This is in the owner-operator manual. If you don't have the manual,order one because there's other important info in it.

 

[Zebrafive]

I had a 1996 Mule 2510. The sensor for the fan is mounted in the radiator, back right side. You have to remove the inner fender liner to see it, get to it. It has two wires, jumper them together and the fan should come on.
If you are quick, you can replace the sensor with very little coolant loss.

 

[PhilG327]

Thank you all for the information and link. I suspect that I did not get all the air out of the cooling system when I refilled it in spring (Mule sits in an unheated barn all winter so I have to drain it). Will do more Google searches to find the correct way to "burp" the cooling system. This apparently is a big deal. Thanks for the sensor location info. For the life of me I could not figure out how to get to the radiator. I did notice the screen and radiator also need a good cleaning out.

 

[PhilG327]

I found diagrams on-line at Kawasaki.com that show a SWITCH,FAN (Ref # 27010) 27010-1317 on the right-hand side of the radiator. Is this the switch/sensor that turns the fan off and on depending on the temperature of the coolant? This is what I need to bypass in order to see if the fan is working and/or getting power? Is there a way to test this switch?

thanks in advance !

 

[Zebrafive]

I found diagrams on-line at Kawasaki.com that show a SWITCH,FAN (Ref # 27010) 27010-1317 on the right-hand side of the radiator. Is this the switch/sensor that turns the fan off and on depending on the temperature of the coolant? This is what I need to bypass in order to see if the fan is working and/or getting power? Is there a way to test this switch?

thanks in advance !

Yes, that is the switch that turns on the cooling fan.
Unplug and jumper the connector and your fan will cone on if it's good.
When mine failed, I got a warning light on the dash.
Why don't you use antifreeze so you don't have to drain the coolant every winter?

 

[rodnok]

Thank you all for the information and link. I suspect that I did not get all the air out of the cooling system when I refilled it in spring (Mule sits in an unheated barn all winter so I have to drain it). Will do more Google searches to find the correct way to "burp" the cooling system. This apparently is a big deal. Thanks for the sensor location info. For the life of me I could not figure out how to get to the radiator. I did notice the screen and radiator also need a good cleaning out.

Jack up the front end of mule when filling with coolant. This helps get all the air out of system. The 2500/2510 mules are hard to burp. Squeezing and releasing the top coolant hose slowly also helps.

 

[PhilG327]

rodnok,
would you have a diagram or map or photo of the top coolant vent (on the top of the engine?) ? I had a diagram, but for the life of me I cannot find it or remember which bolt it was. Thank you !

 

[Zebrafive]

Just a wild guess, from looking at parts drawing. Since it has a gasket and there are two, I think these are it??

 

[PhilG327]

I drove the Mule up the ramp into the barn which put the front wheels about 1foot higher. Ran for about 15 minutes and got no bubbles at the radiator and no air out of the (what I think) bleeder valve on the top of the engine. Next I'll try hot wiring the fan so see if it even works. Can't take a chance on ruining the engine, so I'm going to make arrangements to take it in for service and let the experts figure it out.

Thanks to all for your help and advice!

 

[PhilG327]

Maybe I should have asked this question first: How hot does the engine/coolant have to get before the fan will kick in? My farm is only 25acres and 99% of the time the Mule never leaves my farm. Short hauls only with rare exception a trip around the upper pasture to check on the 5 acres I lease out. Is it possible that the system just isn't getting hot enough for the fan to turn ON? The dash light for overheating has never come ON so that won't help me but in past years a trip to the upper pasture always turned ON the fan. As always suggestions and advice are appreciated.

 

[Zebrafive]

I can't give a temp for the fan to switch on. You might need a service manual for that.
When I had my Mule 2510, the only time I noticed the fan come on was at shutdown after use in, parked in the barn. With the coolant no longer being pumped and no air flow through the radiator, the fan would kick on.
When my fan switch failed, I got the warning light on the dash for first time ever.
I found the radiator switch, bypassed it and the fan came on.
Kawasaki wanted a insanely high price for a new one. EBay had one for much less.
I had to pull the right front wheel and inner fender to get to it. If you are quick you can swap in a new switch with minimum coolant loss.

Have you bypassed the switch to test the fan?

 

[PhilG327]

I can't give a temp for the fan to switch on. You might need a service manual for that.
When I had my Mule 2510, the only time I noticed the fan come on was at shutdown after use in, parked in the barn. With the coolant no longer being pumped and no air flow through the radiator, the fan would kick on.
When my fan switch failed, I got the warning light on the dash for first time ever.
I found the radiator switch, bypassed it and the fan came on.
Kawasaki wanted a insanely high price for a new one. EBay had one for much less.
I had to pull the right front wheel and inner fender to get to it. If you are quick you can swap in a new switch with minimum coolant loss.

Have you bypassed the switch to test the f

 

[jaxs]

I drove the Mule up the ramp into the barn which put the front wheels about 1foot higher. Ran for about 15 minutes and got no bubbles at the radiator and no air out of the (what I think) bleeder valve on the top of the engine. Next I'll try hot wiring the fan so see if it even works. Can't take a chance on ruining the engine, so I'm going to make arrangements to take it in for service and let the experts figure it out.

Thanks to all for your help and advice!

That would be wise at this point. The cost is minor compared to burning engine up.
Let us know what they said about routinly changing water pump. Me thinks that is the problem.

 

[PhilG327]

Not yet but hope to get to it over the weekend. Regardless, as soon as the truck is back from service next week, I plan to call the Kawasaki repair shop.

 

[PhilG327]

Update: (sorry for the long time gone, but life got busy) Finally found a local shop that was willing to work on it. They found the fan did work when direct wired, and set about adding a switch and wiring the fan directly so I can just use it when necessary. In the process, they also checked the oil and coolant and found oil in the coolant and coolant in the oil. Blown head gaskets. Not what I wanted to hear, but better than a new motor expense. Hope to have it back from the shop late next week.

 

[Zebrafive]

Why are you not having the fan switch mounted on the radiator replaced?

 

[PhilG327]

UPDATE: Local repair shop replaced head gaskets and found no internal problems (valves and cylinders were OK). Machine runs great now. Starts right up and runs smoother than ever. Fan was not rewired as it came on right away when they ran it until coolant temp reached 190 (I think that's what he said). Oil and coolant look clean and fresh though I've probably only run it about an hour so far.

Thanks for all your advice and suggestions!