kawasaki mule 550 starting problems

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2001 YAMAHA TDM900 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 20-11-2010

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CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. -3- ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM -4- ELECTRIC STARTING SYSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut-off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start switch 61 Ignition fuse -5- ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the side- stand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay. Does the starting circuit cut-off relay have continuity between blue/white and black? EAS00759 Continuity Tester positive probe sky blue Tester negative probe blue/yellow No conti- nuity 1 2 1 3 Tester positive probe sky blue Tester negative probe black/yellow Battery positive terminal red/black Battery negative terminal black/yellow 1 2 Tester positive prove blue/white Tester negative prove black 3 4 5. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay terminals as shown. Measure the starting circuit cut-off relay for continuity as follows. Tester positive probe blue/green Tester negative probe blue/yellow 4 3 Tester positive probe black/yellow Tester negative probe sky blue 2 1 Tester positive probe blue/yellow Tester negative probe sky blue 3 1 Tester positive probe blue/yellow Tester negative probe blue/green 3 4 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. Are the testing readings correct? YES NO Replace the starting circuit cut-off relay. NOTE: EAS00760

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Kawasaki Mule Lift Kit Installation Manual

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Filed Under (Kawasaki) by admin on 04-05-2012

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Front Lift Installation 1. Ensuring that the parking brake is set, place jack under center of the Mule front end and lift until front wheels clear the ground. Be careful to support Mule properly so that it is secure, but so that the A-arms and struts can droop to full extension. 2. Remove front wheels. 3. If applicable, remove the heater to allow access to the strut mount behind the heater coil. Heater 4. Starting with the left side (driver side), remove the cotter pin and castle nut that secures the strut to the strut mount. Castle Nut & Pen 5. Push bolt through the bolthole, taking care not to damage the brake line that is attached to the bolt. If you are having difficulty removing the bolt, you may have to remove the brake lines that are attached to the front brakes. In this case refer to owners manual for removing brake lines. Screwdriver NOTE: Keep in mind that if you remove the brake lines you must bleed your brakes according to operator’s manual. 6. Once the bottom of the strut has been loosened, then unbolt the top of the strut. The nuts securing the top strut can be located in the dash of the Mule on the left and right sides. In most cases these nuts are easily accessible, but you may have to remove the glove box or heater coils, depending on the model and options purchased with the Mule.

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Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Upgrading the Suspension on the Kawasaki ER6-F/ N

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Filed Under (Kawasaki) by admin on 30-11-2010

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Top fork is as removed. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Before removing the fork from the clamps on the yokes I loosened the fork top. Before removing the fork top the fork-slider was placed in a vice and the bottom bolt loosened….. … before finally being removed with the fork upside down. Because the springs were still in situ this gave sufficient tension on the damper-rod to prevent it from turning and allow the bolt to be removed. When I turned the fork the right-way up to remove the fork-top I did it over a container to catch the oil. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource All the OE components that will no longer be required. Left to right. Fork-top, spacer tube, washer, spring, damper-rod. Bottom bolts get re-used. Old and new, laid-out for comparison. The damper unit, minus spring and fork-top, drops inside the stanchion and slider. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Then the bolt goes back in, as tight as possible, to secure it. Top fork is done, second one awaits. Note the spring seat on the right, just below the spring. This drops over the damping rod after the oil has been added. The small locking-nut screws over the threaded part of the damping-rod next, all the way to the bottom. Spring drops in and then the fork-top screws on to the damping-rod as well, all the way down to the lock-nut which is used to secure it. At this point the stanchion is extended to the fork-top which is screwed in. Job done.

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Kawasaki MULE 600 / 610 SNOW PLOW INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. PRELIMINARY: 1.1 Remove the six 6 mm. screws and plastic skid / splash shield from the bottom front of the vehicle frame. (These bolts and plastic skid / splash shield will not be reused snow plow mounting frame installed onto the vehicle.) 1.2 If the vehicle has the Kawasaki optional brush guard installed, it will have to be removed and then reinstalled after the snow plow mounting frame is installed. (The brush guard will fit with the snow plow mounting frame installed first.) 2. VEHICLE MOUNTING FRAME 2.1 Position the vehicle mounting frame (13) under the front of the vehicle so that the six holes (with pipe spacers) line up with the six 6 mm. threaded holes that the plastic skid / splash shield was attached with and the upper plate is through the large oval hole in the vehicle plastic fascia. Fasten loosely using 6mm. x 1.0mm. x 30mm. bolts (33) , 6mm. lock washers (35) and 6mm. flat washers (34). 2.2 Place a 5/16″-18 “U” bolt (36) around the front cross tube behind the plastic fascia and through each set of holes in the flange of the upper plate of the vehicle mounting frame (total of two “U” bolts). Fasten loosely using 5/16″flat washers (41), 5/16″ lock washers (40), and 5/16″-18 nuts (42). 2.3 Install a 5/16″-18 “U” bolt (36) around the lower frame tubes and through each set of slotted holes in the lower plate of the vehicle mounting frame (total of four “U” bolts). Fasten loosely using 5/16″ flat washers (41), 5/16″ lock washers (40), and 5/16″-18 nuts (42). 2.4 Tighten all the fasteners holding the vehicle mounting frame to the vehicle starting with the 6mm. bolts

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Kawasaki Exhausts – ZX-6 ZX-10 Zx-14 Exhaust – Slip-ons INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 25-10-2010

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Our favorite exhaust options for Kawasaki ZX Ninjas – ZX-10,ZX-6r, and the new horsepower king, Zx-14.. Grab your horsepower today. We love Rob Muzzy and Muzzy Exhausts.Going back to Doug Chandler and Scott Russell, Muzzy has been synonomous with Kawasaki and performance – and for years, if you rode Kawasaki,and you were on the podium, Muzzy was on your exhaust. We also feature Arrow and Yoshimura exhausts for your ZX-6R, ZX-10 and ZX-14. We love the sound of a Yosh exhaust on any Kawasaki Ninja. Yoshimura Oval (RS-3) Race Slip-On for Kawasaki ZX14R 2006 The easiest and least expensive way to experience Yoshimura performance is with our Slip-On/Bolt-On lines. Bolt-On style bolts to the O. E. M. mid-pipe Slip-On style with its stainless steel easily attaches to the mid-pipe RS-1 is available where noted Usually, no jetting or re-programming is required and installation is a snap Hindle Stainless Exhaust High Head Pipes – Kawasaki ZX6R-RR 03-04 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo North Denver News http://northdenvernews.com Powered by Joomla! Generated: 19 October, 2010, 12:28 Hindle Stainless Exhaust Low Head Pipes – Kawasaki ZX9R 00-03 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo

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Kawasaki Mule Roof 600, 610 and 4010 Trans Crew, Roof Installation Manual

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Filed Under (Kawasaki) by admin on 02-05-2012

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INSTALLTION INSTRUCTIONS – Mule 600/610 (4010 Trans skip to pg 4) 1. Place Roof Panel on top of UTV Roll cage and center front to back, and left to right. 2. Using Figure 1 Below – place UTV Roof Mounting Brackets around roll cage bar and using a marker, mark the position of the holes needed in the roof for each Roof Mounting bracket . Figure 1 Copyright 2007 DiamondBack Automotive Accessories, Inc. Page 3 3. Next, remove the roof from the roll cage and using a drill with 1/4″ bit, drill holes using the marks as a guide. 4. Cut (4) 3″ strips of adhesive foam and apply to roof in where mounting brackets are positioned to prevent roof rattling once mounted. Foam should run in the direction of the roll cage as shown in Figure 1 above. 5. Next, reposition the roof on the roll cage according to step 1. 6. Prior to attaching the roof mount brackets, cut the remaining adhesive foam in half and apply one section to the roof in the center of the roof where roof and each roll cage bar meet as shown in Figures 1 above. If additional tape is required to prevent rattling it can be purchased from any hardware store as window sealant foam tape. 7. Next, attach the roof mount brackets according to Figure 2. Use channel locks or pliers to hold top of carriage bolt and turn nut with 7/16″ socket.

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Aprilia RXV 450 – 550 MAINTENANCE MANUAL

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Filed Under (Aprilia) by admin on 06-11-2010

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DIMENSIONS Max. length 2240 mm (88.19 in.) Max. width 830 mm (32.68 in.) Max. height (front fairing included) 1250 mm (49.21 in.) Seat height 950 mm (37.40 in) Wheelbase 1485 mm (58.46 in.) Minimum ground clearance 320 mm (12.60 in.) Dry weight 123 kg (271.12 lb) ENGINE Model (RXV 450) 45RX Model (RXV 550) 55RX Type twin-cylinder, 4-stroke with 4 valves per cylinder, single overhead camshaft Number of cylinders 2 Total displacement (RXV 450) 449 cu. cm (27.40 cu in). Total displacement (RXV 550) 553 cu. cm (33.75 cu in). Bore/stroke (RXV 450) 76 mm x 49.5 mm (2.99 in x 1.95 in) Bore/stroke (RXV 550) 80 mm x 55.0 mm (3.15 in x 2.16 in) Compression ratio (RXV 450) 13 ± 0.5 Compression ratio (RXV 550) 12.5 ± 0.5 Starting electric Engine idling rpm 1800 ÷ 2000 rpm Clutch Multiplate in oil bath. Lubricating system Double separate lubrication with external reservoir Air filter with dry filter cartridge Cooling system liquid-cooled TRANSMISSION Type mechanical, 5 gears with foot control on the left side of the engine CAPACITIES Fuel (including reserve) 7.5 l (1.98 gal) Fuel reserve 2.2 l (0.58 gal) Engine oil 1.3 l (0.34 gal) Fork oil 100 mm (3.94 in.) of air (per leg, measured without spring and compressed rod) Coolant 1.1 l (0.29 gal) (50% water + 50% coolant with ethylene glycol) Seat 1 GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio 1st 22/56 = 1: 2.545 12/31 = 1: 2.583 15/48 = 1: 3.200 1 : 21.042 2nd 13/25 = 1: 1.923 1 : 15.664 3rd 15/23 = 1: 1.533 1 : 12.489 4th 19/24 = 1: 1.263 1 : 10.288 5th 21/22 = 1: 1.047 1 : 8.533 DRIVE CHAIN Type with master link

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Kawasaki 440/ 550 Engine Removal and Installation

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Filed Under (Kawasaki) by admin on 25-10-2010

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1.1 (Above) Remove the two retaining straps, disconnect the battery and remove it from the hull. Disconnect the negative (black) cable first, then the positive (red). Step 2 Exhaust Removal 2.1 (Below) Remove the exhaust hose from the end of the pipe. Remove the water line from the pipe and the head. 2.2 (Below) Remove the water by-pass line from the pipe. 2.3 (Below) Remove the four 10mm nuts / bolts from the exhaust manifold and bracket. Remove the exhaust pipe from the hull. Step 3 Engine Removal 3.1 (Below) Remove the three 10mm bolts securing the PTO shield and remove it. Remove the two 10mm bolts securing the flywheel electrical wire cap. Open the cap and disconnect the harness. NOTE: DO NOT CUT THE WIRES! 3.2 (Below) Disconnect the starter positive wire at the relay box with a 10mm socket

Kawasaki Mule 2003 and newer Plow Mounting Kit INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 01-05-2012

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Prior to installing the plow mount the vehicle must be prepped. If not already done so, install a WARN winch kit. Roller fairlead that comes with the winch kit does not need to be installed. This kit comes with a special fairlead to be used with plow. 2. Begin by locating and removing the two rear bumper mounting bolts. See Figure 1 and 2. Figure 1 Location of bumper bolts to remove Figure 2 Remove bumper bolts, both sides Location of bolt to remove WARN® INDUSTRIES PAGE 5 72171 Rev A0 4. Loosely install the mounting brackets to the vehicle using the 7/16″ hardware in the rear replacing the bumper mounting hardware removed in step 2. Do not tighten. See Figure 4 and 5

Kawasaki Mule Duster Adhesive Hook Strip Installation Instructions

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Filed Under (Kawasaki) by admin on 30-04-2012

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Use the loop on the Duster as a guide to locate the Hook Strip on the front of the bed. Clean the area and install the Adhesive Hook Strip as in Step 1. Install Adhesive Hook Strip to Front of Bed Cut the Adhesive Hook Strip into six (6) pieces to match the loop sewn to the Duster. Use the loop on the Duster as a guide to locate the Hook Strip on the sides of the bed and the tailgate. Clean the areas with a 50% Water/Alcohol Solution. Peel the backing off the hook a little at a time and press it fi rmly into place. Install Adhesive Hook Strip Allow 72 hours for the adhesive to set. Avoid unnecessary fastening and unfastening of the Duster during this period. Open Bed Open the bed of the vehicle. Tailgate Adhesive Hook Strip Allow 72 hours for the adhesive to set. Avoid unnecessary fastening and unfastening of the Duster during this period. Secure Duster to Front of Bed Fasten the loop sewn to the front of the Duster to the Adhesive Hook Strip on the front of the bed

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