1990 – 2004 Kawasaki KAF300A Mule 500 520 550 Service Manual : 99924-1146-02
Note: While we do our best to provide accurate up to date photos, book covers and packaging vary with date of manufacture. Please call if you have questions regarding a product.
This 1990-2004 Kawasaki KAF300A Mule 500 520 550 Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the following Utility ATV models:
1990 Kawasaki KAF300-A1 Mule 500
1991 Kawasaki KAF300-A1 Mule 500
1992 Kawasaki KAF300-A1 Mule 500
1995 Kawasaki KAF300-B1 Mule 500
1996 Kawasaki KAF300-B2 Mule 500
1997 Kawasaki KAF300-C1 Mule 550
1998 Kawasaki KAF300-C2 Mule 550
1999 Kawasaki KAF300-D1 Mule 520
1999 Kawasaki KAF300-C3 Mule 550
2000 Kawasaki KAF300-D1 Mule 520
2000 Kawasaki KAF300-C4 Mule 550
2001 Kawasaki KAF300-D2 Mule 520
2001 Kawasaki KAF300-C5 Mule 550
2002 Kawasaki KAF300-D2 Mule 520
2002 Kawasaki KAF300-C5 Mule 550
2003 Kawasaki KAF300-D2 Mule 520
2003 Kawasaki KAF300-C6 Mule 550
2004 Kawasaki KAF300-C7 Mule 550
MODEL APPLICATION
Model Beginning Frame No.
KAF300-A1 JK1AFBA1_MB500001
KAF300-B1 JK1AFBB1_PB500001, or AF300B-600001
KAF300-B2 JK1AFBB1_TB504651, or AF300B-600251
Service Manual Table of Contents
General Information
Before Servicing
Model Identification
General Specifications
Periodic Maintenance Chart
Torque and Locking Agent
Special Tools, Sealant
Cable, Wire, Hose, and Pipe Routing
Fuel System
Exploded View
Specifications
Throttle Pedal and Cable
Throttle Pedal Free Play Inspection
Throttle Pedal Free Play Adjustment
Full Throttle Pedal Position Adjustment
Throttle Cable Installation
Throttle Cable Lubrication
Throttle Cable Inspection
Governor Link Mechanism
Control Panel Assembly Removal
Control Panel Assembly Installation
Throttle Link Removal
Governor Arm Removal
Governor Arm Installation
Governor Assembly Removal
Governor Assembly Installation
Governor Assembly Inspection
Choke Cable
Choke Cable Free Play Inspection
Choke Cable Free Play Adjustment
Choke Cable Installation
Choke Cable Lubrication
Choke Cable Inspection
Carburetor
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness Inspection
Carburetor Removal
Carburetor Installation
Carburetor Disassembly and Assembly
Carburetor Cleaning
Carburetor Inspection
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Cleaning and Inspection
Fuel Pump
Fuel Pump Removal
Fuel Filter;
Fuel Filter Removal
Fuel Filter Installation
Fuel Filter Inspection
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning and Inspection
Engine Top End
Exploded View
Specifications
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Disassembly and Assembly
(Valve Mechanism Removal and Installation)
Breather Valve Installation
Cylinder Head Warp
Breather Valve Inspection
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Seat Inspection
Valve Seat Repair
Valve Head Thickness
Valve Stem Bend
Valve Stem Diameter
Valve Guide Inside Diameter
Measuring Valve/Guide Clearance (Wobble Method)
Rocker Arm/Shaft Wear
Rocker Arm Push Rod Inspection
Exhaust Pipe and Muffler
Exhaust Pipe Removal
Muffler Removal
Exhaust Pipe and Muffler Installation
Exhaust Pipe and Muffler Inspection
Spark Arrester Cleaning
Converter System
Exploded View
Specifications
Torque Converter
Torque Converter Removal
Torque Converter Installation
Drive Belt
Drive Belt Inspection
Drive Pulley
Drive Pulley Disassembly
Drive Pulley Assembly
Drive Pulley Inspection
Driven Pulley
Driven Pulley Disassembly
Driven Pulley Assembly
Driven Pulley Inspection
Engine Lubrication System
Exploded View
Specifications
Engine Oil and Oil Filter
Oil Level Inspection
Oil and/or Filter Change
Oil Filter Removal
Oil Filter Installation
Oil Pump and Relief Valve
Oil Pump and Relief Valve Removal
Oil Pump and Relief Valve Installation
Oil Pump and Relief Valve Inspection
Oil Screen
Oil Screen Removal
Oil Screen Installation
Oil Screen Cleaning and Inspection
Engine Removal / Installation
Engine Bottom End
Exploded View
Specifications
Crankcase Cover
Crankcase Cover Removal
Crankcase Cover Installation
Crankshaft Axial Play Adjustment
Ball Bearing Inspection
Oil Seal Inspection
Camshaft and Tappets
Camshaft Removal
Camshaft Installation
Camshaft Inspection
Cam Wear
Camshaft Bearing/Journal Wear
Cylinder and Piston
Piston Removal
Piston Installation
Piston Ring, Piston Ring Groove Wear
Piston Ring End Gap
Cylinder Inside Diameter
Piston Diameter
Boring, Honing
Crankshaft, Connecting Rod, and Balancer
Connecting Rod Removal
Connecting Rod Installation
Crankshaft and Balancer Removal
Crankshaft and Balancer Installation
Crankshaft Cleaning
Connecting Rod Bend and Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing/Crankpin Wear
Undersize Connecting Rod
Crankshaft Runout
Crankshaft Left Main Bearing/Journal Wear
Balancer Link Rod Bearing/Journal Wear
Balancer Weight Bearing/Support Shaft Wear
Transmission / Final Drive
Exploded View
Specifications
Transmission Shift Control Lever and Cable
Removal
Installation
Adjustment
Shift Cable Inspection
Transmission Oil
Oil Level Inspection
Oil Change
Transmission Case
Transmission Case Removal
Transmission Case Installation
Transmission Case Splitting
Transmission Case Assembly
Transmission
Transmission Removal
Transmission Installation
Gear, Sprocket, Chain, and Shifter Damage
Differential Shift Mechanism
Shift Control Lever and Cable Removal
Shift Control Lever and Cable Installation
Shift Cable Lubrication
Shift Cable Inspection
Shift Mechanism Removal
Shift Mechanism Installation
Shift Mechanism Inspection
Differential Gear Assembly
Differential Gear Removal
Differential Gear Disassembly
Differential Gear Assembly
Differential Gear Inspection
Drive Shafts (Axle Shafts)
Drive Shaft Removal
Drive Shaft Installation
Drive Shaft Inspection
Ball Bearings and Oil Seals
Ball Bearing Replacement
Ball Bearing Inspection
Oil Seal Inspection
Wheels / Tires
Exploded View
Specifications
Wheel Alignment
Toe-in Adjustment
Wheels (Rims)
Wheel Removal
Wheel Installation
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tires
Tire Removal
Tire Installation
Tire Inspection
Front Wheel Bearings and Grease Seals
Front Wheel Bearing Removal
Front Wheel Bearing Installation
Front Wheel Bearing Inspection
Grease Seal Inspection
Brakes
Exploded View
Specifications
Brake Fluid
Brake Fluid Recommendation
Brake Fluid Level Inspection
Brake Fluid Changing
Brake Line Air Bleeding
Brake Pedal and Master Cylinder
Brake Pedal Free Play Adjustment
Master Cylinder Removal
Master Cylinder Installation
Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection
Brake Hoses and Pipes
Brake Hose and Pipe Inspection
Brake Hose and Pipe Replacement
Brake Drums
Brake Drum Removal
Brake Drum Installation
Brake Drum Wear
Brake Panel Assemblies
Front Brake Panel Removal
Rear Brake Panel Removal
Brake Panel Installation
Wheel Cylinder Assembly
Wheel Cylinder Inspection
Brake Shoe Lining Wear
Brake Shoe Spring Inspection
Parking Brake Lever and Cables
Parking Brake Lever Travel Adjustment
Parking Brake Lever Installation
Parking Brake Cable Lubrication
Parking Brake Cable Inspection
Suspension
Exploded View
Specifications
Shock Absorbers
Spring Preload Adjustment
Front Shock Absorber Removal
Rear Shock Absorber Removal
Shock Absorber Installation
Shock Absorber Inspection
Trailing Arms
Trailing Arm Removal
Trailing Arm Installation
Trailing Arm Inspection
Swing Unit
Swing Unit Removal
Swing Unit Installation
Swing Unit Inspection
Steering
Exploded View
Specifications
Steering Wheel and Main Shaft Assembly
Steering Wheel Positien Adjustment
Steering Wheel Free Play Inspection
Steering Wheel Centering
Steering Wheel and Main Shaft installation
Steering Gear Assembly
Steering Gear Assembly Removal
Steering Gear Assembly Installation
Steering Gear Preload Adjustment
Dust Boot Inspection
Steering Arms and Tie-rods
Steering Arm Removal
Steering Arm Installation
Steering Tie-rod Removal
Steering Tie-rod Installation
Steering Knuckles
Steering Knuckle Removal
Steering Knuckle Installation
Frame
Exploded View
Seat and Seat Belt
Seat Removal
Seat Installation
Seat Belt Removal
Seat Belt Installation
Cargo Bed
Cargo Bed Removal
Cargo Bed Installation
Front Fender
Front Fender Upper Removal
Front Fender Left and Right Removal
Front Fender Left and Right Installation
Front Fender Lower Removal
Front Fender Lower Installation
Front and Rear Bars
Front Bar Removal
Rear Bar Removal
Rear Bar Installation
Electrical System
Exploded View
Specifications
Parts Location
Wiring Diagram
Precautions
Battery
Electrolyte Level Inspection
Electrolyte Specific Gravity Inspection
Initial Charging
Ordinary Charging
Charging System
Alternator Rotor and Stator Removal
Alternator Rotor and Stator Installation
Charging System Operational Inspection
Stator Coil Resistance
Regulator/Rectifier Inspection
Ignition System
Ignition Coil Installation
(Air Gap Adjustment)
Spark Plug Removal and Installation
Igniter Inspection
Ignition Coil Inspection
Spark Plug Cleaning and Inspection
Spark Plug Gap Inspection
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Carbon Brush and Yoke Inspection
Commutator Cleaning and Inspection
Armature Inspection
Pinion Gear Inspection
Starter Motor Relay Inspection
Starter Circuit Relay Inspection
Lighting System
Headlight Beam Adjustment
Headlight Replacement
Tail/Brake Light Replacement
Switches
Brake Light Switch Adjustment
Switch Inspection
Fuse
Fuse Inspection
Electrical Wiring
Wiring Inspection
Appendix
Troubleshooting Guide
General Lubrication
Lubrication
Nut, Bolt, and Fastener Tightness
Tightness Inspection
Unit Conversion Table
Supplement-KAF300B Model – This chapter, “Supplement KAF300-B Model”, is designed to be used in conjunction with the front part of this manual (up to 15-8). The maintenance and repair procedures described in this chapter are only those that are unique to the KAF300-B model. Complete and proper sen/icing of the KAF300 B model therefore requires
mechanics to read both this chapter and the front part of this manual.
This supplement includes the following additional information for KAF300B models:
Model Identification
General Specifications
Fuel System
Exploded View
Governor Link Mechanism
Control Panel Assembly Removal
Control Panel Assembly Installation
Throttle Link Removal
Governor Arm Removal
Governor Arm Installation
Governor Assembly Removal
Governor Assembly Installation
Governor Assembly Inspection
Frame
Exploded View
Seat and Seat Belt
Seat Removal
Seat Installation
Seat Belt Removal
Seat Belt Installation
Cargo Bed
Cargo Bed Removal
Cargo Bed Installation
Electrical System
Wiring Diagram
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