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How to Rebuild a Mule 2510 Motor?

The Kawasaki Mule is a widely admired four-wheel drive all-terrain vehicle that has been made for decades. In 2000, the Mule was the 2510; the 2012 model is the 4010, with a more budget version being designated the Mule 600. Kawasaki considers these as utility vehicles, and their square, boxy shape is well-known. The 2510 engine can be rebuilt with some careful searching for parts. All the issues regarding wear, tear and maintenance of an older model car or motorcycle are important part of rebuilding a Mule 2510 motor.

Things You'll Need

Ratchet wrenches
Puller/extractor
2510 engine parts
Oil filter
Spark plugs
Battery
Engine oil

Instructions

- 1
  Disassemble the existing engine. The engine and transmission are connected by a plate. The belt drive pulleys have one bolt in each shaft, one on the crank and one on the transmission input shaft. Remove the long 12mm bolt in the front shaft with a socket wrench or pliers, and use the special puller/extractor to push the crankshaft out of the clutch center.
- 2
  Pick up and install new bushing kits for both clutch units, as they generally wear out.
- 3
  Install new shoes for the driven clutch helix, as well as new rollers, pins and weights for the drive clutch.
- 4
  Maintain all the spacers on the driven clutch, as the order of the spacers regulates the correct offset. Use the owner's manual for all references, as the manual provides the measurements for the offset.
- 5
  Replace the spark plugs, filters, belts, oil, and adjust all valves as would be done on any car engine being tuned.
- 6
  Install a new car DC battery in place of the small original Kawasaki battery. Money put into the Kawasaki Mule 2510 to bring it to as-new standards will ensure its reliable operation.

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