Kawasaki Mule 2500 Died Twice on Hot Day

[PhilG327]

My Kawasaki Mule 2500 (2wd) died twice yesterday while hauling grandsons and several loads of mulch. It was hot too. Used 3'x4' foot small trailer for the mulch and two passengers at a time. Steep hills to my pear trees. Was running fine and first time I thought it might be out of gas (cannot read the bubble gauge). Hiked back to the barn and promptly overfilled it. Started right up and off we went for about another 1/2 hour when it died again. Just stalled out. Sat for a couple of minutes and it had to crank a few times before it fired right up. Luckily we were done hauling so drove right back to the barn and put it away.

Any ideas where to start troubleshooting? Did we just overwork it on a hot day? Ignition or fuel feed problem? Does this thing have an electric fuel pump? If so, would a weak battery cause this? Haven't charged it recently. Maybe crud in the fuel line? Any suggestions on where to begin? I'm no mechanic, but in a previous life I did race sports cars and did plenty of work on 4cyl DOHC engines.

Any and all help much appreciated! I'd just haul it to somebody for service, but I only have a 1/2ton trailer and besides have no clue where to take it

 

[monkeyduster]

One thing to check would be fuel filter. Could be some water in it.

 

[shooterdon]

If it cranks, the battery is OK and the fuel pump has enough power. Agree with MD above...check fuel filter first

 

[boomer1025]

Vapor Locking

 

[Zebrafive]

My guess is the fuel pump. It's along the right frame rail on the inside, you have to lift the box to see it. Disconnect the fuel line at the carb and see if it pumps. Could be going bad, and runs/stops.
Also is your radiator fan working? Did the high temp light come ON?

 

[Trails2004]

Kinda sounds like a vapor lock ?

 

[LouNY]

The older mules used a solid state relay with a signal from the ignition box to control the relay which controls the fuel pump.
The fuel pump is external in the right rear of the vehicle with the bed up it's easy to access it, also the fuel filter is a simple inline filter right in front of the pump.

I found a thread on a utv site which detailed the issue and trouble shooting and how to bypass the relay if desired.

An easy way to trouble shoot it is to splice in a small light in parallel with the fuel pump if the light goes out when it quits no power to the pump.

 

[Kyle_in_Tex]

I have a 2002 Deere Gator with the Kawi V-twin 750 engine. The original fuel pump went out years ago. They are so pricey at Deere, I buy the chinese knock offs for about $16-20 each. They last a year or 3. I've also had to take the carb off and clean it multiple times.

On the carb, there is a solenoid to cut off fuel supply under certain conditions. Some times, when it's bogging down about to stop, try pulling out the choke cable to see if it takes off again. If it does, it's a fuel problem.

I had to replace the spark plug coils on my wife's uncles Mule. Also, the $$$ ignitor boxes do go out sometimes. When it quits, pull the plug out, put it in the plug wire and ground it to the side of the engine, then turn it over to see if you have spark. Being very careful of course.

 

[PhilG327]

Thank you! All good suggestions. I'm inclined to go along with the vapor lock suggestions, but will start with the fuel filter first. Years ago I had a problem with a car that kept stalling. This was before any emissions stuff, and the vent in the gas cap no longer vented. As the fuel pump built up a vacuum in the gas tank the car would die. Fixed it by leaving the gas cap loose Might check that too.

 

[radios1]

you could be boiling the gas in the float bowl..