Kawasaki Mule rebuild!

Harley Jim · Apr 17, 2025

Just checking in! I have been so busy with non atv stuff. We had a good show in pigeon forge, we have to build 73 frames to get stock back to level.
I ordered a bunch of parts for my mule, I don't know what tariffs are going to do to the price so I just got them coming.
I did have to replace the starter on my Yerf Dog yesterday and I added an echo dot gen 3 to it so I can listen to music while I'm working in the yard and garden. The gen 3 has an operating voltage of 12 volts so it's an easy install.

See y'all soon!

Harley Jim · Apr 22, 2025

It rained today so I got to spend some time working on my Mule.

I was able to find the problem with the clutch.

The case bolts were all stripped and someone put some nuts and bolts in it. It was a mess.

The secondary is worn out. So I got on the internet and ordered one. It will be here Thursday.

I cut off a bunch of crap that someone welded onto the back. I also cut off the old muffler brackets and shaped up the trailer hitch a bit.

It didn't have a muffler so I had this one off of a Chinese 4wheeler, it will fit fine.

I have a problem with putting things back to stock, it's been a problem all my life. I don't like the bug eyes on the stock hood. I'm toying with the idea of putting this hood on it.

This is stock.

This is the golf cart hood with the headlight kit installed. I just can't decide which way to go right now.

EddieWalker · Apr 23, 2025

I'd change the headlights if I could.

Harley Jim · Apr 23, 2025

Eddie, I'll definitely do something other than those tractor lights. If I was better at 3D printing, I could make some headlight buckets and trim rings, but I am not that good yet.

yanmars · Apr 24, 2025

Nice job

Harley Jim · May 27, 2025

I finally got some time to work on my Mule.

There is a lot going on, first this linkage is a total mess, I looked at a manual to see what it was supposed to look like, and discovered that it's supposed to be a cable shift, this is somebody's nightmare!

I still don't know why the yolk was welded in the mess! But it's all gone now. The cable will be here Friday.

I replaced the driven clutch half earlier, it was still grinding gears so I pulled the drive half off and took a look, there has been a lot of heat in there, there's actually some melted nylon in there. The weights are supposed to be tight against the tabs, they are not. New drive unit will be here in 7 to 14 days!

It has been leaking gear oil from the right rear brake, so I disassembled it and found that a seal is missing. It should be here tomorrow! Notice a pattern! Lol.

Got everything cleaned and wire brushed.

I pulled the bearing.

Cleaned and painted everything.
The brake kit is already here, as are the new ebrake cables.
Bearings and seals should be here Thursday!

So since I was having so much luck, I thought I would pull the front right!
There are no linings on the shoes!

Got it cleaned and wire wheeled, I already knew the brakes were in rough shape so I bought a full set of brakes, hardware, slave cylinders, and a master cylinder, there here waiting on me.

I had a little fight with a cut off wheel and had a couple of weeks off to allow things to heal, I lost a tendon in my thumb, it grips ok but I can't hich hike to my left anymore!
I know this mule sounds like a total wreck but even with the purchase price I'm still around 1000 dollars, decent 550s in this area are bringing over 4000.

My plan is to restore the Mule and sell this Yerf Dog. It has a live axle and is tearing up my lawn. So I'm doing more to the Mule than I would if It was a flip! Hopefully it works out, if not the Mule will be sold.

EddieWalker · May 28, 2025

Where are you buying your parts from? I'm impressed that you are finding everything you need for it. Mine is a 2011, but I haven't had to do any repairs on it since buying it. Just oil and filters.

part-time-Farmer-NC · May 28, 2025

Thanks for the update. I think about your project every time my mule starts squealing as I take off.

Wondering when I should break down and replace the CVT. I didn't see a resemblance of a CVT in any of your pictures. So different design or opposite side of it.

As I looked at your brake pictures reminded me I need to replace the pads on the rears. I have brakes when using the pedal but the parking brake is nearly shot. I have adjusted it all the way but it barely holds anymore. That came from the wife vs me driving habits. She ALWAYS pulls up the parking brake, I never do. If I forget to release it I usually notice it a bit later. Over the years it has worn it down a lot.

Hope you get full recovery of your finger. Looks like a deep gash.

Harley Jim · May 28, 2025

EddieWalker said:
Where are you buying your parts from? I'm impressed that you are finding everything you need for it. Mine is a 2011, but I haven't had to do any repairs on it since buying it. Just oil and filters.

Eddie most of it I am finding on Amazon!