Kawasaki Mule rebuild!

[Harley Jim]

I have been so busy with trikes this summer that everything else has suffered!

We just did pigeon forge and the Redneck Rumble and I had covid in between all of that.

We built a sulky, we have so many folks that ask for two seats, this is our answer.

Then the muskadines got ripe, had to pick them and make jelly and wine!

Then my great great nephew bought a truck and needs Uncle Jim's help fixing it up!

But I did find some time yesterday to strip all if the paint off of the front of my Mule.

If you remember, the fender supports were destroyed, so they got cut off.

The new pieces are now welded on and I will get everything painted. I did the first coat in gloss black, the second coat will be semi gloss, I needed to use the gloss paint somewhere to get rid of it. It was purchased by mistake so had to hide it somewhere!
Knox is coming today to work on his truck so I probably won't get to do much to my mule!

 

[EddieWalker]

Will the new suspension be all factory stock?

 

[laurencen]

cool projects, have 3 mules, one is a 550 they are the machines we run at the lake in summer and farm in winter

 

[Harley Jim]

Will the new suspension be all factory stock?

Yes, mostly stock. It will never be off roading, just doing yard work and visiting the neighbors.

 

[Harley Jim]

cool projects, have 3 mules, one is a 550 they are the machines we run at the lake in summer and farm in winter

Im hoping this one works out. I have a yerf Dog that I use now but it has a solid rear axle and it tears up the grass.

 

[Harley Jim]

I did get a chance to work on it some yesterday and this morning!
The front suspension is done. I want to finish sanding and painting the frame and firewall before I put any parts back on it.

My great nephew got his first truck and I have been helping him get it on the road.

Did a 5" drop on it, installed bucket seats and console, had to replace all of the valve seals. Its been a project.

 

[grsthegreat]

Man, you have way more patience than i would have.

 

[Harley Jim]

Man, you have way more patience than i would have.

Thank you, my Mother used to call me Jobe, said I had the patients of the world! I just like things to look good.
I finished painting the frame yesterday, I painted and closed the shop, Ill get pics today. My Nephew is supposed to be here around 1:00 to work on his truck, so probably won't get much done to the Mule today.

 

[Harley Jim]

I have one more day of trike building, then I can get back to my toys. I did manage to get a coat of paint on the chassie last week.

Im hoping to get it back onto its tires by this weekend.

 

[Harley Jim]

I finally got some quality mule time in!

Got the new rack installed.

Both control arms and all of the new brakes.

Front end is basically done.

The rear crossmember was in bad shape, had rust holes in it. I have reciever type hitches on all of my other equipment, and all of my attachments are on reciever tubes so I want this one the same.

A buddy gave me an old hitch so I took the ends out of it.

I cut 2½" off of the ends of the swing arm and welded the hitch on, then I moved the reciever head up and welded it straight to the tube, it was hanging too low.

I couldn't find the correct muffler, so I used this one from a Chinese 4wheeler. I added some brackets for a heat shield.

I had this old shop light cover lying here so I cut it and rolled the end. Im going to dimple die all of the small holes, they will be punched out to 1/2".

The end of the muffler was large like a motercycle muffler so I welded a washer into the end and added an elbow to direct the exhaust down and away.
I have to mount the master cylinder, mount the shifter and shift cable, and reassemble the steering column, then I can take it to the tire shop and get new tires and wheels!
Hopfully I can get that far by Friday.

 

[yanmars]

Nice work

 

[Harley Jim]

Thank you.

 

[part-time-Farmer-NC]

Love the details/pictures. Its been fun watching your progress from afar.

 

[Harley Jim]

Thank you, I like lots of pics when Im reading someone else's posts so I try to add enough, I hope its not too much!

 

[part-time-Farmer-NC]

Thank you, I like lots of pics when Im reading someone else's posts so I try to add enough, I hope its not too much!

Not too many pics at all. Good visuals to accent the play by play. A before and after would be a good touch what it was and where it is now. Just an idea.

 

[Harley Jim]

She was rough when I drug her home.
Im about ready to start the body work, so Ill put some before shots of the pieces!

 

[Harley Jim]

Someone shredded a drive belt sometime and cut the clutch cover.

I had to clean the old belt pieces out of the cover.

I made a couple of patches.

Gave it a coat of paint.

Another piece finished.

Back in place.

I got my new set of dimple dies and finished the heat shield.

 

[grsthegreat]

Someone shredded a drive belt sometime and cut the clutch cover.
View attachment 4425017
I had to clean the old belt pieces out of the cover.
View attachment 4425018
I made a couple of patches.
View attachment 4425019
Gave it a coat of paint.
View attachment 4425021
Another piece finished.
View attachment 4425024
Back in place.
View attachment 4425025
I got my new set of dimple dies and finished the heat shield.

My 4010 doesnt have a heat shield by muffler….was there supposed to be one?

 

[Harley Jim]

It shows a heat shield on top of the pipes but not one on the muffler.
I put this one on mine because I can see me grabbing the muffler when trying to hook up a trailer!

 

[Harley Jim]

I got the steering column finished and reinstalled, now I have to come up with a center cap for the steering wheel. They want 35 dollars for a new one! I need to find a kid with a 3D printer!!!