Kawasaki Mule rebuild!

[Harley Jim]

Yanmars, no worries Brother. Its all good conversation. Ill keep going with the Mule, y'all keep going!

 

[Harley Jim]

I started preparing the plastic to go back on the Mule, it is rough and going to take some time.

This model is my least favorite of all of them, because of the front end. The headlights look like an afterthought!

Someone started fiberglassing the backside of the dash, Im sure they were trying to stabilize it.

I have been trying to identify a couple of switches, Im not sure, is this the brake light switch? Anyone know?

Im pretty sure this is the headlight switch, I need to sort a bunch of cut wires and hook up some temporary lights to get this sorted out.

 

[EddieWalker]

I have a switch like that on mine for they hydraulics dump bed. My light switch is a push button. My Mule is a 2011 model year.

 

[grsthegreat]

On my 2012, the light switch is a push button. Not much help there. How do you fix scratches and damage in the plastic body?

 

[Harley Jim]

I think I finally figured it out! The first one is the brake light switch, I found a decent pic in a parts catalog, the second one almost has to be the headlight switch.

Im thinking that I will add this to the dash, so that will eliminate any old wiring and the old switches, the headlight wires are missing anyway so I think this will be the solution.

 

[Harley Jim]

GRS, Im not quite sure how I will handle the plastic.
I have some headlights that I would like to use but they will require some cutting and plastic welding and I have never tried that before.
The small scratches should sand out ok the cracks will require stabilization.

I bought this from Amazon, it embeds a wire in the plastic, Ill place the wires in the cracks and figure it out from there.

 

[sandman2234]

I bought a used, cracked fender for an F350 to play with trying to patch it using a plastic welder. I didn't have much luck at it. Same truck, had it painted and the bodyman said he could weld the crack up. He tried, and I finally took a fender off a spare bed I had to put on the truck. He couldn't get it to weld either!
Point being, before you start cutting holes for headlights, make sure that you can weld them up!
David from jax

 

[jjeff]

I think I finally figured it out! The first one is the brake light switch, I found a decent pic in a parts catalog, the second one almost has to be the headlight switch.
View attachment 4482777

Im thinking that I will add this to the dash, so that will eliminate any old wiring and the old switches, the headlight wires are missing anyway so I think this will be the solution.

Definitely first switch/ button is what they call a micro brake light switch I've replaced a few on what my state considers vintage snowmobiles (25 yrs or older). Can get after market on eBay etc 1/4 price of oem in my case. They corrode so I use dielectric grease liberally on them. I enjoy bringing, fixing, tinkering , with older things back to usable condition I like to think some of my tinkering on old stuff is better than OEM .

 

[Harley Jim]

Sandman, I agree 100%, I have been researching the plastic, looks like my plastic is hdpe and the other hood is abs, so that isn't going to work. I need to get some hdpe and see if I can make a repair!

jjeff, thanks for verifying that, I thought it looked like one I had seen on the back of a motercycle once. Ill check amazon for one, this one is seized!