Newcomer to the sideXsides

desertjoe · 2011-06-23 05:35:13

Hello,,, To all here. Am brand new here to this site as I just purchased two slightly mistreated 1999 Mules from a going out of business Dairy. They both had engines but both engines locked up. One is Army green and the other is the red. I am going to begin on the green one by jerking the engine out as from what I have read, these small 286 engines leave a little bit to be desired,,,,and me being the speed crazy Guy I am,,, It's got to have a decent sized engine. Having a CB450 laying around and not getting used,,,I think the Mule will just love the new Honda power.
I began by removing the swing arm and fabricated a new engine/trans/rear end swing arm out of 1"X2"X1/8" rectangular tubing. I fabricated the swing arm to be 12" longer than stock to accomodate the new drive train. The engine will chain drive to a sprocket on a jack shaft,,,to another sprocket mounted on the trans input shaft. I have not decided whether to re-use the Kawasaki design locator or fab something like I saw on a SideXside at Tractor Supply which used a "anti sway bar" type on each side of the swing arm that looked good and will allow for more travel of the semi IRS rear.
One thing I plan to do is to upgrade the charging system as the Honda engine generator just does not produce enough KW's for peace of mind when out on the trails. I plan to install a belt driven 70 amp alternator on the jack shaft that should keep the full size battery up to snuff.
These Mules have some decals that are very hard to remove. The rest of the paint is decent if I can get these removed. Does anybody have a suggestion or two to get em off without ruining the paint? Thanks

RANGERDALEXP · 2011-06-23 12:49:14

Hello,,, To all here. Am brand new here to this site as I just purchased two slightly mistreated 1999 Mules from a going out of business Dairy. They both had engines but both engines locked up. One is Army green and the other is the red. I am going to begin on the green one by jerking the engine out as from what I have read, these small 286 engines leave a little bit to be desired,,,,and me being the speed crazy Guy I am,,, It's got to have a decent sized engine. Having a CB450 laying around and not getting used,,,I think the Mule will just love the new Honda power.
I began by removing the swing arm and fabricated a new engine/trans/rear end swing arm out of 1"X2"X1/8" rectangular tubing. I fabricated the swing arm to be 12" longer than stock to accomodate the new drive train. The engine will chain drive to a sprocket on a jack shaft,,,to another sprocket mounted on the trans input shaft. I have not decided whether to re-use the Kawasaki design locator or fab something like I saw on a SideXside at Tractor Supply which used a "anti sway bar" type on each side of the swing arm that looked good and will allow for more travel of the semi IRS rear.
One thing I plan to do is to upgrade the charging system as the Honda engine generator just does not produce enough KW's for peace of mind when out on the trails. I plan to install a belt driven 70 amp alternator on the jack shaft that should keep the full size battery up to snuff.
These Mules have some decals that are very hard to remove. The rest of the paint is decent if I can get these removed. Does anybody have a suggestion or two to get em off without ruining the paint? Thanks

Welcome to the forum and post pictures of your progress as it come together :idea:

As for decal removal, Heat gun and plastic scraper are the only way I know of on plastic but be careful. 3m makes a decal tool for use in automotive, but I am not sure it would be good on plastic....

Badley · 2011-06-23 15:05:20

I agree as Dale suggests. Remove any residue with Goo be Gone from a Hardware Store.

desertjoe · 2011-06-24 09:10:32

Hey Guys,,, thanks for the replys. I tried the heat gun and scraper first and got some of it off but most of it still there. Then I went to Hardware store and got some of that Goop that was supposed to work guaranteed,,,,but that decal still there,,,,I think if the goop was in a paste form, it might have a chance but the stuff i got ran off real fast and would not stay on the decal long enough to even start to work. Paint stripper,,,?
Hey Badley,, that is some serious "air" you are getting with your SXS,,,, what engine you running?

Badley · 2011-06-24 21:35:42

Joe - the stuff I use is a gel, but it will not work until the top layer of the sticker is gone. Top layer is a plastic, heat gun should soften the glue below and make it easier to pull the sticker off. If it has been baked on for years the glue may be tough...

BTW my ride is a RZR S with a stock 800 engine. Engine still stock, but this is what it looks like now (de-stickered and lots of non-engine mods)

RANGERDALEXP · 2011-06-24 23:33:37

Joe - the stuff I use is a gel, but it will not work until the top layer of the sticker is gone. Top layer is a plastic, heat gun should soften the glue below and make it easier to pull the sticker off. If it has been baked on for years the glue may be tough...
BTW my ride is a RZR S with a stock 800 engine. Engine still stock, but this is what it looks like now (de-stickered and lots of non-engine mods)

Oh, common and tell him you know george lucas and it was done with CGI .....

MR. KRYPTONITE · 2011-06-27 22:48:54

Welcome to the forum!

desertjoe · 2011-07-09 13:08:15

Hey Guys,,,Does anybody here have a 1999-2000 Mule manual that can tell me how to disassemble the drive and driven clutches? The driven clutch is stuck and needs to be disassembled for clean-out and repair.
Also, I tried kawasaki.com and they only go as fas back as the mule 600 and mine are older,I think. 1999 Mule 550. Any help is greatly appreciated. Joe r

RANGERDALEXP · 2011-07-09 16:01:29

Hey Guys,,,Does anybody here have a 1999-2000 Mule manual that can tell me how to disassemble the drive and driven clutches? The driven clutch is stuck and needs to be disassembled for clean-out and repair.
Also, I tried kawasaki.com and they only go as fas back as the mule 600 and mine are older,I think. 1999 Mule 550. Any help is greatly appreciated. Joe r

Try This link....
http://cgi.ebay.com/Kawasaki-Mule-500-5 … 4aacb2f9cc

desertjoe · 2011-07-11 06:59:37

Hey Rangerdalexp,, Thanks for the reply and the info on the item on Ebay. This person has received a few greys and reds as this appears to be a copy and the complaints are that pics are not clear. I shot him an email to see I f I can look at an actual,,,, but I'll keep looking. Thanks Joe r

RANGERDALEXP · 2011-07-11 12:33:24

Hey Rangerdalexp,, Thanks for the reply and the info on the item on Ebay. This person has received a few greys and reds as this appears to be a copy and the complaints are that pics are not clear. I shot him an email to see I f I can look at an actual,,,, but I'll keep looking. Thanks Joe r

You are welcome, There were also other manuals on the site as well. Let us know how it works out with your communications with the guy on EBay as well.....

desertjoe · 2011-07-14 07:18:54

Hey Rangerdalexp,,,I sent the guy a question about the concerns about the quality of the pics in the reproduction CD,,,,,,and at least he is honest cause he did agree that some of the pics were not very clear,,!!! But,,But,,,BUt,,,he says the value of all the other info overshadows the bad pics,,,,????? Told him i think i will pass as often times, the pics are what really let you see what the print is talking about. So,I'm still looking for a manual. thanks Joe r

RANGERDALEXP · 2011-07-14 16:35:15

Hey Rangerdalexp,,,I sent the guy a question about the concerns about the quality of the pics in the reproduction CD,,,,,,and at least he is honest cause he did agree that some of the pics were not very clear,,!!! But,,But,,,BUt,,,he says the value of all the other info overshadows the bad pics,,,,????? Told him i think i will pass as often times, the pics are what really let you see what the print is talking about. So,I'm still looking for a manual. thanks Joe r

I will keep an eye open and see what comes up for you.......

#1 2011-06-23 05:35:13

Re: Newcomer to the sideXsides

#2 2011-06-23 12:49:14

Re: Newcomer to the sideXsides

#3 2011-06-23 15:05:20

Re: Newcomer to the sideXsides

#4 2011-06-24 09:10:32

Re: Newcomer to the sideXsides

#5 2011-06-24 21:35:42

Re: Newcomer to the sideXsides

#6 2011-06-24 23:33:37

Re: Newcomer to the sideXsides

#7 2011-06-27 22:48:54

Re: Newcomer to the sideXsides

#8 2011-07-09 13:08:15

Re: Newcomer to the sideXsides

#9 2011-07-09 16:01:29

Re: Newcomer to the sideXsides

#10 2011-07-11 06:59:37

Re: Newcomer to the sideXsides

#11 2011-07-11 12:33:24

Re: Newcomer to the sideXsides

#12 2011-07-14 07:18:54

Re: Newcomer to the sideXsides

#13 2011-07-14 16:35:15

Re: Newcomer to the sideXsides

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