How to Replace the Belt on a Kawasaki Mule

Written by tim anderson | 13/05/2017
How to Replace the Belt on a Kawasaki Mule
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The Mule is a light utility vehicle manufactured by Kawasaki, although the term is used to describe any other type of light utility vehicle. The Mule is designed to be a multi-surface vehicle that can handle land and water with equal ease, making it ideal on farms or ranches where a variety of terrains exist. The Mule's engine components are turned by a belt, and from time to time that belt needs to be replaced to keep the engine functioning properly. Replacing the belt is fairly straightforward and requires basic tools, in addition to a special pulley tool.

Find your owner's manual or contact your local Kawasaki dealer to determine which type of special pulley tool your Mule needs for you to remove the drive pulley from the engine.

Loosen the bolts on the converter cover with a wrench, socket or screwdriver, depending on the model of Mule you own. Lift the cover off carefully and see if there are any wires connected to the cover itself. Disconnect them if there are. Place the cover to the side.

Remove the drive pulley by loosening the three upper bolts that protrude up from it, using a socket or wrench. Slot the pulley tool over the drive pulley nut and turn it counterclockwise to remove it. Slide the belt off with a flathead screwdriver.

Install the new belt and replace the drive pulley nut. Check the deflection of the belt by placing a straight edge from the drive pulley to the driven pulley and push down on the belt in between. There should be no more than 1 inch of deflection. If there is more, you will need to add or subtract shims from the pulley, which must be done by a licensed Kawasaki mechanic using specialised tools. Reverse the process to put the Mule back together.

Things you need

  • Wrench set
  • Socket set
  • Screwdriver set
  • Kawasaki pulley tool
  • Straight edge or ruler/yardstick

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