Created: September 9, 2019
[0:00] Is it time to replace your worn or broken belt on your Kawasaki Mule? Today I’m gonna show you how to do that. My name’s Kristen and this is Maintenance Matters.
We’re gonna start by raising the dump bed. If you have any aftermarket accessories like a roof or windshield, you might have to remove or loosen them. We’re also gonna remove this trim panel and this access panel. If you have nerf bars, you might have to remove those as well.
[0:27] Next we’re gonna remove all these bolts around your clutch cover.
Next we’re gonna make these bolts loose, off of your primary clutch holder. Once you’ve got this removed, you’ll clean any dirt or dust. You can see this one’s quite dusty. Make sure that bearing seal is still in good shape.
[1:00] Now that you’ve got that holder removed, you’ll take any kind of bolt or screw driver and stick through this hole. Attach a rope and off comes the primary. Now your clutch is obviously gonna have grease on it so be careful not to get that on the inside of the clutch or on the belt itself.
[1:28] With the primary clutch removed we’re gonna remove the secondary clutch. This bolt here is reverse thread, so make sure you go the opposite direction that you normally would.
Now we’re gonna remove the secondary clutch. We’ll use bolts to thread in and hold it still, and insert a pry bar in between the bolts to keep the clutch from moving. With that, remove the bolts and the secondary slides right off.
[2:12] At this point you wanna make sure you’re watching which direction the lettering and the arrows are going on the belt. Arrows should be facing forward but if you’re reusing the belt, put it on how it came off.
With your clutch housing exposed, you can make sure everything’s clean and dust free. Now’s a good time to make sure there’s no grooves or anything in your clutch sheaths. If there are, you do need to replace your clutch.
If there is any excess belt dust you can use Scotch Brite and brake cleaner to get everything cleaned up. Just make sure you don’t get any fluids on your belt and make sure everything’s dry before reassembling.
[2:50] Now that everything’s cleaned up we’ll reinstall our belt. Place the secondary first, and then install your primary. Once that’s installed, give it a couple good, hard shoves and it will actually seat back up against the face of the housing.
Reinstall your secondary bolts. You’ll wanna torque this bolts to 69 ft./lbs.
Now with your clutches reinstalled, you can reinstall all the rest of your components and you’re good to go. Happy riding!
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What’s the best way to remove the trim.
Hey Greg! Depending on the exact model, there may be screws holding the panels on or there may be pop rivets. Just raise the bed and start pulling them out. Should be as simple as that. Thanks for hanging out with us!
what size bolts to use on the secondary clutch? Thanks
what if the clutch is stuck and will not come off give me some pointers help thank you nita
Hey Nita, I would recommend taking it to a dealership so if it gets damaged (high risk), you aren’t out all of the money to replace it. Thanks for checking in with us!
thanks for feedback nita