Kawasaki Mule 500 KAF300 B1 with FE290D Engine – Piston Ring Replacement Cleaning, Governor Assembly

In this video, we pick up with our ongoing "budget project" on the 1993 Kawasaki Mule 500 KAF300 B1 with the FE290D engine, which I believe is also very similar to the FE290 engine. At the beginning of the video, our budget project is at the total cost of $446.45. The parts used in this video are as follows:

Kawasaki 14090-1106 - Air Filter Cover - $24.85
Kawasaki 11009-2487 - Exhaust Pipe Gasket - $3.06
Kawasaki 13008 - 6007 - Piston Ring Set - Standard - $29.12
Kawasaki 92150-1687 - Secondary Clutch Bolt - $12.49 (Not shown in video)
Kawasaki 130AA0820 (Replaced 130D0820) - Converter Case Bolt - $0.95
Kawasaki 49040-2067 - Fuel Pump - $9.85
Kawasaki 92037-113 - Harness Clamp - $3.94
Kawasaki 92037-1181 - Clamps (2) - $4.92
Kawasaki 92037-1505 - Tube Clamps (6) - $22.92
Kawasaki 92059-3731 (Replaced 92059-1295) - Tube, 5.8x10.8x215 - $6.36
Kawasaki 92075-1853 - Fuel Filter Damper - $9.96
Kawasaki 92059-1277 (Replaced 92190-1104) - Tube, 7.5x3.5x200 - $23.87
6mm Inside Diameter High Temp Vacuum Hose - $17.87
Kawasaki 92190-1180 - Tube, 5.8x10.8x55 - $2.55
Kawasaki 220AA0614 (Replaced 220B0614) (2) - Fuel pump mounting screws - $2.36
Kawasaki 15003-2178 (Replaced 15003-2104) - Carburetor Assembly - $104.03
Kawasaki 11009-2827 - Carburetor Gasket - $2.95
Kawasaki 11009-2939 - Insulator Gasket - $2.95
Kawasaki 92190-2051 - Tube 6x10x175 - $3.18
Kawasaki 16073-2154 - Insulator - $3.58 (mine was broken)
Arrowhead Electrical Products (AEP) SND0401 - Starter - $102.66
Kawasaki 11060-2334 - Gasket - $1.45
Kawasaki 14090-1141 - Cover - $14.99
Kawasaki 14090-1361 - Cover - $17.92
Kawasaki 16171-2061 - Throttle Link - $3.18
Kawasaki 92145-2054 - Governor Spring $2.95
Kawasaki 49113-2127 - Panel-Comp-Control - This is the main control plate - $31.96
Kawasaki 56031-1790 - Label-Manual, Oil Capacity - $4.41
Kawasaki 92002-2269 - Bolt, 6x28 (Attaches arm to governor) - $1.95
Kawasaki 92027-1064 - Collar, 9x13x17.2 - $9.99
Kawasaki 92037-2098 - Clamp - $1.49
Kawasaki 92144-2340 - Spring (attaches to control plate) - $4.33
Kawasaki 92144-2345 - Spring ( attaches to control plate ) - $6.26
Kawasaki 130BA0612 - Bolt-Flanged, 6x12 (2) - $2.80
Kawasaki 311B0600 - Nut-hex,6mm - $5.95
Kawasaki 411B0600 - Washer plain small, 6mm - $6.99
Kawasaki 130BA0612 - Bolt-Flanged, 6x12 (2) - $2.80
Kawasaki 317BA0800 - nut-Hex-Small, 8mm (for battery bolt)
Kawasaki 92072-7507 - Battery Band - $10.70
Kawasaki 92075-1076 - Damper for Battery - $7.20
Kawasaki 92075-1214 - Damper for Battery - $3.58
Kawasaki 51001-1465 (Replaces 51001-1343) - Fuel Tank - $268.34
Kawasaki 51048-1004 - Fuel Tank Cap - $18.68
Kawasaki 52005-0735 (Replaces 52005-1098) - Fuel Gauge - $31.47
Kawasaki 54017-1155 - Choke Cable - $9.99
Yuasa YUAM62H4A - Battery , 12V 14AH, YB14A-A2 - $74.53
Kawasaki 26030-1068 - Main Electrical Wiring Harness - $65.00 (ebay)
Kawasaki 27002-1051 - Starter Relay Assembly - $43.40
Kawasaki 25031-1013 - Hour Meter - $14.99 (ebay)

Our video begins on the heels of the disappointment of the work performed in video 6 failing to fix our low compression problem. After reassembling the engine and performing a compression test, we still only had 40psi, which was not enough to even start the engine.


We pick up after the removal of the piston from the cylinder and the honing (Not BORING!) of the cylinder wall with the flex hone system. The piston rings were completely stuck and compressed into the piston grooves. After removing them, we soaked in Chem Dip and scrubbed them with a tooth brush. Our video shares that cleaning experience, as well as ring replacement and piston re-installation that followed. In addition, we tried to detail the installation of the springs and linkage related to the governor assembly for those folks out there like me who were completely missing the governor assembly. A quick run through of all of the steps necessary to reinstall the engine back into the chassis for testing was also performed.

By the end of the video, we have spent $1,570.71 and we still have a few projects left to do. We need to address the brakes, as well as suspension and the complete lack of a differential lock cable. We're getting really close to getting this old best out in the woods for a little testing. If you haven't done so already, please subscribe to see the previous videos and the ones to come. Thanks so much!