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#6171129 - 02/05/16 04:38 PM 96 Kawasaki Mule Electrical Issue
Texdu01 Offline
Light Foot

Registered: 03/15/12
Posts: 25
Loc: Fort Worth
So my mule was running fine, with the exception of the starter grinding from time to time. I cranked it up, cruised around and stopped at one of the feeders and turned it off. Tried to start it and nothing. It was like the battery was completely dead. Pulled the battery and charged it over night. Next day same thing. Started fine a time or two and then would die. This time I pulled the battery and replaced it. Charged the new battery over night and stuck it on. Same problem. I took the new battery back and had it tested. No issues with the battery. Brought the battery back put it back on and my mule started right up. Next day it started up fine for two or the times and the she died again. When I turn the key the starter is not turning. I thought the starter might be getting grounded out but I called the Kawasaki house and they said not likely. Anyone have this problem before? Any help is appreciated.

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#6171147 - 02/05/16 04:53 PM Re: 96 Kawasaki Mule Electrical Issue [Re: Texdu01]
Navasot Offline
Hollywood

Registered: 09/22/11
Posts: 27152
Loc: Normangee/Navasota TX
Your alternator is not charging or you have something drawing really bad.. do you have a spray rig or something similar hooked up to a circuit going strait to the battery? also depends on the type of engine but if no alternator the starter going bad can make this happen even with a new battery... Id suggest starting with a good clean on all the battery connections, and also the ground connections at the battery and the frame... then if nothing changes put new power cables and ground cables.. these are the cheaper eliminating steps.. after that youll need a new solenoid/starter.. they also have alternator kits for the mules that didn't have them.

One other thing... just to be sure if nothing is making a single click at all when you turn the key.. there should be at least one safety/neutral switch on the unit.. may see if power is getting past there...

A multi meter could solve a lot of the guess work if you have one though.. my guess is ground and power cable connections started fading through time... then with lower power source the starter/solenoid started slowly going with it...


Edited by Navasot (02/05/16 04:53 PM)
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http://www.j5tractors.com/

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#6171156 - 02/05/16 05:03 PM Re: 96 Kawasaki Mule Electrical Issue [Re: Texdu01]
Texdu01 Offline
Light Foot

Registered: 03/15/12
Posts: 25
Loc: Fort Worth
Thanks for the suggestions!!! I had KC lights but that was the first thing I disconnected and have not hooked them back up. When I took batter to have it tested it was showing a full charge.

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#6171194 - 02/05/16 05:28 PM Re: 96 Kawasaki Mule Electrical Issue [Re: Texdu01]
bill oxner Online   content
THF Celebrity

Registered: 11/03/09
Posts: 39312
Loc: Katy-Fulshear
It could be a kill switch.
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Quail hunting is like walking into, and out of a beautiful painting all day long. Gene Hill









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#6171487 - 02/05/16 08:50 PM Re: 96 Kawasaki Mule Electrical Issue [Re: Texdu01]
Navasot Offline
Hollywood

Registered: 09/22/11
Posts: 27152
Loc: Normangee/Navasota TX
Originally Posted By: Texdu01
Thanks for the suggestions!!! I had KC lights but that was the first thing I disconnected and have not hooked them back up. When I took batter to have it tested it was showing a full charge.


No problem let me know how it goes.. My number is on the link or pm me if you get into it... I'd be happy to help
_________________________


http://www.j5tractors.com/

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#6171819 - 02/06/16 09:23 AM Re: 96 Kawasaki Mule Electrical Issue [Re: Navasot]
Texdu01 Offline
Light Foot

Registered: 03/15/12
Posts: 25
Loc: Fort Worth
Will do. It's down at the lease still so might be a few weeks before I can get to it.

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#6171970 - 02/06/16 11:16 AM Re: 96 Kawasaki Mule Electrical Issue [Re: Texdu01]
stxranchman Offline
Obie Juan Kenobi

Registered: 08/04/10
Posts: 52092
We had an older Grizzly 4 wheeler that was acting like this. It ended up being a wiring issue and had to finally replace the whole wiring harness. That solved all the issues of dead acting battery and stopping then it not wanting to start.
Like Nav, said check the wire connections and especially the ground wire. I have on old riding mower at my parents house that will act like it has a low battery or dead battery when you try to start it. it is always the ground wire that is corroded or rusted at the frame connection. Get a good ground and it starts perfect after I though the battery was dead.
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#6172440 - 02/06/16 08:48 PM Re: 96 Kawasaki Mule Electrical Issue [Re: Texdu01]
TX_LT230FH Online   content
Extreme Tracker

Registered: 05/16/07
Posts: 4076
Loc: North Dallas
Had the same issue with our 09 Mule 610. It was the battery cable connection. Not the main one, but the secondary one on top of the thicker positive terminal connector. Next time it does it, lift the seat and take a screwdriver and tighten it and wiggle it at the same time.
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This is what's left of my pic after getting violated by Photobucket

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#6173787 - 02/07/16 10:01 PM Re: 96 Kawasaki Mule Electrical Issue [Re: Texdu01]
Cajunrotor Offline
Bird Dog

Registered: 01/02/11
Posts: 374
Loc: Fairview, TX
I've had that exact thing happen to me on my Kubota RTV900 twice this season. Both times I discovered corrosion on the positive terminals. When it happened the first time I cleaned up the ring terminals that weren't too bad and replaced two others that were questionable. Sprayed everything down with WD40. Had the same thing again this past week while moving from old lease to my new place. Cleaned everything up again but sprayed it all down with Fluid Film. We'll see how this stuff works. It comes very highly recommended by all the guys on the Kubota forum. I think the real long-term solution however is to switch from the regular lead acid battery to a gel type so I won't have the acid fumes that I believe are the primary cause of the terminal corrosion from bouncing around in the Kubota.

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