Mule 610 battery change now lights are acting weird
 

My 610 Mule issue with light after installing new battery.... prior to installing a new battery I tried to "jump" my Mule with a battery charger set to "Start".... when doing so I expected the lights to come on but they didn't.... I thought it might be an ignition switch issue at first but then I tested the battery and it was only showing 5v and my charger indicated it was no good.... so naturally I start with changing the battery....I got the Mule started..... strangley now my head lights and brake lights only come on when I turn the key to the "start" position.... after the engine starts and the key returns to the "on" position the lights go out..... Kawasaki seems to think I have something wired backwards but the only thing I did was change the battery.... I'm suspect of the ignition switch but Kawasaki is doubtful.... an help would be appreciated... thank you beforehand

Hi ,
Check the Negative battery Cable , There Is Single black Wire W/ yellow Stripe
Connected to the cable end bolt . This wire is the Entire Wire Harness Negative Ground
back to the battery. It is wrapped To the Neg. Cable Sometimes , very easy to break .
Hope This helps.....
later,
Mark

Thanks for the response..... I'll check it out and let you know.

didn't work..... any other ideas?

Part 1
 

Hi,
Don't Get Pissed At My Question(s) .....
First , Was the Battery ''HOOKED UP Backward's (( Polarity Reversed )) ???
Ok,Ok , Had To ask.... Some Batteries Are made with the Terminals/ Connections """REVERSED""" ( The Batteries Look the SAME , SAME SIZE /
DIMENSIONS !!! ,,, LOCATION OF THE TERMINALS !!! ...
The Only Way To Tell ,,, Is To Physically LOOK At The Battery , Also The PART# ( Example _- # 0000R ) The ' R ' Means The Terminals/ Connections
(( BATTERY_ - _ + Polarity )) !!! ARE REVERSED !!!!!
This Happens More Than You Think !!!!!!!!!!!

Part 2
 

Hi ,
Let's Check The Charging System ,
I was Told The 610 and a 3010 Mule with the Gas Engine , Share
The Same Electrical/ Charging System ...
Ok, ( I Don't Have A 610 Service manual , But I Have a 3010 (w/v-twin Gas ) Service Manual ) ...
Tool Need ; A Good Multi - Meter
My Manual Shows the Everything goes to ( THRU )
the "" Voltage Regulator """
The Manual Shows how to Test the Built In Alternator in the Engine .
next , To Test the Voltage Regulator .

Part 3
 

Hi,
Let's Start With Location Of Parts : Behind the Battery , ( Starting At Twelve O'Clock ) : At-12 : Starter Relay ,, At-2 : Fuel Pump Relay ,, At-3 : Ignition Igniter , At- 9 - : Charging Regulator/ Rectifier .
((( WARNING !!!! ___---___ Disconnecting The Battery While The Engine
IS Running !!!!!!! WILL DAMAGE THE CHARGING // ELECTRCAL SYSTEM !!!!!!!!!! ))))) .
Check And Test All Fuses ( I Mean Pull The Fuses And Clean the Contacts )
Ok, ( Battery Disconnected and Set out of the way ,, < Set It on A Trickle Charger > ) :) .
Disconnect the Charging Stator Lead ( 3- Wire ) On the Engine , Take Your " Multi- Meter ( set To OHMMETER ) Probe the 2 outer wires in the Connector , The Stator Coil Resistance :: 0.2 - 0.4 ohms .. If The Meter does not Read as Spec's ,, Replace Stator .. If Stator is Ok ,, The Magnets Can Get Probably Weakened ,, Replace Rotor ...

Part4
 

Hi,
This Is from my 3010 Mule , I was Told the 610 and the 3010 W/ The
(KAW. ) V-Twin Gas Engine Share The Same Charging /Electrical System .
Tools ,, Multi-Meter , Writing Pad And Pencil Ready ???
Got your Shop manual yet ???????????
Remove the " Regulator " Set it on the Work bench , Cooling Fins ^ Up .
The Terminal plug lock up . Terminals Are : ( 12 o'clock ) ..
at-10 "W' , at-12 " BR " , at-2 "BK/Y " ... at-8 " BK1 " , at-6 "BK2 ,
at-4 "BK3 " ...
Test Meter Set to "OHMMETER" Red Lead To " W " Term. , Black Lead To
" BK1 " , next Black to " BK2 " , Next Black to " BK3 "
Write Down your Findings .... Now Swap Leads , Repeat test Write down
Findings ...

Part 5
 

Hi ,
This Is Bull ,, I Keep Getting TIMED OUT!!!!!!!!! ( Cannot Type fast )
Ok ,,,,
The First half of the test is done ,, Now ,, Red Test Lead Hooked to ::
" BK/Y " , Black lead to "BK1" , Next Black Lead To "BK2 " , Next Black lead to " BK3 " .. Write down your findings ,, Swap Leads,, Retest ,, Compare?
The Readings Should be Low in one Direction ,,> If ANY TWO Terminals
ARE Low Or HIGH In BOTH DIRECTIONS,
THE REGULATOR IS DEFECTIVE ..............
Last Thing Is Checking Ground to frame Connections ( Shop Manual ???? )
The Engine Is In a Rubber Mounted Cradle , So The Main Black ground Cable
Is Mounted To the Engine Under The Starter . ( To Run Starter Only )
Ground for Alternator/ Stator Grounds thru its Terminal Connector ...
The Ground for ignition goes thru its own connector , Respectively ...


Whew , Hope This Helps ...
Later ,
Mark

Before Buying Parts ,,, Let Us Test , Dirty Hands Time,
" Got / GET Your Service/ Shop Manual """"" ?????????