I have a 2006 KAF400A Mule 610 that I use for work. For a while it has been having issues starting (clicking, only starting when jumped, etc.). So to remedy this, I replaced (in this order)

1) The battery with a larger lawn mower battery (used the kit to allow a larger battery)
2) Starter
3) In the process of replacing the starter, I noticed the negative battery cable lug was corroded and worn out, so I put a new ring terminal on... and that is when the trouble started.

The battery was definitely bad. Replacing it made the clicking start again and it would start if I jumped the bendix with a screw driver. That is how I figured out the starter itself was bad.

So I drove it around my yard after fixing it for a little bit, and everything was fine other than a burning electronics smell. The next day I had it out on a job site and pulled over for a second and noticed some smoke coming out of the e-brake area. I didn't know what it was but I felt the area around the battery (the frame) and it was super hot. I got it back home and after taking some things apart to gain access, noticed it was the voltage regulator/rectifier that was hot.

I tested it out using the resistance test in the manual, and all resistance values were the same. Not to mention it was really burnt to a crisp on the outside. I checked around for any visibly shorted wires (and felt all to see if any were hot). No issues. I also tested the resistance of the stator and it was within spec (0.3 ohms I believe).

I ended up driving it the next day without the VR hooked up (to avoid a meltdown, and I was at a jobsite I couldn't do without the mule). It drives fine without it. Nothing I can see wrong other than the battery would lose charge over time.

Got my boss to buy a new reuglator. I tested it compared to the old one and it tested good.

I installed it and drove it around for 5 minutes or so and the damn thing is so hot I can't hold my hand to it for longer than a couple seconds. I feel like it is going to burn up again.

Any ideas? I assume this isn't normal...... any tests I can perform?

Note: I have no headlights or tail lights hooked up (they broke before I got ahold of it) and none of the wires are touching eachother to short. already checked that.

Thanks for any help!

 

About the only active discussions on this forum revolve around KLX 250S bikes. You may have better luck at this forum:

Kawasaki ATV and Mule - Kawasaki Motorcycle Forums

or this one is even more focused:

https://www.kawieriders.com/forum/

 

Okay thanks