Kawasaki Mule only starts when warm or when on battery charger

[ShowroomShine]

Kawasaki Mule 520 with the single cylinder, 1900hrs. For the past few years the machine has had little use, but I'm starting to use it more and more now. If the machine sits for a while or its cold, when I turn the key I just get a click. If I hook the mule up to a battery charger on the 2 amp setting, still a click. If I use the 40amp or 200amp it starts up perfectly like the battery was never dead at all.

Once running, I can go for a few hours and the mule starts up fine. Let it sit for a few hours, and its back to just a click.

What could this be, a solenoid or coil?

 

[2ndhalf]

Kawasaki Mule 520 with the single cylinder, 1900hrs. For the past few years the machine has had little use, but I'm starting to use it more and more now. If the machine sits for a while or its cold, when I turn the key I just get a click. If I hook the mule up to a battery charger on the 2 amp setting, still a click. If I use the 40amp or 200amp it starts up perfectly like the battery was never dead at all.

Once running, I can go for a few hours and the mule starts up fine. Let it sit for a few hours, and its back to just a click.

What could this be, a solenoid or coil?

Clean the battery post and the connectors.. put some Deox on them... If that doesn't work take the battery to NAPA or auto store and have them check it.

 

[Dave M7040]

Another possibility to consider.
There are a number of safety switches between the start terminal on the key switch and the terminal on the starter solenoid.
As these switches age, they develop a little resistance to current flow. Several switches with this condition can case enough of a voltage drop at the starter solenoid "kick it on terminal" that the solenoid does not engage forcefully and does not make a good enough connection to turn the starter over.

Two ways to investigate this.

Remove small wire from the solenoid when it wont start and apply power to the terminal directly from the battery using say a 12 gauge wire. Remember you are by passing all safety features when doing this. Be extra careful. Have someone on the machine so it does not start and run you over.

Buy a cheap $15 multi meter. Measure the voltage on the "kick it on terminal" on the starter when you have the key turned to start and it just clicks.

If you are unsure about the terminals on the starter, post a picture and we can help you understand it further.

Garden tractors are notorious for developing this condition over time if the owner lets the machine sit outside in the rain. The safety switches on these machines are very cheap and have no water or mud protection to keep their contacts clean. I don't know about the quality of Mule components.

The multimeter will also allow you to verify the charging system. You can also check for voltage drop in your battery cables without having to clean each end of both just in case.

This link to DENSO starter trouble shooting tips shows you how to approach the problem in a methodical way. The illustrations near the end showing how to check for poor cables or connections are invaluable if you have even a cheap multimeter

http://densoautoparts.com/sites/default/files/tech-tips/DENSO Starter troubleshooting tips.pdf

Dave M7040

 

[Texasmark]

You are talking about a sulphated battery. Load check your battery. If it can't hold 11v across the terminals while supplying 200 amps on a supposedly full charge it's time to use it for light loads and get another for starting.....just went through that with my 9 year old battery. Not that cleaning up things, nice and brite and tight, won't improve your starting, but that's not the main solution here.

 

[Zebrafive]

Time for a new battery. If you have room put in a bigger than factory supplied.

 

[Btown]

Time for a new battery. If you have room put in a bigger than factory supplied.

I agree this sounds like a battery issue. Get it checked. My guess it's time for a new one

 

[dickfoster]

I'll second third or forth the idea of getting a new battery. Either that of try to desulphate the one you have with a desulphating charger. They do work but it does takes some time.

 

[crazyal]

On my Honda Big Red SxS I replaced the battery with a full sized car battery. There's enough room so I was able to make a nice strong mount for it. Before that it would always be hard to start when cold. Very slow turning over unless I left he battery charger on it overnight. For the past 5 years since doing the upgrade it starts great. If you do need to replace your battery and are handy I would see if you have a spot to do the same. Your starter will thank you for it with a much longer life and it's probably cost about the same as a motorcycle battery.