Hello All, thanks for looking at my situation. I am new to the UTV world, but not small engines. Hoping you can help and I thank you in advance for your support / suggestions. My neighbor gave me his old 550 mule, which needed some TLC.


It is a late model 2003 or earlier Kawasaki Mule 550, not sure of the VIN as I cannot locate it, and they re-painted / powder-coated it. However I was able to get the right new parts as they matched the old ones.


* I have replaced the entire electrical chassis wire harness (headlights to tail light)
* Brand new battery
* new starter relay
* Still have the same voltage regulator - not sure if this has failed - may need to test resistance
* battery reads 12.8 volts
* start and solenoid work
* not sure about the Neutral Safety Switch - I pulled it, (light green wire from harness attached) - what appears to be drop of oil on tip.

After I take the battery tender off the Mule, turn the key it starts up just fine and runs well. After using it for sometime or letting it run, after I shut it off, it will not start again via the key. I turn the key and nothing, no clicking, dimming of lights, nothing. It is as something i is blocking the starter trigger wire. If I remove the starter relay and test for voltages I get 12 volts on 1 prong and about 1 volt or so from the starter trigger wire (red / black) - if I turn the key, that wire registers 12v. If I jump the blades and turn the key - it starts no problem / every time.

These steps also work, with the starter relay plugged in, if I turn the key and touch the metal top of the relay on the chassis , you will hear the starter clicking and engage and eventually it will start. I find this odd as it started this morning, cold with no issue.


Is it a bad brand new relay?
that I just got, a bad regulator
the NSS?

I am drawing a blank, I called a few guys I know over at the local power sports service center and they could not think of anything.



Thanks for your help

 

In case anyone stumbles across this thread, apparently the "new" starter relay I got from Autozone wasn't compatible or it was defective. So I found a exact match, 056700-5260 Denso Heavy Duty Relay for $7.13. Note: the same relay found from other parts places on the internet, sells for $37+ so shop around first. Hope this helps someone who may have the same issue.

 

Did this actually fix your intermittent starting issue?

 

I have had what appears to be a starter issue (maybe connections) on my 2020 Pro Mx mule. Just clicks when it happens. 2 times in the past 3 months it won’t start after running for a while. Fixed itself first time, 2nd rolled it down a hill and pulled it into reverse. Next crank it started... this should not happen. Lucky to be under warranty.

 

did you solve this problem? I have replaced my starter, starter solenoid, battery. The only other thing in the circuit is the ignition. Switch. Mine starts sometimes and then just clicks. If you found the problem , I would love to know what you did!