Quantcast
Jump to content

dalem

08 kawasaki Mule 600 Not Charging Battery

Recommended Posts

Earlier this year my battery was weak and I had to boost my mule to start it then I decided to remove the battery to check the fluid level which was very low, I set the levels and recharged the battery a few months later it did the same thing, so I had to boost it again then checked the voltage running was getting around 16 vdc ( which is too high) and fluid level was very low again and wouldn't hold a charge. Note: The battery was maybe 1-1/2 years old. Then I replaced the battery and checked the voltage running nothing changed I was only reading battery voltage it wouldn't increase with increased engine speed. I changed the voltage regulator with an aftermarket  one, same thing not charging. I checked the alternator per the service manual which states .3 ohms or less it checks at .2 ohms and not shorted to ground. With the engine running I disconnected the alternator and it had around 22 vac idling and around 60 vac revving the engine, so I figured the regulator was bad so I replaced it with another new one (aftermarket) from a different company, again not charging only reading  battery voltage. I did put the original voltage regulator on nothing changed still not charging. Using the manual wiring diagram did continuity checks going to the voltage regulator everything checks out OK. Now what am I missing?

Share this post


Link to post
Share on other sites


This may sound silly, but are your battery cable ends free of corrosion?

Share this post


Link to post
Share on other sites

The battery connections are perfect and should be on the positive at the solenoid but I'll check it to be sure.  I had changed the starter last year. Now I did not check the negative side to the frame, I will check it out tomorrow. Thanks! I see in your picture you have a 550, I have a 550 also, looks just like yours. They are good utvs also

  • Like 1

Share this post


Link to post
Share on other sites

This one's been going for 19 years. I replaced the rear axle seal and bearing, and pulled th engine, put new rings and seals on it. It's been a good machine with very few problems over the years.

 

Share this post


Link to post
Share on other sites

Overcharging with a hot voltage >14.5VDC can damage battery cells.  You can also get low quality batteries fresh from the store.  Your hot voltage may have killed a new battery.  

Share this post


Link to post
Share on other sites


The new battery works ok.  I read the same battery voltage running or not. I checked all connections to the battery and grounds all are OK. If I use the lights the battery voltage will drop while its running. Two aftermarket voltage regulators and the original all do the same thing the battery voltage stays the same (now at 12.25 vdc) if I don't use the lights. I just keep recharging the battery(every other week). I use this mule everyday. I'm just wondering would a genuine Kawasaki Regulator make any difference (they are a lot more expensive)

Share this post


Link to post
Share on other sites

2 things are bouncing around in my mind.... here goes!

1. if i remember correctly the 600 engine uses a stator (alternator) behind the flywheel, on the inside edge of the flywheel are magnets that rotate around the stator as the engine is running and generates AC voltage.

its possible something is wrong with the magnets, but not very likely. Sometimes they can fall off/out of the flywheel, but you would more than likely know if they did.

2. Also,  sometimes (i know this is true on some Riding Lawnmowers) they have Diodes in the wires that carry the AC voltage, diodes allow current to flow one way, but not the other. And if they go bad current will not flow through the wire.

im not 100% sure your mule has them, but i figured its worth putting out their incase someone else knows.

 

Share this post


Link to post
Share on other sites

OEM lights and not LEDs, correct? If that's the case those OEM lights draw a lot of current, probably in the neighborhood of 50w each.  The stator on an old Mule isn't that beefy to begin with, so you will get a significant voltage drop when the lights are on.  Maybe you don't really have an issue.  Or maybe you have a slight short to ground somewhere in the wiring with rubbed through wire insulation.  

Share this post


Link to post
Share on other sites

Yep I replaced the headlights on my mule with  2 small Pod LED s.

Brighter, but less power consumption.

Share this post


Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.


  • Similar Topics

    • By bjones
      Strange issue and it has happened twice.  Changed oil twice and after a while when oil is checked it is always to full on dip stick.  Looks like at least 1/2 qtr.  I have looked at manual and put in amount called for, 1.16 qt without filter.  What would cause level to appear to full.  Thanks
    • By Pamm r
      Mule still not charging after replacing a new regulator.  Need to figure out how to test the alternator at the plug on top of the motor.  Any easy way to check it?
    • By Acarguy
      I cant seem to get my mule into posi traction. The lever moves but i don't think im engaging it the right way? What is the procedure for getting it in posi traction?
    • By Mike McDonald
      The Intimidator is made in Arkansas and the company was affiliated with the Bad Boy products at one time. The engine is a Kohler 750. I replaced the flywheel and stator a year ago, so I feel like they are okay. The battery was replaced and all the cables are good, no corrosion. 
       
      The wiring diagram shows a rectifier/regulator and an inline fuse that the manual said could be my charging problem.  My  questions are:
      1. Are these rectifier/regulators some generic or, are they specific to each machine?
      2. Are there UTV parts companies that handle parts for all brands of buggies?
       
      3. If the answer to #2 is yes, could  someone recommend the names of parts companies I could contact?
    • By jkitsmiller
      I bought a used RTV 900 and was told it is a 2012. I thought I would verify that. I can't find anywhere I can look this up.
       
      KRTV900A61057114 is the product identification number.
       
      Thanks for any help.


×
×
  • Create New...