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88 Mule 1000 KAF450
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Had a few wires melt over year ago repaired as best I could. It worked after so I was pleased. Fuel pump stopped pumping next so we wired it straight to battery with alligator clips. Hooked it up when we needed it to run unplugged when it was time to stop. This worked for a good year for us. Never figured out was caused the wire melt to start with so I figured we got lucky. Recently the original fuel pump failed so I replaced it with a cheap internet unit, that according to the seller would work for my application. hooked it up, started, worked ok around the house, took it out to the deer spot and it failed, stopped pumping. Figured it was a lemon so replaced it a 2nd time but it lasted about 100 yards. Obviously I need to do something different if I want to get 1 more deer season out of it. We are too old to drag a deer and the machine is too old to take it to the dealer and dump hundreds of dollars in it. Can someone please give me some needed help/direction?? Thanks!
 

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Hmmm.....the fleabay replacement pump I installed (likely no real different from yours) has performed well for me. Seems a direct connection would work, but might be well worth sorting out the original wiring issue. Odd that two pumps immediately failed.....but hey.....quality control on $18 pump likely not great. Did it not pump at all, or just poorly? Does it try to pump when lines disconnected?
 

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88 Mule 1000 KAF450
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3 Posts
Discussion Starter #3
Just left of the fuel pump is a small black box/device (not sure what it's called? wish I knew that!!) that has 3 wires coming out of it. Those are the wires that started to melt, lucky my brother unhooked the battery immediately and prevented more damage. I was able to replace the damaged section of those three wires. I am pretty sure we already had the original fuel pump wired direct to battery when that mishap occurred. After repairing that damage it seemed to run the same as before the melting occurred so figured we got lucky. I lost power to the original fuel pump so that's why we wired it direct in the first place, I didn't know what else to do and not smart enough to figure it out. Just wanted to get I it to run safely, try to get it through another hunting season with out dumping $$ into it at a repair shop. The original pump and both replacements, when we hooked them up to the battery you can hear a slight clicking sound ( assume that's because it pumping). Again the original lasted over a year, when it wouldn't fire up we noticed the clicking sound was gone & verified it wasn't pumping gas so that's why I bought a $15 replacement on ebay. Both replacements stopped clicking thus stopped pumping and that's how I got to this point. It's not making a lot of sense to me but I am far from being a technician so that's why I NEED HELP!!!! THANKS
 

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Found a thread that might provide some good insight into your issue....
Search this ATV and Mule forum for keyword "igniter"
Then scroll down list of results until you spot a thread...."2001 & newer gas Mule 3010 igniter / CDI. Ignition coil, fuel pump problem"
Lots of good info!
 

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Indiana,

I know this is a long shot that you will even see this, or that you haven't already gotten rid of this or bought something else... But ill post anyway. I have a mule 1000, same thing. the relay eventually burns up, and then you get mad and bypass it directly to the pump, then the pump wires burn up. Long story short, here's what i did, and will never fail you.

Get a primer ball off an old outboard gas tank and replace the fuel line from the tank to the pump with it. Position it so that the fuel line comes up inbetween the seats, so that the primper ball is accesible, and the line goes back down between the seats. now what you can do is manually keep the fuel system primed. Just reach over and give her a squeeze every so often and you will be good to go.
 

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Well after seeing this and posting yesterday i decided i was tired of pumping that primer ball, and now I'm back to post this here so that it can live on the internet forever and maybe someone else will stumble across it looking for answers.

I mounted a vacuum fuel pump for a Polaris sportsman 600 found HERE and it hasn't missed a beat yet. Super simple install and the pump was only 13$.... carbs already have a vaccum nipple, just pull the cap and hook up a vacuum line to the pump, reroute your fuel lines to it instead of the electric pump and boom you have a bullet proof system that should have been made this way in the first place.
 

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ask yourself why it wasn't that way in the first place

pulse pumps are MUCH cheaper than electric so why didn't they (kawasaki) use them?

The 454 engine doesn't have any vacuum to speak of and very little pulsing in the intake tract, thus the pulse pumps typically cannot supply enough volume of fuel to support the mighty 454 at their maximum fuel usage

the Polaris pump works I have done it, but you will find it's downfall in time
 
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