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Starting problems - Mule 610

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11K views 2 replies 3 participants last post by  pkolb  
L
#1 ·
I have an 06 Mule 610 with about 650 hours on it. I have been having in intermittent problem with starting. The battery is good, no loose ground wires, or any other easily identified issues. But about 50% of the time when you turn the key, you can hear (and feel) the solenoid moving in the starter motor, but the motor itself fails to turn, so it does not start. And then 5 minutes later you might be able to go back to it and turn the key and it will start right up. Or it won't start at all. But every time you can hear the solenoid moving.

I have pretty much decided that the starter needs to be replaced. I can see it sitting there right on top of the engine. (Did I mention that my mule is 120 miles away from where I am sitting now? I keep it at my property and only get to use it - or work on it - on the weekends.) But when I look in the service manual - man, they have you removing a whole lot of parts, apparently just to allow you to get to it. (You are instructed to remove the torque converter among other parts.) And some of these steps require tools that I don't have.

I would prefer to do this work myself as the nearest dealer is 2 hours away. Anyone have first-hand experience changing the starter? Is it really as hard as it is described in the service manual?

Thanks in advance!

Martin
 
I
#2 ·
No, it's easy. Just a matter of removing the cable bracket on the R.H. (as you're sitting on it) side, which gives a little more room. Then jsut removing the 2 12mm head bolts that hold the starter to the block. It is not uncommon for these starters to fail-for whatever reason. I haven't disassembled very many to see what's going on with 'em. It's usually not cost effective to try to fix them when a new chinese starter is about $70.

BTW I usually use a 12mm short socket on a 1/4 drive ratchet, along with a 12mm combination wrench. The cable bracket doesn't "need" to be removed, but it does make things go a little smoother-and I can't remember what tools are required for that. Seemed like 14mm socket on a 3/8 drive ratchet, with a 6" extension, IIRC.

The Kawasaki service manual tends to overcomplicate things sometimes.
 
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