Hello, John Talley here with Partzilla.com.
Today I'm going to show you how to install a secondary battery on our 2018 Kawasaki Mule
Pro-FXT.
Not that tough to do, I just need to go gather up my parts and tools and I'll show you how
to get it done.
Alright guys, this is going to be a skill level 2, but don't break out in a cold sweat
just because we're working with electrical.
It's not going to be that bad.
Alright, as far as the tools you're going to need, you're going to need a set of needlenose
pliers, set of side cutters, Phillips screwdriver, a 10, a 12, and a 13mm wrench, a 10mm and
a 12mm socket, and I suggest you use a quarter inch on the 10 because it gets real tight
in there.
And as always, just a 3/8ths ratchet.
Alright, as far as the parts list goes, they make a kit to do this but there's other pieces
that have to be purchased to go along with it just for this part of the installation.
Compounded by the fact this is all really centered around re-routing power to what they
call an accessory fuse box.
So if you have not put that on your machine, you need to go reference our video and order
the correct parts and get it installed first or at least in tandem with doing this project.
So, once you have all of your tools and your parts together, we can go over there and I
can show you how to do it.
Alright guys, step number one now that you've got all your tools and your parts ready is
I like to lay out all the parts and accessories an any other additional pieces.
Just lay 'em out in a really clear fashion to where it's easy to go back and pick up
exactly what you need as you're going through this video.
So, now that I've got everything accounted for, let's start the installation.
Let's go ahead and get this cover out of the way.
It's just got a couple of latches on it.
One down at the bottom and one at the front.
Alright next, just to give us a little more working room, let's take off the airbox cover
because it does get a little tight in here.
Release that breather hose.
There, just lay that to the side.
Because what's going to happen here is we're going to have another battery next to the
factory one.
And we're also adding in another relay.
On this particular machine we've already installed an accessory fuse panel and this second battery
is going to be dedicated to that only.
So, if you're sitting out and doing some work and you've got your light on-- that front
LED light on-- it'll only be drawing from the secondary battery.
Now, when you go to start it, you've got a fully charged battery that has not been touched.
When you turn it on, it starts recharging, it reconnects the secondary battery back into
the charging system and charges it back up.
Really great way to be sure that it's going to start every time because the battery that's
dedicated to just the machine is never drawn upon.
IT only goes through that secondary battery and through that accessory fuse panel.
So, that being said, let's go grab our secondary relay and get it installed on this plate.
Let's go ahead and disconnect the battery.
You want to keep from shorting it out and doing a little freehanded welding.
Do your negative side first.
Now, that breaks the circuit and so if you to take the positive terminal off, if you
were to hit the frame with your wrench, can't complete a circuit so it wouldn't matter.
Alright, with that disconnected we need to remove this panel that I installed when we
did the fuse accessory panel installation.
So it's gotta come out and that second relay is actually going to mount to the same bracket
but a little bit lower.
So, this bracket is held in by two points.
Basically there's a long bolt that actually goes through and holds down the top of the
battery.
That has to be removed and then there's a 10mm that was going forward, so I need to
get those two off and then I can lift the bracket up.
Like that.
Now we can go ahead and bolt up our batter isolater relay.
Alright next, we need to remove this ground bolt right here and add to it our ground wire
as well as this black wire from the secondary relay.
So, we have one, two, three wires on this side and it's going to go through the mounting
bracket and on the other side I need to reconnect the ground wire.
And don't forget this lock washer and then the nut.
Alright, see at the original black wire from up here on the contactor this new wire we're
adding in and this black one from the bottom of our additional relay.
And also, the wire actually heading over to the ground strap that just went to the battery.
Now, we can go ahead and reinstall this bracket.
It starts by reinstalling our bolt up front.
Let's get this battery mount bolt back up through there.
Get it fastened back down.
Alright next, the second battery actually goes up under the air filter.
There's a couple of rubber plugs that you need to remove.
One toward the outside and other one towards the inside, because that's where your mounting
bolts are going to come up.
Alright, let's go ahead and get this rubber damper in place.
Just center it the best you can in between those two holes in that bottom tray.
What we're gonna do next is go and put on this upper damper, which is going to make
contact with the top of the battery.
Now, before we actually set the battery in place we want to go ahead and bring the bolt
up and go through this sleeve and then attach loosely the back half of the bracket.
Go ahead and put that nut in place.
Then, just swing it up and over the top of the primary battery.
Slide the battery in and the tighten it down.
Now we can do the same thing on the outside.
Bolt up, through the spacer, then up through the bracket, then put on the nut.
Now let's get those tightened down.
I almost couldn't pull my hand out.
alright, what we're doing now is we're going to move the main battery cable from this location
down to here.
Take off this zip tie so I can push this cover back far enough to get a good grasp of the
connector.
Alright, so bring this down to that lower terminal.
Lock washer, then nut.
Get it tightened back down.
That's tight.
Let's bring around our cover and get that zip tie back in place.
Alright, we're gonna make a jumper from here to here but then we're also going to take
our positive and make it connect down at the bottom so it'll look something like this when
we're done.
Alright, our drop's out.
Like so, then we've got a jumper, get our lock washer and our nut back on.
Now the other half of the jumper goes up here.
Now, we can tighten this down.
Now, you want to take this wire with the bullet connection on it and connect to the red one
down at the bottom.
You may need to grab this with a couple of sets of pliers because it really needs to
snap all the way in.
There we go.
That needs to connect to this trigger point right here.
Next, let's go ahead and do our positive.
Make sure you have the right one-- into the auxiliary battery.
Get this cover on before we do it.
Get the cover on.
Now take the negative and that needs to go to the negative terminal of the battery.
Guys I'm actually going to take this air intake the rest of the way off because there's no
way I can get my hands up in there to do this.
Now we've got a little bit of working room.
Let's get this bolted on down.
Now, let's go ahead and get the main ground going back to the primary battery.
Now we'll ground everything at this point.
Now let's go ahead and remount that air box.
Get your air filter back in.
Get the cover put back on.
Get this hose back in its little holder at the bottom of the cover.
Last but not least, battery cover.
Redo these clips.
Well alright guys, that pretty much wraps this one up.
Well listen, if you need any parts for your machine, believe me we've got 'em up to 80
percent off.
So no matter what you need, you can come see us at Partzilla.com and we can get you taken
care of.
Listen, if you have any questions or comments about this procedure, leave them in the section
below and I'll do my best to answer them.
Til next time we just want to say thank you for shopping at Partzilla and we will see
you in the next video.