How to Install an Accessory Fuse Box on a Kawasaki Mule 

Your Kawasaki Mule Pro-FXT UTV is ripe for upgrades such as bigger winches, light bars and other electrical components. As great as that sounds, you'll need an accessory fuse box to handle the additional electrical loads.

Installing an accessory fuse box on a Mule doesn't require any fancy equipment. All you need are a few basic tools you probably already have in your toolbox, and the OEM Kawasaki accessory fuse box kit.

Watch our installation video above, as well as the instructions included with your Kawasaki accessory fuse box kit.

Tools and Parts Needed - Kawasaki Mule Accessory Fuse Box Installation

Tools

  • Ratchet and extensions
  • 8mm, 10mm, 12mm, 14mm sockets
  • 8mm, 10mm, 12mm, 13mm wrenches
  • Screwdrivers

 

Prepping Kawasaki Mule PRO-FXT Accessory Fuse Box Installation

Step 1. Remove the three Philips screws and the seven plastic push pin rivets on each side of the headlight grille. Use push pin pliers to avoid damaging the push pin rivets.

Kawasaki Mule Pro-FXT accessory box diagram

Step 2. Once the grille is loose, carefully pull it away from the Mule and unclip the headlight connectors behind each headlight enclosure. Lift the grille out and set it aside.

Step 3. Remove the front compartment cover and set it aside.

Kawasaki Mule fuse box installation

Step 4. Remove the battery cover located behind the right side door. The battery cover is secured in place by two latches.

Kawasaki Mule Pro-FXT accessory fuse box install

Step 5. Unclip the airbox cover above the battery, and remove the airbox cover and air filter so you'll have a little extra room to work in.

Assembling Kawasaki Mule PRO-FXT Fuse Box Relay

Step 1. Attach the 6-inch ground cable to the front of the relay panel, and the 8-inch cable wire to the back of the relay panel.

Kawasaki Mule fuse box relay installation

Step 2. Install the edge protector along the top edge of the relay panel.

Step 3. Mount the accessory fuse box relay onto the relay panel using two 10mm bolts and locknuts.

Installing Kawasaki Mule PRO-FXT Fuse Box Relay

Step 1. Disconnect the ground cable from the negative battery terminal to break the electrical circuit and prevent any accidental grounding.

Step 2. Position the relay panel in front of the battery, and install mounting bolts located to the upper left of the panel and lower right of the panel.

Kawasaki Mule fuse box relay mounting

Step 3. Remove the plugs from each end of the corrugated tube that runs from behind the battery up to the front compartment.

Kawasaki Mule accessory fuse box relay

Step 4. Take the main accessory fuse box cable and feed it into the corrugated tube in the front compartment. Work it through until it comes out of the corrugated tube behind the battery. 

Kawasaki Mule Pro-FXT fuse box cable and battery

PRO TIP: To make working the main cable through the corrugated tube easier, remove the rubber end cap and the protective corrugated covering from the main cable, then bend back and tape the smaller brown wire to the main cable. This should minimize the chances of the main cable catching on the inside of the corrugated tube as it passes through. 

Watch the clip below to see this step in action.

Step 5. Once the main cable is through to the area behind the battery, cut the smaller brown wire free, then replace the protective corrugated covering to the main cable and reinstall the rubber end cap. 

Watch the clip below to see this step in action.

Step 6. Connect the main cable to the right side terminal on the accessory fuse box relay.

Kawasaki Mule Pro FXT fuse box relay connection

Step 7. Connect the smaller brown wire that's attached to the main cable to the center-left terminal on the accessory fuse box relay.

Fuse box relay installation Kawasaki Mule

Step 8. Connect the other end of the 6-inch ground cable you've already attached to the front of the relay panel to the center-right terminal on the accessory fuse box relay.

Fuse box relay connection Kawasaki Mule Pro-FXT

Step 9. Connect the end of the positive relay battery cable with the rubber end cap to the left side terminal on the accessory fuse box relay.

Kawasaki Mule fuse box relay install connection

Installing Kawasaki Mule PRO-FXT Accessory Fuse Box

Step 1. Position the accessory fuse box to the right on the shroud covering the radiator in the front compartment. Use a punch tool to mark drill points through the bolt holes in the fuse box.

Kawasaki Mule UTV accessory fuse box installation

NOTE: Position the fuse box as far to the right side as possible to avoid the radiator, which is located below the shroud.

Step 2. Drill through the drill points using a 15/64 drill bit, and mount the accessory fuse box with 3mm Allen bolts and locknuts.

Kawasaki Mule Pro-FXT UTV fuse box install

Step 3. Position the ground post to the right on the shroud covering the radiator in the front compartment. Use a punch tool to mark drill points through the bolt holes in the ground post.

NOTE: Position the ground post as far to the right side as possible to avoid the radiator, which is located below the shroud.

Kawasaki Mule accessory fuse box ground post

Step 4. Drill through the drill points using a 15/64 drill bit, and mount the ground post box with 3mm Allen bolts and locknuts.

Step 5. Connect the main accessory fuse box cable to the fuse box terminal, then replace the fuse box lid and pull the cable's end cap over the terminal.

Kawasaki Mule fuse box install

Step 6. Attach one end of the 13-inch ground cable (from the kit) to the ground post.

Kawsaki Mule Pro-FXT fuse box ground cable install

Installing Kawasaki Mule PRO-FXT Fuse Box Ground

Step 1. Remove the five plastic push pin rivets from around the dashboard. Use push pin pliers to avoid damaging the push pin rivets, and pull the dashboard out of the way.

Kawasaki Mule fuse box ground installation

Step 2. Run the smaller brown wire with the bullet connector from the main accessory fuse box cable from the front compartment to behind the dashboard, and connect it to the brown wire with red stripe behind the dashboard. Reinstall the dashboard and push pin rivets.

Step 3. Measure a point one inch from the front and one inch from the bottom in the side of the radiator shroud and drill a hole with a 1/2 inch drill bit.

Kawasaki Mule Pro-FXT accessory fuse box ground installation

Watch the clip below to see this step in action.

Step 4. Move under the Mule and locate the unused bolt hole in the frame near the 1/2 inch hole you just drilled to the right of the radiator.

Kawasaki Mule UTV accessory fuse box mounting

Step 5. Remove the paint around the hole so you can use it as a ground point. 

Pro Tip: Use sandpaper or a wire brush on a drill to remove the paint.

Step 6. Feed the 13-inch ground cable from the ground post down through the hole you drilled and bolt it to the hole in the frame.

Kawasaki Mule fuse box accessory install

Step 7. Spray the area of the frame you removed paint from with an epoxy paint to protect it from rusting.

Kawasaki Mule accessory fuse box mounting bolt

Completing Kawasaki Mule PRO-FXT Fuse Box Relay

Step 1. Take the positive relay battery cable and connect it to the positive terminal of the battery. Run the cable through the end cap that's already on the battery's positive terminal.

Step 2. Reconnect the ground cable to the negative battery terminal and connect the 8-inch ground cable you've already attached to the back of the relay panel to the negative battery terminal.

Kawasaki Mule accessory fuse box battery connection

Step 3. Reinstall the air filter, airbox cover and battery cover.

Kawasaki Mule air box cover installation

Step 4. Reinstall the front compartment cover, reconnect the headlights and reinstall the headlight grille.

Kawasaki Mule Pro-FXT headlight grille installation

Since you made it this far and have your accessory fuse box installed, the next step is to fit an additional battery to your Kawasaki Mule. Watch the dual battery kit installation video below to get that done! 

 

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