Hello,
First off this problem is coming from Afghanistan. I'm in the Air Force and I have a Kawasaki Mule over here that we are driving around for duty related purposes. Well wouldn't you know it the keys got lost and someone broke the ignition switch so it would work with out the key. Well The Chief asked me if we could find another switch to make the Mule work without using the screw driver. I said I would look into it.

I found 2 toggle switches......one on off only (ignition on and off) and one momentary spring loaded switch (used for starter motor)

When I pulled the old switch out there were 5 wires in the wiring harness connection going to 4 wires on the switch side of the connection. So obviously I know one wire isn't used.

I checked for power on all 5 of the wires from the wiring harness side and only one was hot. (Thats the main power wire)

I connected that to the one side of the on/off toggle and the other side to the ignition on side.

Everythings good ....ya all still with me?

I then made a jumper from the ignition on side to the spring loaded toggle switch. then ran the starter wire off of that. Hooked everything up and the thing works as it is supposed too.

Now, there is a problem when we are driving this thing it will just die. It will take a couple of minutes trying to start then it will run fine for the trip we need to make. It seems to be doing this quite often and not sure if this was doing before the mod or not as we just arrived here and not familure with this mule.

Now remember that there were four wires coming off of the switch side and I only have 3 hooked up. Is that forth wire supposed to come with power from the ignition side to activate the fuel pump or something when in the on position?

So my question is when does the fuel pump get power? Should it be on as soon as the ignition switch is in the on position? Is this a fuel pump problem? All filters were cleaned and the spark plugs and oil seem fine. Any help would be greatly appreciated.