It sounds like my 2018 Mule 4010. It will get worse to where it will not idle at all. Kawasaki recycles your crankcase vapors and gas tank vapors back through the throttle body. If you run your engine mostly at low speed, you do not get the vapors hot enough, so they foul the electronics managing your EFI. If you take it to the dealer he will clean the throttle body, and that works for about 1 or 2 months, then it will start stalling when idling. It does not seem to impact the engine when running at high or full throttle. To check it, disconnect the hose going to the throttle body from the vacuum cannister and it should start running better. You will.need to seal off the exposed inlet to your throttle body to keep dirt and debris from being pulled in. Hope this helps.
My 2016 mule 4010 trans 4x4 (gas)(270 hours) is currently in the shop with the same issue. Runs rough at idle and fine at full throttle. Noticed oil leaking around throttle body and plugs oil soaked. PCV system also oil soaked. Kawasaki dealer says it’s covered by Kawasaki under a recall. They cleaned the throttle body and pcv system, changed plugs, and reprogrammed ECM and it runs flawless now. All covered under a warranty recall.
First I've noticed the Air/Fuel adjustment screw tension springs aren't very tight so they may loosen out over time. Problem I have is I am working on one too and I found one screw at 5.5 turns out and the other at 3.25 turns... this doesn't seem normal to me, but I don't know for sure. If there's a spot on the throttle you can hold it at to reach normal idle, then your idle stop screw under the rubber flap on the carb May have backed out a little. Give it slight turns in and keep track of your turns on it in case of no change in idle or too much idle rpm.
2019 mule 4010 same problem,happened two times with only 100 hours. Kawasaki dealer says coil pack was bad. First time was under warranty second time not.
Fuel pump going out and needs new fuel filters. Also make sure you change both air filters. It will probably flood some and if you had an old spark plug mess it up. Replace it if not new. About 6 years too late. But if you still have same problem like I did for 4 years then maybe right on time.
We use 4010 miles at my work and we had the same issues what we did is change the fuel pump filter looks like a sock on the bottom and seafoamed the engine, then changed oil and spark plugs and it ran normal again
I have a 2017 mule 4010 transform...doing that...half the time i cant keep it running...or it runs and the minute i go to stop it cuts out...constantly fighting with it...a little over a 100 hours...HELP..
I have a 2011 trans 4x4 4010 and the Drive belt was the problème.used Too Much on Esch Side so IT keep engine engage and stall as soon as i let IT idling
I have a 2017 as well and had the same issues. The problem is common with the fuel injection. It is completely electronically controlled. The engine is a generator design and meant to be run at full RPMs. A common issue is the fuel injection system gets gummed up with oil coming from the hose off the engine back to the air intake hose. At idle or low RPMs it kicks oil back into the fuel injection. I pulled the entire fuel injection system off and carb cleaned it. It was COATED in oil. Like a lot of sticky black oil. Once fully cleaned it idles like a champ, hot or cold. On area to note, if you adjusted the manual idle screws you will need to slowly adjust them back to factory settings. You can run into issues with the computer controlled idle if it thinks your foot is on the gas vs under electronic control of the idle. One easy way to check is pull the short 90 degree hose off the bottom of the injections system (coming from the air intake frame and injection housing. Check the hose or stick your finger up in the fuel injector housing. My finger was coated with wet thick oil.
People always overfill a little with oil and it sends a lot of oil mist from windage thru the crankcase vent to intake right before throttle body, Just clean the throttle and it will fix the problem. Then quit overfilling with oil to stop it from doing it again. If it has over 2000 hours then it needs cleaning anyway. We have seen units with 5000 to 8000 hours that the throttle motor is just worn out. Then you need to replace whole assy. its ouch like 700.00
both of our mules do this crap too, one is 2018 with 1700 hours, the other is 2017 with over 5000 hours, on the 2017 cleaning the TB and sensors fixed it as well as changing the fuel filter to new helped, on the 2018 its something different sense the fuel filter change and cleaning of TB and IAT and pressure sensor, iv been looking around the internet on this and it seems like pretty much everybody that has the mule 4010 gas engine gets an idle issue at some point or another.
I have a 2016 410 Mule XC with 93 hours on it and it just stalled yesterday and is now making the same sounds as yours. My battery went dead trying to start the mule, had to buy a new battery and once I was able to get it started it sounded exactly like yours and had a really bad gas odor, along with back firing. I'm thankful I got the extended warranty, taking it to the dealership next week. Also, I run non-ethanol fuel and had it serviced at 50 hours. What I'm pissed about is this must be a common Kawasaki mule defect that should have been a recalled. UNSAT!!
the problem is the throttle body is dirty. the root of the problem is the placement of the crankcase breather hose. I clean about ten of these a month and it fixes the problem every time.
My parents have a mule doing the same. Backfires, too. Kawasaki knows there is a problem with the throttle body sensors getting dirty (@ least on this 2010 yr mod). Will never buy another mule. Their fix is to put a new one on every 2 years @ $700. The cylinders sync electronically and it is a big messup. You can clean the air system out totally which in this dusty environment would be every month or so. GOOD LUCK.
Oh, the wiring harnesses are made in a 3rd world country in a shack. They threw them in a big metal bin outdoors with no lid always on. Oh, it rained last night, oops. Sorry you got the harness off the bottom that was rotting in water. Now your electronic communications aren't so trusty. Sorry about that, ha. Google these people in shacks recycling hdpe, breathing smoldering plastic cancer fumes. That's the kind of work we're getting sold...
100% throttle body is dirty from the crankcase breather hose. It kicks oil and oil fumes back into the air intake hose and throttle body. I pulled mine off and carb cleaned the shit out of it. Had to use a toothbrush too. Super thick sticky black out coating it everywhere. A lot of the problem occurs during idle and when to much oil is added. The use of a oil catch can works great.
I hear the problem is from ethanol fuel, most people say the problem will come back, not sure, I see some people are cleaning the Throttle body with WD-40 when it acts up
another problem is the crank case vent comes right back to the throttle body causing idle problems for 2012 and older models, Kawasaki may warranty it under emission repair, mine is in shop for same thing right now, first time ever in shop
It sounds like my 2018 Mule 4010. It will get worse to where it will not idle at all. Kawasaki recycles your crankcase vapors and gas tank vapors back through the throttle body. If you run your engine mostly at low speed, you do not get the vapors hot enough, so they foul the electronics managing your EFI. If you take it to the dealer he will clean the throttle body, and that works for about 1 or 2 months, then it will start stalling when idling. It does not seem to impact the engine when running at high or full throttle. To check it, disconnect the hose going to the throttle body from the vacuum cannister and it should start running better. You will.need to seal off the exposed inlet to your throttle body to keep dirt and debris from being pulled in. Hope this helps.
My 2016 mule 4010 trans 4x4 (gas)(270 hours) is currently in the shop with the same issue. Runs rough at idle and fine at full throttle. Noticed oil leaking around throttle body and plugs oil soaked. PCV system also oil soaked. Kawasaki dealer says it’s covered by Kawasaki under a recall. They cleaned the throttle body and pcv system, changed plugs, and reprogrammed ECM and it runs flawless now. All covered under a warranty recall.
First I've noticed the Air/Fuel adjustment screw tension springs aren't very tight so they may loosen out over time. Problem I have is I am working on one too and I found one screw at 5.5 turns out and the other at 3.25 turns... this doesn't seem normal to me, but I don't know for sure. If there's a spot on the throttle you can hold it at to reach normal idle, then your idle stop screw under the rubber flap on the carb May have backed out a little. Give it slight turns in and keep track of your turns on it in case of no change in idle or too much idle rpm.
2019 mule 4010 same problem,happened two times with only 100 hours. Kawasaki dealer says coil pack was bad. First time was under warranty second time not.
Fuel pump going out and needs new fuel filters. Also make sure you change both air filters. It will probably flood some and if you had an old spark plug mess it up. Replace it if not new. About 6 years too late. But if you still have same problem like I did for 4 years then maybe right on time.
I had the same problem with mine. I ran some sea foam in and filled it up with higher octane fuel and it runs great now
How much seafoam
@@coreylane8977 you can't really use to much. Right
We use 4010 miles at my work and we had the same issues what we did is change the fuel pump filter looks like a sock on the bottom and seafoamed the engine, then changed oil and spark plugs and it ran normal again
Mine idles great runs poorly with DFI light on
I have a 2017 mule 4010 transform...doing that...half the time i cant keep it running...or it runs and the minute i go to stop it cuts out...constantly fighting with it...a little over a 100 hours...HELP..
I have a 2011 trans 4x4 4010 and the Drive belt was the problème.used Too Much on Esch Side so IT keep engine engage and stall as soon as i let IT idling
I have a 2017 as well and had the same issues. The problem is common with the fuel injection. It is completely electronically controlled. The engine is a generator design and meant to be run at full RPMs. A common issue is the fuel injection system gets gummed up with oil coming from the hose off the engine back to the air intake hose. At idle or low RPMs it kicks oil back into the fuel injection.
I pulled the entire fuel injection system off and carb cleaned it. It was COATED in oil. Like a lot of sticky black oil. Once fully cleaned it idles like a champ, hot or cold.
On area to note, if you adjusted the manual idle screws you will need to slowly adjust them back to factory settings. You can run into issues with the computer controlled idle if it thinks your foot is on the gas vs under electronic control of the idle.
One easy way to check is pull the short 90 degree hose off the bottom of the injections system (coming from the air intake frame and injection housing. Check the hose or stick your finger up in the fuel injector housing. My finger was coated with wet thick oil.
People always overfill a little with oil and it sends a lot of oil mist from windage thru the crankcase vent to intake right before throttle body, Just clean the throttle and it will fix the problem. Then quit overfilling with oil to stop it from doing it again. If it has over 2000 hours then it needs cleaning anyway. We have seen units with 5000 to 8000 hours that the throttle motor is just worn out. Then you need to replace whole assy. its ouch like 700.00
both of our mules do this crap too, one is 2018 with 1700 hours, the other is 2017 with over 5000 hours, on the 2017 cleaning the TB and sensors fixed it as well as changing the fuel filter to new helped, on the 2018 its something different sense the fuel filter change and cleaning of TB and IAT and pressure sensor, iv been looking around the internet on this and it seems like pretty much everybody that has the mule 4010 gas engine gets an idle issue at some point or another.
Did you find out the problem?
Did you ever find out what the problem was with the idling issue. Mine is currently doing the exact same thing
Lucas fuel treatment, does wonders!!!!! Easy fix!!!
Check your battery. Mine was doing that as well, but it turned out to be a bad battery.
Wait til you have to replace the junk transmission on it
I have a 2016 410 Mule XC with 93 hours on it and it just stalled yesterday and is now making the same sounds as yours. My battery went dead trying to start the mule, had to buy a new battery and once I was able to get it started it sounded exactly like yours and had a really bad gas odor, along with back firing. I'm thankful I got the extended warranty, taking it to the dealership next week. Also, I run non-ethanol fuel and had it serviced at 50 hours. What I'm pissed about is this must be a common Kawasaki mule defect that should have been a recalled. UNSAT!!
What was the outcome of this?
I work on Kawasaki’s it sounds like you’re running on 1 cylinder more than likely you have a bad coil. Very common problem with that series.
That mule has a recall for new throttle body, pcv system and reprogram of ECM as told to me by my Kawasaki dealer.
Its most likley the throttle sensor.
first disconnect the engine brither from the intake , calibrate the TPS sensors as spec
the problem is the throttle body is dirty. the root of the problem is the placement of the crankcase breather hose. I clean about ten of these a month and it fixes the problem every time.
Throttle body for fuel injected or carb model?
My parents have a mule doing the same. Backfires, too. Kawasaki knows there is a problem with the throttle body sensors getting dirty (@ least on this 2010 yr mod). Will never buy another mule. Their fix is to put a new one on every 2 years @ $700. The cylinders sync electronically and it is a big messup. You can clean the air system out totally which in this dusty environment would be every month or so.
GOOD LUCK.
Oh, the wiring harnesses are made in a 3rd world country in a shack. They threw them in a big metal bin outdoors with no lid always on. Oh, it rained last night, oops. Sorry you got the harness off the bottom that was rotting in water. Now your electronic communications aren't so trusty. Sorry about that, ha. Google these people in shacks recycling hdpe, breathing smoldering plastic cancer fumes. That's the kind of work we're getting sold...
100% throttle body is dirty from the crankcase breather hose. It kicks oil and oil fumes back into the air intake hose and throttle body.
I pulled mine off and carb cleaned the shit out of it. Had to use a toothbrush too. Super thick sticky black out coating it everywhere.
A lot of the problem occurs during idle and when to much oil is added. The use of a oil catch can works great.
I hear the problem is from ethanol fuel, most people say the problem will come back, not sure, I see some people are cleaning the Throttle body with WD-40 when it acts up
another problem is the crank case vent comes right back to the throttle body causing idle problems for 2012 and older models, Kawasaki may warranty it under emission repair, mine is in shop for same thing right now, first time ever in shop
Lucas fuel treatment!!!
Yes I went to a non ethanol gas. Then an over the counter additive. Working good
Gas ended up being a solution for my mule. Add staybill.
Sea Foam and fuel filter.
Fuel pump and filter. Sea foam