7 Common Kawasaki Mule 4010 Problems And Solutions

Kawasaki Mule 4010 Problems

These versatile 2- to 4-person side x sides are capable of handling a hard day’s work and going for a ride at the same time. For added convenience, there are two glove boxes, a 12V DC outlet, cup holders, along with a fuel gauge and an hour meter on the dashboard.

A Power Steering system (EPS), and thick seat cushions with handholds for passengers make the ride more comfortable.

The 15.8-gallon storage space under the hood makes it convenient to stow additional belongings. You can store materials, tools, or your entire crew in the Trans Cab system.

Even with all these features, you may encounter some problems with this ATV after some time. But that is not something to worry about, as the problems can be solved with some knowledge about the solution.

Common Kawasaki Mule 4010 Problems

  1. Loss of engine and electrical power
  2. Under-seat overheating & poor idle
  3. Trouble With Gear Shifting
  4. Fuel pump problems
  5. Malfunctioning throttle body and sensor
  6. Transmission Problem
  7. Wiring Harness Problems

Problems And Solutions of Kawasaki Mule 4010

When you are aware of the causes of the problem, it becomes very easy to solve. Also, when you know how to solve it, you might be able to solve the issues by yourself and that will not cost you any money to hire a mechanic.

So, to help you to solve the problems by yourself the common problems of Kawasaki Mule 4010 and their solution are given below:

1. Loss of engine and electrical power

If you notice sudden acceleration declining and significant power loss after some hundred hours then it means your Kawasaki Mule 4010 is suffering from loss of engine power and electrical power.

You might think this has to do with the fuel pump issue but it is not if you check properly.  This usually happens when the user rides on hilly areas frequently.


It is not always easy to determine if fuel lines or filters are blocked at first since symptoms are not always immediately visible.

Not charging or a bad charging system can cause electrical power loss of this off-road vehicle. So, fix the loose battery terminals, clean up if there is debris that blocked the filters and finally takes help from an expert while changing battery and wires if the battery or the wires are worn out.

2. Under-seat overheating

If you experience overheating from behind and under the seats or hot air around the front seats, that means your ATV has unrestricted airflows directed to the engine compartment from under the floor.

This is a very serious issue. It can burn the users and cause many damages.


Although the Kawasaki Mule 4010 does not provide a heat shield by default, it should because this is a common problem.

However, although you do not get a shield from your off-road vehicles, you can always find these attachments on amazon.

3. Trouble With Gear Shifting

You might experience problems when you try to increase your 4010’s gears. Especially when you try to higher or lower or reverse mode your Kawasaki Mule’s gear.

Gear shifting is a quite common problem for many off-road vehicles. Sometimes, the manufacturer design is to blame for this and sometimes happens when the gear is stuck.


There is no definite solution as it comes with the factory fault. You can still complain to them and see whatever they can do to solve this problem.

4. Fuel pump problems

Whining noise and troubles with starting might be a cause of fuel pump problems.

When there are fuel pump problems, fuel pumps do not work properly and eventually stop working.

However, it does not happen without any reason. In fact, your negligence can be a huge cause for this problem to occur.


Make sure to clean your fuel filter regularly or otherwise, dirt and debris will block it and damage it beyond repair.

5. Malfunctioning throttle body and sensor

Although throttle body and sensor problems are common for Kawasaki Mule 4010, you will not find the TPS sensor parts separately without a full-throttle body, which creates another problem.

However, the malfunction in the throttle body and sensor is caused by the fact that the engine exhaust is vented directly into the air intake tubing per USEPA standards, rather than to the environment.

This means the burned oil gets glued to the throttle body.


You have to act fast to solve this problem. Firstly you have to disconnect the tube from the TB before spraying throttle body cleaner on it.

You have to do it while the engine is running. And if it can not be solved like this, then you might need to replace it.

6. Transmission Problem

Transmission problems usually cause loud raking noises while shifting gear. This might not seem like a major problem but slowly it becomes unbearable.


Replace or repair the transmission. If you need help regarding repairing or replacing the transmission you can call a mechanic or take it for a warranty fix.

7. Wiring Harness Problems

Wiring harnesses are supposed to keep your ATV’s wiring secured. the wiring harness main connector with about 20 pins, might have loose pins. This might damage your ATV’s wiring system.


You should replace the wiring harness with the help of an electrician as this is a risky task and will be hard for you if you have no experience.

Frequently Asked Questions

How fast is a Mule 4010?

Mules are built to endure years of rough use and are serious machines. With a fuel-injected 617cc V-twin engine and a top speed of 25 mph, power is delivered smoothly and linearly.
Making sure your Kawasaki Mule tires are fully inflated is an easy way to increase your top speed, but if your tires are too flat, you will have to go slower. Getting faster speeds is also possible by disabling the governor.

How good is the Kawasaki Mule 4010?

Kawasaki Mule 4010 is an excellent ATV vehicle. It offers very comfortable suspension rides even when the roads are rough. Mules are built to last, and this one is built tough enough to get the job done. Injection of fuel into the twin-cylinder 617cc engine ensures smooth power delivery up to a top speed of 25 mph.

What engine is in the 4010 Mule?

With a fuel-injected 617cc V-twin engine, the Mule 4010 side by side delivers much muscle and strength to your works. Whether it’s hot or cold, this smooth-running four-stroke engine provides smooth, powerful performance to get the job done.

Final Words

It would be expected that Kawasaki’s Mule 4010 would perform as well as its low asking price because it is Kawasaki’s least expensive 4×4 utility UTV.

That is why you should not be overwhelmed by the problems it might have. The provided solutions will help you to solve the problems by yourself 

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