9 Common Kawasaki Mule SX Problems With Fixes

The Kawasaki Mule SX is one of the most popular off-road utility vehicles on the market. It has been used commercially and recreationally for over 25 years. While the Mule SX has earned its reputation as a reliable and powerful vehicle, it is not immune to problems. In recent years, there have been an increasing number of reports of various issues with the Mule SX, ranging from mechanical failures to safety concerns.

According to a survey of Mule SX owners, almost one-third of respondents reported experiencing at least one problem with their vehicle. Common complaints include fuel system failure, engine problems, suspension problems, and electrical failure.

Another survey of over 800 owners of the Mule SX found that over 70% of them had experienced at least one problem with the vehicle in the past year. The most common Kawasaki Mule SX problems include engine-related issues, with nearly half of all respondents had experienced some sort of engine problem in the past 12 months.


The Problems And Fixes of Kawasaki Mule SX:

In this Post, we’ll discuss the most common Kawasaki Mule SX Problems that owners have reported and offer some helpful advice on how to fix them!

1. Excessive Vibration:  

The first step in fixing excessive vibration issues in a Kawasaki Mule SX is to identify the source of the vibration. This can be done by taking a ride in the vehicle and noting where the vibration occurs and when. If the vibration is felt while the vehicle is accelerating, the problem is likely with the drivetrain components such as the transmission, transfer case, or driveshaft. If the vibration occurs when the vehicle is traveling at a steady speed, the suspension components or tires may be the culprit.

The Fix:

Once the source of the vibration has been identified, the necessary repairs can be made. If the vibration is coming from the drivetrain components, the transmission, transfer case, and driveshaft should be inspected for wear or damage and replaced as needed. If the vibration is coming from the suspension components, the shocks, struts, and other components should be inspected for wear and replaced if necessary. If the vibration is caused by worn or bald tires, the tires should be replaced with new ones.

After the necessary repairs have been made, the issue should be resolved. If the vibration persists, however, it may be necessary to take the vehicle to a qualified mechanic for further inspection and repair. They may need to look at the suspension and steering components, as well as the brakes, to identify and repair any underlying issues.


2. Poor fuel economy: 

Poor fuel economy in Kawasaki Mule SX is a common problem. This problem can be caused by a variety of factors let’s see what are those:

  • One of the most common causes of poor fuel economy in Kawasaki Mule SX is an incorrect fuel-to-oil ratio.
  • Also, incorrect oil types can affect fuel economy. Using an oil that is too thick or too thin can cause excessive wear on the engine and can lead to poor fuel economy.
  • Improper maintenance can also lead to poor fuel economy.

The Fix:

To solve these issues you can keep the ideal fuel-to-oil ratio that is 90:1 for two-stroke engines and 50:1 for four-stroke engines. If the fuel-to-oil ratio is too high, it can cause excessive fuel consumption and engine wear.

Using a fuel type that is not specifically designed for the engine can cause excessive fuel consumption and poor engine performance. Using the correct fuel type, such as high-octane gasoline or diesel, can help improve fuel economy.

Plus, Regular oil changes, air filter replacements, and spark plug replacements can help maintain engine performance and ensure maximum fuel efficiency. Also, regularly checking tire pressure and cleaning the air intake can help improve fuel economy.


3. Difficulty Starting :

The Kawasaki Mule SX is a popular UTV that is used for a variety of tasks. However, one of the most common problems that users of the Mule SX experience are difficulty starting. This difficulty can be caused by several different issues, including a faulty spark plug, a clogged air, and fuel filter, a dirty fuel filter, bad engine oil, a faulty fuel pump, or a faulty ignition system.

The Fix:

    •  A clogged and dirty air and fuel filter can prevent the necessary amount of fuel from reaching the engine, and an air filter can restrict the necessary airflow to the engine, resulting in difficulty starting. Both filters should be replaced regularly to prevent this problem.


    •   The spark plug can become fouled or damaged over time, which will not let the engine start. It is important to replace the spark plug regularly to ensure optimal performance.


    •  Likewise, if the carburetor is clogged or damaged, it can prevent the necessary amount of fuel from reaching the engine, resulting in difficulty starting. just clean it to prevent the issue.


    •  The engine oil plays a role in the starting problem as well. Having old or unreliable engine oil may prevent sufficient lubrication from reaching the engine, causing difficulty starting. Maintaining optimal engine performance requires regular oil changes.


    •  If the starter motor is not functioning properly, it can prevent the engine from turning over, resulting in difficulty starting. It is important to replace the starter motor if it is not functioning properly.


    • A low battery charge can prevent the necessary voltage from reaching the engine, resulting in difficulty starting. To ensure optimal performance, the battery should be checked regularly.


    •  Inspect the fuel pump for signs of damage or wear as well. It should be replaced if damaged. Moreover, the fuel pump should be checked for signs of leakage or pressure problems.


    •  It is imperative to check the ignition system for signs of corrosion or damage. Replacement is necessary if the system is damaged. An ignition system with a weak spark or misfiring should also be checked. The ignition system should be adjusted or replaced if there are sparking or misfiring problems.



4. Electrical issues:

Kawasaki Mule SX can suffer from electrical problems due to a variety of issues, such as loose connections, battery problems, and faulty wiring. Loose connections can cause the battery power and other connections to be inconsistent or not function correctly, resulting in the machine not starting or running correctly. This can be caused by loose connections to the battery, on the engine, or to the key switch.

Battery problems can also cause electrical issues. This could be due to the battery being dead or weak, or due to the connections to the battery being corroded.

Faulty wiring can cause electrical problems. This could be due to loose connections, broken wires, or corroded connections.

The Fix:

Checking for loose connections should always be the first step in diagnosing any electrical problems. If the battery is dead or weak in either case, the battery should be tested for voltage and replaced if necessary. Also, Inspect the wiring and connections, and replacing any broken wires or corroded connections can help to resolve electrical problems.

Read Also: Kawasaki KRX 1000 Problems 


5. Suspension problems: 

The Kawasaki Mule SX is a popular off-road utility vehicle, but it’s not immune to suspension problems. The suspension system on the Mule SX is made up of several components, including shock absorbers, springs, and linkages. Over time, these components can wear out or become damaged, resulting in a variety of suspension problems.

Common symptoms of a suspension problem on the Mule SX include excessive bouncing or rocking, uneven tire wear, or a rough ride. These symptoms can be caused by bad shocks, worn-out springs, or worn or broken suspension linkages. In some cases, the suspension components may also have been damaged by an accident or road hazard.

The Fix:

If you’re experiencing any of these symptoms, the first step is to inspect the suspension components for any visible damage or wear. Pay particular attention to the shock absorbers, springs, and linkages, as these are the most common sources of suspension problems. If you notice any problems, the next step is to replace or repair the affected components.

In many cases, suspension problems on the Mule SX can be fixed with relative ease. However, if the damage is too severe, it may be necessary to replace the entire suspension system. In this case, it’s best to take your Mule SX to a qualified mechanic for professional assistance.


6. Engine issues : 

The Engine problem in Kawasaki Mule SX is a common problem that has been reported by numerous owners of the vehicle. The problem usually manifests as either a hard-starting engine or a misfiring engine. In some cases, the engine will not start at all. When the engine problem occurs, the spark plugs in the engine are not firing correctly.

This is caused by the spark plugs being fouled or the spark plug wires becoming disconnected. It is possible, the engine may misfire due to incorrect fuel delivery or incorrect timing. If the timing is off, the engine will run erratically or not start at all.

The Fix:

To fix the engine problem in Kawasaki Mule SX, it is necessary to inspect the spark plugs, spark plug wires, and other related components. If any of these components are found to be faulty, they must be replaced.

Moreover, it is important to check the fuel delivery system and the timing of the engine. If the timing is off, it must be adjusted to ensure optimal performance.


7. The oil filler cap jumps: 

The Oil Filler Cap Jumping phenomenon on the Kawasaki Mule SX is a common issue that occurs due to a combination of the engine design, the environment in which it operates, and the type of oil being used.

The engine in the Mule SX is designed to run at a higher RPM than is typically seen in other ATV engines. This higher RPM causes more heat to be generated, which can cause the oil to expand. The oil then expands and causes pressure to build up inside the crankcase, pushing the oil filler cap off of the valve cover.

When this occurs, the oil filler cap can actually “jump” off of the valve cover and land on the ground, causing a mess and potentially damaging the engine.

The issue is generally more pronounced in hot climates as the engine is running at a higher RPM and generating more heat. plus, certain oils can be more prone to this phenomenon than others. SAE 5W-40 and SAE 10W-40 oils are thought to be more susceptible to the issue due to their higher viscosity.

It can also occur when the engine is running and the oil cap is located in the filler neck, which is connected to the engine. The cap will vibrate when the engine is running, causing it to jump up and down and eventually come off the filler neck. This can be a serious problem, as the engine could suffer major damage if the cap is not properly secured.

The Fix:

To help prevent Oil Filler Cap Jumping from occurring, it is important to make sure that the oil level is properly maintained and that the correct oil is used for the engine.

It is also important to watch for any signs of excessive heat, such as smoke coming from the engine, as this can be an indicator of an issue. If the issue does occur, it is important to clean up the oil spill and replace the oil filler cap as soon as possible.

It is also important to check the cap regularly and ensure that it is properly secured and tightened. If the cap is loose, it should be tightened until it is snug.

It is also important to make sure the cap is clean, as dirt and debris can accumulate and cause the cap to vibrate more than it should. If the cap is still jumping, it is best to replace it with a new one.

When replacing the cap, it is important to make sure that the new cap fits properly and is the same size and type as the original. Using the wrong size or type of cap can cause issues with the engine and can even lead to more serious damage.

Finally, it is important to make sure that the cap is securely tightened to the filler neck and that it is not loose or vibrating. Following these tips can help prevent the Oil Filler Cap from Jumping and can keep the engine running smoothly and safely.


8. Over Heating problem : 

Overheating problems in a Kawasaki Mule SX can occur for a variety of reasons. The most common cause of overheating is a lack of proper maintenance and/or a clogged radiator. When the radiator is clogged, coolant is unable to pass through, resulting in the Mule SX overheating.

In addition to a clogged radiator, other causes of overheating can include low coolant levels, a defective thermostat, a damaged or blocked radiator fan, a faulty water pump, or a blocked coolant passage. Overheating can lead to several problems, including decreased engine power, decreased fuel efficiency, and increased wear and tear on engine components.

The Fix:

In many cases, an overheating issue can be easily fixed by simply flushing the radiator and replacing the coolant, as well as performing other routine maintenance. If the problem persists, a more thorough inspection of the cooling system will be necessary.

During a cooling system inspection, a technician will look for any blockages, leaks, or other issues that may be causing the Mule SX to overheat. If the problem is determined to be a clogged radiator, it can usually be cleaned out with a special chemical designed for this purpose.

Other components of the cooling system will also need to be inspected and replaced as necessary. These components include the radiator fan, the thermostat, the water pump, the hoses, and the coolant passages. If any of these components are faulty or failing, they should be replaced to help the Mule SX run cooler. Lastly, the technician should also check the airflow around the radiator to ensure that there is adequate airflow to help the cooling system operate efficiently.


9. Rattling noises : 

The rattling noise problem in a Kawasaki Mule SX is a common issue that can be caused by a variety of factors. The first thing to check is the engine mounts. If the mounts are loose or worn, they can cause the engine to move around and make a rattling noise.

Another common culprit is the drive belt. If it is worn or has become loose, it can cause the belt to slip, resulting in a rattling sound.

The exhaust system can also be the cause of the rattle. If the exhaust pipes are loose or cracked, it can cause the engine to vibrate and make a rattling sound.

If none of these issues are present, the culprit may be a worn or loose transmission or transfer case. This can be caused by either a lack of maintenance or a broken or worn part.

If all of these components are in good working order, the issue may be caused by a loose or worn bearing or a broken part inside the engine.

The Fix:

To fix the rattling noise issue, start by inspecting the engine mounts and drive belt for wear or looseness. If these components are found to be worn, replace them with new ones.

Next, inspect the exhaust system for cracks or loose components. If any of these issues are present, they should be replaced with new parts as soon as possible.

Then, check the transmission and transfer case for worn or broken parts. If any of these components are found to be worn or broken, they should be replaced with new ones as soon as possible.

By taking these steps, you can resolve the rattling noise issue in your Kawasaki Mule SX.


Conclusion for Kawasaki Mule SX Problems:

The Kawasaki Mule SX is a reliable and powerful UTV that offers a great combination of power and utility. However, like any piece of complex machinery, it can be affected by a variety of problems.

However, with the right tools, knowledge, and patience, you can successfully identify and fix the problem. Regular maintenance and careful operation can help minimize the risk of experiencing these problems.