need help with 07 mule 3010 noise.

[majkowskid]

first off, i'd like to say i'm new here, but i've been lurking for a while. TONS of great info here!

i recently purchased an 07 mule 3010 4x4 with 179 hrs on it. looks as though it has been maintained pretty well.

did all the normal maintenance... oil, fluids, etc. 4wd was out of adjustment, and i fixed that.

i've noticed that there is a rattling / vibrating noise coming from somewhere in the engine area when under hard acceleration, or climbing a hill where the rpm's go up a bit.

if i give it half throttle, it will not make the noise. if it's in neutral, and i rev the engine, it will not make the noise, only because it seems the engine will not rev high enough to do so...

i did do a slight modification to the governor, but the noise was present before this.

to me, it does not sound like valve tapping or anything like that. as the mule is speeding up, it simple reaches a certain rpm where it makes the noise for a moment, but as the rpm's climb, it goes away, like it's "passing" the rattling range. it's weird and hard to explain.

i read something on the site about a clutch pully or something making this noise possibly? could this be it?

[RCW]

179 hours is well beyond where I would run one without adjusting the valves. Be careful to use metric feelers to get the correct lash.

The clutches are sensitive to excessive clearances and belt dimensions. Hours and mileage is not as important a factor as calendar time and proper storage when not used for long periods when performing adequate maintenance and adjustment to keep them happy.

My recommendation is to do the valve adjustment, and I expect the noise will go away.

Pull the torque converter cover and check everything to be sure center to center distance, offset, and belt size are all spot on. Check your bushings, the pivot pins, etc., to make sure they are all in good shape. Then lube all the moving and sliding parts (except for what touches the belt) with Comet Clutch Lube (special molly lube that dries like a coat of paint on all the metal to metal contact points and eliminates wear. Use of clutch lube will extend the life of both torque converters significantly, and can eliminate a bit of noise from worn bushings or pivot pins as long as they are not worn beyond salvage.

[majkowskid]

thanks for the input!
last night i checked the valves. they were perfectly adjusted. i'm assuming that the previous owner actually did have them adjusted.
i checked all fluids (rear end, oil, etc) and they were all perfect as well.

as far as the converter goes, can you explain how i check this? if i'm correct, i have to remove the large plastic cover on the drivers' side of the engine compartment correct? where can i find something on how to check the enter to center distance, offset, and belt size are all in correct specs? i have the service manual for this, but i couldn't find anything on adjusting or measurements on it?

thanks again for your input!

[okieduc104]

Originally Posted by majkowskid

thanks for the input!
last night i checked the valves. they were perfectly adjusted. i'm assuming that the previous owner actually did have them adjusted.
i checked all fluids (rear end, oil, etc) and they were all perfect as well.

as far as the converter goes, can you explain how i check this? if i'm correct, i have to remove the large plastic cover on the drivers' side of the engine compartment correct? where can i find something on how to check the enter to center distance, offset, and belt size are all in correct specs? i have the service manual for this, but i couldn't find anything on adjusting or measurements on it?

thanks again for your input!

You need to order a Kawasaki repair manual for your Mule if yoy plan to do your own service and repair work. But to see what you should see go to Kawasaki.com or th the Kawasaki parts vendor that is has a link to their site on the header to this forum, and is the sponser of this site. While you are there get their phone number and call and order the repair manual. It is well worth the money for a hard copy of an original repair manual.

[majkowskid]

so i found out that my manual was incomplete. got it now! did the checks on the torque converter. all is well. belt is a perfect 33 mm.

after further investigation, i removed the bed completely. i am 90% confident that the noise at high rpm's is coming from somewhere in the bottom of the engine. i ran it for 8 hrs this weekend in the woods without hearing the rattle because i never went above half throttle on the dirt roads (bumpy). i'm still worried that something major is wrong, although there is NO symptoms besides the noise at 1/2 throttle and above.

that being said, where can i go to buy a complete replacement motor? i'd like to just go ahead and buy one to have it ready when/if this one bites the dust.

i haven't been able to find anywhere online to buy the complete motor. is there an aftermarket one somewhere that will bolt right up?

[DrPeeb]

I have the same rattle at some speeds in my '06 610. Seems to happen when I'm at top speed and let off the throttle, especially going downhill; Like maybe the belt can't keep up with the engine speed. I dunno. But since I've done all the maintenance and treated it pretty gently, and since it's never seemed to affect the operation at all, I've always figured it was just some random utility vehicle rattling at just a specific RPM range, or under a specific condition. I'd rather it wasn't there, but oh well.

The noise I hear sounds kinda like small chunks of wood, or maybe dice, rattling around in a metal or thick plastic enclosure.

[majkowskid]

that's kind of what it sounds like. like something rattling around in a metal housing. mine only happens at higher rpms, moreso when there is a load on the motor. if i put it in neutral and rev it (while overriding the governor) it will do it. when i'm driving it happens at lower rpms than when i'm in neutral, like there needs to be a load on the engine.

either way, it's annoying as hell. runs fine, but i'd hate for her to leave me stranded in the woods someday!

[okieduc104]

Originally Posted by majkowskid

first off, i'd like to say i'm new here, but i've been lurking for a while. TONS of great info here!

i recently purchased an 07 mule 3010 4x4 with 179 hrs on it. looks as though it has been maintained pretty well.

did all the normal maintenance... oil, fluids, etc. 4wd was out of adjustment, and i fixed that.

i've noticed that there is a rattling / vibrating noise coming from somewhere in the engine area when under hard acceleration, or climbing a hill where the rpm's go up a bit.

if i give it half throttle, it will not make the noise. if it's in neutral, and i rev the engine, it will not make the noise, only because it seems the engine will not rev high enough to do so...

i did do a slight modification to the governor, but the noise was present before this.

to me, it does not sound like valve tapping or anything like that. as the mule is speeding up, it simple reaches a certain rpm where it makes the noise for a moment, but as the rpm's climb, it goes away, like it's "passing" the rattling range. it's weird and hard to explain.

i read something on the site about a clutch pully or something making this noise possibly? could this be it?

A good set of earplugs solved that problem for me!

[majkowskid]

your location says you are in central texas... what part? i'm in san angelo.

that aside, did you seriously have a noise like this?

[okieduc104]

Originally Posted by majkowskid

your location says you are in central texas... what part? i'm in san angelo.

that aside, did you seriously have a noise like this?

Noise yeah! But I found that it was a missing bolt in the bed allowing the end panel to bang against the side panel at cruise speed and the tailgate was messed up which also allowed the other end of the side panel to rattle.

I bought a new tailgate in San Angelo for my Mule I found it on ebay.

I live up in Comanche County near Lake Proctor

[Irion County]

You mean they sell Mules in San Angleo?
I am in Irion County

[okieduc104]

Originally Posted by Irion County

You mean they sell Mules in San Angleo?
I am in Irion County

This vendor does not sell Mules, he sells parts for ATVs on eBay,but there should be a Kawasaki dealer somewhere around the Angelo area. If not that would be a good place to start one!
I know that there are a lot of Mules in Central Texas, also a bunch of Mule wanna-be golf carts converted to act like Mules. We also have an EZGO electric golf cart. It works very well on roads and turf. The grandkids prefer the Mule.

[mosearch]

can you recommend a source for that original repair manual? Do I NEED to go to a kawasaki dealer for it, or can I find it online?

[okieduc104]

About the repair manual. I bought and downloaded one on the internet for $9.95 There is one of my earlier threads with the URL of the vendor. I used it while I waited for the hard copy to come in from Kawasaki. I ordered it online, the Kawasaki.com site had it dropped shipped from a dealer close by, and the credit card invoice was from the dealer. I checked them page against page and they are identical. I use the one on the computer to figure out things I am going to work on and use the hard copy in the shop.