[Pogi]

Well I am back. I had an overheating problem with my mule 3010. It is now fixed! Here is what I did... I started simple and went more complex. Initial problem mule would overheat. No radiator fan would run and air would accumulate in hard line near thermostat. Step one: checked hard lines for leaks. Found 2 pin holes in hard lines. Solution replaced hard lines and hoses. Step 2: checked radiator for air circulation and leaks. Result removed weed seeds plugging radiator fins replaced radiator cap because original had a bad gasket. Mule was still overheating. Did compression test results were 170 psi for each. This stumped me because I was thinking head gasket but the compression was normal. At this point I used multi meter and checked operation of radiator fan switch it worked ok. Step 3: replace water pump. Nothing seemed wrong with the old pump but what the heck I already had the new one so I replaced it. Still the overheating presisted! Step 4: the last and final step replace the head gaskets. This did it!!!!! Problem solved!!!! No over heating. I did check heads to see if they were in tolerance and not warped. They were less than .001 but close so gaskets are all that were required. Hope this helps some one.

 

[ddouberley]

I have a Kawasaki Mule 610 4X4 it cranks fine when it's cold but when we take it hunting and shut it off and crank it a few times it won't engage the starter it makes a sound not a clicking sound you have to turn the key a few times before it will crank again. We have replaced the solenoid on the starter, and it's still acting up!!

 

[unknwn]

My 2510 overheated and I finally removed the water pump and found it to be defective.
On mine the impellar cross pin rotted off and kept the pump from circulating. The fact that the oil got icky was a firm indicator that something more drastic than air in the system or fan difficulties was occurring.

 

[imported_cookie_monster]

I have a Kawasaki Mule 610 4X4 it cranks fine when it's cold but when we take it hunting and shut it off and crank it a few times it won't engage the starter it makes a sound not a clicking sound you have to turn the key a few times before it will crank again. We have replaced the solenoid on the starter, and it's still acting up!!

Should've started your own thread with this topic rather than hijack someone elses. But you're gonna want to check the small wire on the solenoid while it's attached to the starter via backprobing the connector. It should have 12.5v +/- 1v while the key is turned to the crank position. If low (and I suspect it will be), follow your wiring diagram from the starter back to the key switch. Chances are you find your problem either in the wiring, starter relay, or key switch.

 

[Craigmorris]

If your fan is not coming on, chances are that someone did not get the air out of the cooling system. There is a switch in the radiator that controls the fan, if no coolant is in contact with the sensor then your fan wont come on and the engine gets hot. To solve this you have to run the Mule until it gets warm and then park it on a hill with the nose up in the air. Let it cool completly down then check your coolant level on level ground. 9 out of ten times that will solve the problem. Otherwise it is a stuck thermostat. Hoever if it is diesel Mule.....Hope this helps

Does this work on a 2510 diesel 4x4 mule

 

[tatatatommy]

I have a 2003 Diesel Mule 3010 and it has been over heating. When I would drive it for about 10 minutes the water would overflow out of the coolant reservoir to the left of the steering wheel. The fan never comes on but the over heating warning light would turn on. The water pouring out of the reservoir didn’t seem hot. I tried burping the air out of the system and that didn’t work. I bought a new fan switch and a thermostat but didn’t get a chance to change them because I found out the real problem.

This is what fixed my problem. Also Another problem I had at the same time was the battery would sort of die out after about a week of use. If your mule is from the early 2000’s maybe your belt that turns the water pump and alternator is worn out and loose.

I had to raise the bed. Then removed the cage that covers the water pump fan. I’m not sure why the water pump pulley has a fan. Then I had to takeoff the shaft that runs the 4 wheel drive to get the guard off the belt. The belt was very thin. When I move the tensioner on the alternator to the max tension the belt was still loose.The belt was so loose that it was hitting the fan blades and sort of melted the plastic. I bought a new belt from my local Kawasaki dealership for $30. The serial number for the belt is Mitsubishi 90048 32100 and it matched with the old belt but the new belt had about twice the thickness. When I put on the new belt the tension was maxed out at about half way compared to the old belt being loose at the max tension on the alternator.

I test drove it and after ten minutes the fan came on and my overheating problem was finally solved. If the water pump belt is loose the water won’t circulate to the radiator and the fan won’t come on but the water will expand and leak out of the reservoir tank.

 

[WFO-KZ]

Welcome to the forum Tatatatommy and thanks for posting your solution to overheating! This could be very helpful for others. Cheers. 🍺

 

[NateH]

I have a 2003 Diesel Mule 3010 and it has been over heating. When I would drive it for about 10 minutes the water would overflow out of the coolant reservoir to the left of the steering wheel. The fan never comes on but the over heating warning light would turn on. The water pouring out of the reservoir didn’t seem hot. I tried burping the air out of the system and that didn’t work. I bought a new fan switch and a thermostat but didn’t get a chance to change them because I found out the real problem.

This is what fixed my problem. Also Another problem I had at the same time was the battery would sort of die out after about a week of use. If your mule is from the early 2000’s maybe your belt that turns the water pump and alternator is worn out and loose.

I had to raise the bed. Then removed the cage that covers the water pump fan. I’m not sure why the water pump pulley has a fan. Then I had to takeoff the shaft that runs the 4 wheel drive to get the guard off the belt. The belt was very thin. When I move the tensioner on the alternator to the max tension the belt was still loose.The belt was so loose that it was hitting the fan blades and sort of melted the plastic. I bought a new belt from my local Kawasaki dealership for $30. The serial number for the belt is Mitsubishi 90048 32100 and it matched with the old belt but the new belt had about twice the thickness. When I put on the new belt the tension was maxed out at about half way compared to the old belt being loose at the max tension on the alternator.

I test drove it and after ten minutes the fan came on and my overheating problem was finally solved. If the water pump belt is loose the water won’t circulate to the radiator and the fan won’t come on but the water will expand and leak out of the reservoir tank.

My mule is doing the same thing as your mule was. I have a 2009 4010 trans 4x4 diesel. I just replaced the battery in it two weeks ago. Battery started dying, i'd charge it up then it would work for a day or two then i'd have to jump it off again. So I changed the battery. After I changed the battery I have noticed my mule has started overheating. I will be on it for 15 minutes or so and the temp light comes on. I use this thing everyday to feed and check cows. I have noticed that the fan is not kicking on again. I went through some issues last year with the fan not kicking on. traced the wires and some of them were corroded and shorted out. Replaced fuses, fixed wiring and it started working again. So #1 I have got to check the fuses and the fan motor. If that doesn't work then what do I check? I am smelling a burnt oil smell and see the smoke coming out the tailpipe. Oil on the dipstick looks fine. Could I have a problem with the belt that turns the water pump and alternator like tatatatommy mentioned above? Any other ideas? Thanks....

 

[WFO-KZ]

It sure sounds like the same problem. I would check that belt pronto.