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7/14/08
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Section 11: Troubleshooting
4400EX Heavy Duty Off Road Utility Vehicle 720-051M
Table of Contents
Section 11: Troubleshooting
Symptoms Probable Causes Suggested Remedies
Battery is dead
Key switch is not in the off position. Switch key to off position.
Disconnect and recharge battery.
Battery is worn out or defective. Replace battery.
Starter solenoid is shorted. Replace starter solenoid.
Battery will not charge up
Battery connections are loose or
corroded.
Clean and tighten battery connections.
Battery fluid level is low. Add distilled water to battery cell.
Battery cell is dead. Replace battery.
Battery is worn out or defective.
Brakes are sticking (won’t release)
Master cylinder linkage is out of
adjustment.
Adjust master cylinder linkage.
Master cylinder return spring is broken. Replace master cylinder return spring.
Ground debris in brake linkage. Clean debris from brake linkage.
Brakes don’t function
Master cylinder oil level is low. Add brake fluid to the master cylinder.
Brake line is broken. Replace brake line.
Brake line has air in it. Bleed brake line and add brake fluid.
Master cylinder is defective. Replace master cylinder.
Electrical system does not work
Electrical fuse is blown or missing. Replace electrical fuse.
Battery connections are loose or
corroded.
Clean and tighten battery connections.
Battery is worn out or defective. Replace battery.
Ignition switch is defective. Replace ignition switch.
Clutch is malfunctioning
Clutch does not engage. Readjust clutch linkage and/or replace
throw-out bearing.
Clutch does not disengage. Readjust clutch linkage and/or replace
throw-out bearing.
Clutch worn out. Replace clutch.
Engine backfires
Spark plug is fouled. Replace or clean spark plug.
Air intake restrictor upstream of air
cleaner is missing or incorrectly
installed.
Replace or correctly install air intake
restrictor.
Throttle cable is defective or out of
adjustment.
Clean and oil throttle cable. Replace
worn or damaged cable.
Engine knocks
Engine speed is set too low. Adjust engine idle screw.
Engine is overloaded. Avoid overloading the engine.
Fuel is stale or dirty. Replace fuel with new fuel.