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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
Engine starts in gear
Clutch switch is improperly adjusted. Adjust clutch switch to be engaged
with clutch fully down.
Engine stops running
Gas tank is empty. Refill gas tank.
Spark Plug wiring is defective. Replace spark plug wiring.
Ignition switch is defective. Replace ignition switch.
Battery is worn out or defective. Replace battery
Crankshaft is broke. Replace broken crankshaft.
Gear Shift is malfunctioning
Clutch is not fully depressed. Fully depress clutch.
Clutch plate does not release. Adjust clutch linkage
Shift linkage is out of adjustment. Adjust shift linkage.
Synchronizer is defective. Replace synchronizer.
Transmission jumps out of gear. With gear shift in neutral, adjust shifter
link at transmission to be in neutral
position.
Park brake doesn’t work
Park brake cable is broken. Replace park brake cable.
Park brake cable is jammed with debris. Clean debris from park brake cable.
Park brake is out of adjustment. Adjust knob on end of park brake lever
clockwise to tighten brake tension and
counterclockwise to loosen brake
tension.
Starter cranks slowly
Battery power is low. Recharge battery.
Battery connections are loose or
corroded.
Clean and tighten battery connections.
Battery is worn out or defective. Replace battery.
Harness connections are loose. Reconnect harness connections.
Harness pin connections are bent. Straighten harness pins.
Harness is defective. Replace harness.
Ignition switch is defective. Replace ignition switch.
Starter is defective. Replace starter.
Engine oil is too heavy. Replace with SAE 10W30 oil.
Symptoms Probable Causes Suggested Remedies