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Section 11: Troubleshooting

Section 11: Troubleshooting

Symptoms Battery is dead

Battery will not charge up

Brakes are sticking (won’t release)

Brakes don’t function

Electrical system does not work

Clutch is malfunctioning

Engine backfires

Engine knocks

7/14/08

Table of Contents

Probable Causes Key switch is not in the off position.

Suggested Remedies

Switch key to off position. Disconnect and recharge battery.

Battery is worn out or defective. Starter solenoid is shorted.

Replace battery. Replace starter solenoid. Clean and tighten battery connections.

Battery connections are loose or corroded.

Battery fluid level is low. Battery cell is dead. Battery is worn out or defective.

Add distilled water to battery cell. Replace battery.

Master cylinder linkage is out of adjustment.

Adjust master cylinder linkage.

Master cylinder return spring is broken. Ground debris in brake linkage. Master cylinder oil level is low. Brake line is broken. Brake line has air in it. Master cylinder is defective. Electrical fuse is blown or missing.

Replace master cylinder return spring. Clean debris from brake linkage. Add brake fluid to the master cylinder. Replace brake line. Bleed brake line and add brake fluid. Replace master cylinder. Replace electrical fuse. Clean and tighten battery connections.

Battery connections are loose or corroded.

Battery is worn out or defective. Ignition switch is defective. Clutch does not engage.

Replace battery. Replace ignition switch.

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. Spark plug is fouled.

Replace clutch. 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 speed is set too low. Engine is overloaded. Fuel is stale or dirty.

Adjust engine idle screw. Avoid overloading the engine. Replace fuel with new fuel.

4400EX Heavy Duty Off Road Utility Vehicle 720-051M

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