Table of Contents
Section 11: Troubleshooting
Symptoms | Probable Causes | Suggested Remedies |
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Engine starts in gear | Clutch switch is improperly adjusted. | Adjust clutch switch to be engaged |
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| with clutch fully down. |
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Engine stops running | Gas tank is empty. | Refill gas tank. |
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| Spark Plug wiring is defective. | Replace spark plug wiring. |
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| Ignition switch is defective. | Replace ignition switch. |
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| Battery is worn out or defective. | Replace battery |
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| Crankshaft is broke. | Replace broken crankshaft. |
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Gear Shift is malfunctioning | Clutch is not fully depressed. | Fully depress clutch. |
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| Clutch plate does not release. | Adjust clutch linkage |
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| Shift linkage is out of adjustment. | Adjust shift linkage. |
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| Synchronizer is defective. | Replace synchronizer. |
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| Transmission jumps out of gear. | With gear shift in neutral, adjust shifter |
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| link at transmission to be in neutral |
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| position. |
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Park brake doesn’t work | Park brake cable is broken. | Replace park brake cable. |
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| Park brake cable is jammed with debris. | Clean debris from park brake cable. |
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| Park brake is out of adjustment. | Adjust knob on end of park brake lever |
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| clockwise to tighten brake tension and |
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| counterclockwise to loosen brake |
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| tension. |
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Starter cranks slowly | Battery power is low. | Recharge battery. |
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| Battery connections are loose or | Clean and tighten battery connections. |
| corroded. |
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| Battery is worn out or defective. | Replace battery. |
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| Harness connections are loose. | Reconnect harness connections. |
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| Harness pin connections are bent. | Straighten harness pins. |
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| Harness is defective. | Replace harness. |
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| Ignition switch is defective. | Replace ignition switch. |
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| Starter is defective. | Replace starter. |
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| Engine oil is too heavy. | Replace with SAE 10W30 oil. |
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6/30/05 | 4400EX Heavy Duty Off Road Utility Vehicle |