Table of Contents
Section 12 Troubleshooting
Symptoms | Probable Causes | Suggested Remedies |
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Battery is dead | Key switch is not in the off position. | Switch key to off position. |
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| Disconnect and recharge battery. |
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| Battery is worn out or defective. | Replace battery. |
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| Starter solenoid is shorted. | Replace starter solenoid. |
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Battery will not charge up | Battery connections are loose or | Clean and tighten battery connections. |
| corroded. |
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| Battery fluid level is low. | Add distilled water to battery cell. |
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| Battery cell is dead. | Replace battery. |
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| Battery is worn out or defective. |
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Brakes are sticking (won’t release) | Master cylinder linkage is out of | Adjust master cylinder linkage. |
| adjustment. |
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| Master cylinder return spring is broken. | Replace master cylinder return spring. |
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| Ground debris in brake linkage. | Clean debris from brake linkage. |
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Brakes don’t function | Master cylinder oil level is low. | Add brake fluid to the master cylinder. |
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| Brake line is broken. | Replace brake line. |
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| Brake line has air in it. | Bleed brake line and add brake fluid. |
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| Master cylinder is defective. | Replace master cylinder. |
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Electrical system does not work | Electrical fuse is blown or missing. | Replace electrical fuse. |
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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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| Ignition switch is defective. | Replace ignition switch. |
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Clutch is malfunctioning | Clutch does not engage. | Readjust clutch linkage and/or replace |
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| Clutch does not disengage. | Readjust clutch linkage and/or replace |
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| Clutch worn out. | Replace clutch. |
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Engine backfires | Spark plug is fouled. | Replace or clean spark plug. |
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| Air intake restrictor upstream of air | Replace or correctly install air intake |
| cleaner is missing or incorrectly | restrictor. |
| installed. |
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| Throttle cable is defective or out of | Clean and oil throttle cable. Replace |
| adjustment. | worn or damaged cable. |
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Engine knocks | Engine speed is set too low. | Adjust engine idle screw. |
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| Engine is overloaded. | Avoid overloading the engine. |
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| Fuel is stale or dirty. | Replace fuel with new fuel. |
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44 | 4400EX Heavy Duty Off Road Utility Vehicle | 7/01/05 |
