35
16599 rev. B pub. 11/07/2017
section 5
troubleshooting
Fuel in the Cylinder Cavity
(applies only to single
cylinder engines)
In the event that the fuel valve is left open while transporting or towing this Utility
Vehicle it is possible that fuel has leaked down into the cylinder cavity . If this has
occurred the engine will not start . With the cylinder cavity full of fuel the engine
will feel like it has “locked up” . At right are the proper steps to follow if your Utility
Vehicle engine seems to have fuel in the cylinder cavity .
1 . Move the vehicle to a well ventilated area, away from sparks or flame .
2 . Park Vehicle on a level surface, set park brake, turn off ignition switch, and
remove key .
3 . Remove the wire connected to the spark plug and remove the spark plug
from the engine . (See figure 5 .1)
4 .
WARNING:
Stand away from the spark plug hole when performing step 5 . Fuel
can spray several feet .
5 . Wearing eye protection, slowly pull the recoil start grip handle (See figure 5 .xx)
in an upward motion . This should force the fuel out of the cylinder cavity through
the spark plug hole .
Caution: This gasoline spraying out of the
cylinder cavity is very flammable, use extreme caution and
make sure there are no sparks or flames nearby.
6 . Repeat step 3 until only air escapes out of the spark plug hole .
7 . Properly replace the spark plug back into the cylinder head, move the vehicle
away from any spilled fuel . If there is fuel on the vehicle itself, allow for it to
evaporate before continuing .
8 . Connect the plug wire . Your Utility Vehicle is now ready to start .
SYMPTOMS
DEAD BATTERY
PROBABLE CAUSES
SUGGESTED REMEDIES
Key switch left on
Bad battery
Shorted starter solenoid
Turn key off, recharge battery
Replace battery
Replace starter solenoid
ENGINE KNOCKS
Engine idle speed too low
Overloaded engine
Stale or dirty fuel
Adjust engine idle (see engine manual)
Avoid overloading engine
Replace fuel with new fuel
ENGINE BACKFIRES
Fouled sparkplug
Missing or incorrectly installed air intake restrictor
Throttle cable is defective or out of adjustment
Replace or clean sparkplug
Replace or correctly install air intake restrictor
Clean and lubricate or replace cable
ENGINE SHUTS DOWN WHILE TURNING,
ON INCLINES, OR ON UNEVEN TERRAIN
Low engine oil
Oil sensor is bad (if equipped)
Check oil level with unit on level ground
Low tire pressure
Inflate tires to proper levels
(12 p.s.i. recommended for full size UTVs)
Get low oil sensor changed by authorized
engine manufacturer service center
STEERING FEELS FUNNY / PULLING TO
ONE SIDE / HARD TO STEER
(CALL NORMALLY FOR 4WD)
One side may still be engaged in
4WD with the switch off
One side may still be engaged in
4WD with the switch off
Put unit in reverse and back up straight a few feet
to get the axle to release
Take unit to a service center
BRAKES DONT WORK WELL / HARD
TO PUSH / NO TRAVEL IN PEDAL
Brake rotors are dirty
Brakes are out of adjustment
Clean rotors with brake cleaner and test.
Put unit in reverse, back up at low speed and step
hard on the brake (2WD units have an auto brake adjuster)
ELECTRICAL SYSTEM NOT WORKING
Blown or missing fuse
Loose or corroded battery connection
Worn out or defective battery
Replace fuse
Clean and tighten connections
Replace battery
Defective ignition switch
Bad connection in wire harness
Replace ignition switch
Repair or replace wire harness
BATTERY WON’T CHARGE
Loose or corroded battery connection
Defective voltage regulator
Dead battery cell
Clean and tighten connections
Bad magneto on engine
Contact engine manufacturer service center
Contact local service center
Turn key on and pull rope to start engine (if equipped).
Replace battery as soon as possible
Worn out or defective battery
Turn key on and pull rope to start engine (if equipped).
Replace battery as soon as possible
4WD
2WD
BELT SLIPPING / WILL NOT PULL
UPHILL
Too much weight - bed / cab / towing
The belt is wet
Torque converter pulleys are dirty
Lighten load
Dry the belt
Belt may have stretched or have a
low spot causing slipping
Replace the belt
Clean the torque converter
Use EXTREME CAUTION when performing the activity
below. Gasoline is EXTREMELY FLAMABLE!
WARNING
section 5
troubleshooting
