6 Most Common Coleman UTV 400 Problems and Effective Fixes

The Coleman UTV 400 is every outdoor enthusiast’s workhorse built for work and recreation. It’s a user-friendly utility vehicle combining additional accessories, an attractive exterior build, and an affordable price. 

The UTV’s selectable 2WD/4WD allows you to switch between the drive systems for smooth rides. However, this UTV is prone to some issues that can halt its operations. The most common Coleman UTV 400 problems are starting issues, sticky gears, clutch issues, engine stalling, rattling noises, and stability problems.

Does your Coleman 400 UTV break down from time to time? Keep reading and learn how to fix your UTV.

Won’t Start

Your Coleman UTV 400 engine might have starting problems due to poor maintenance. The engine will start after several attempts or fail to start at all. When this happens, your UTV might have one of the following issues:

  • Drained battery
  • Old fuel
  • Faulty spark plugs

Effective Fixes:

The Coleman UTV 400 uses stock batteries from Hisun Motors that need 12+ volts to start the engine. If the battery has a low voltage issue, the injector fails to pump the fuel required to start the UTV. The battery can get drained if it supports additional electronics.

So, if the UTV fails to start, test your battery’s voltage and charge it if it has less than 12 volts. Sometimes, the battery might fail to charge due to loose cables. Inspect the connections and tighten them if necessary. Then clean the terminals to clear any corrosion.

If the charging issue persists, the battery could be defective and needs replacing.

Allowing fuel to sit idle in your UTV for an extended period will cause it to degrade. The engine won’t start if the UTV has old or degraded fuel. Drain this fuel, refill the tank with fresh fuel, and add an additive to clean the lines.

If the UTV starting issue persists, remove the spark plugs and inspect them. Replace the plugs if they appear coated with oil, fuel, or coolant. If the plugs’ tips look burnt, replace them. Buy high-quality iridium plugs to replace the fouled spark plugs.

Engine Stalling

The Coleman UTV 400 engine might start properly but stall after driving for a while. Your UTV might lose power gradually, sputter, and eventually stall.

Common issues that will cause your Coleman UTV to stall are:

  • Fuel starvation
  • Dirty/clogged throttle body
  • Faulty wiring

Like many Coleman UTV 400 problems, a stalling issue occurs when you neglect routine maintenance. Below we detail how to troubleshoot stalling problems in your UTV.

Effective Fixes:

First, check the tank to ensure it has sufficient fuel. An empty tank or a low fuel level can cause the engine to stall, so refill the tank if necessary.

Fuel starvation can also occur due to a bad fuel vault valve. Examine this device to see if it allows sufficient fuel flow into the engine. A bad fuel vault valve will cause the engine to stall and should be replaced.

If your UTV stalls after resolving the fuel issue, inspect the throttle body to see if it’s dirty or gummed up. Over time, dirt, soot, and grime clog up the throttle body, causing the engine to stall. If you have a clogged or gummed-up throttle body, clean it with a throttle body cleaner.

Damaged or frayed spark plugs and battery wires might affect current flow, causing the engine to stall. Inspect these wires and replace them if frayed or broken. If you find loose cables, secure them tightly.

Sticky Gears

Some Coleman UTV 400 users experience problems when attempting to shift gears. Often, the gears will be sticky and fail to shift. Sometimes, they make a grinding noise while shifting.

When gears get stuck, they can cause the transmission to overheat and damage engine components.

If your UTV has sticking or grinding gears, it might have issues such as:

  • Insufficient gear oil
  • Dirt or debris in the transmission cover plate
  • Shift linkage adjustment problems

Effective Fixes:

The gears need sufficient lubricant to shift appropriately. If the gears stick or make a grinding noise while shifting, check for a low oil level and refill the reservoir if necessary. Old or contaminated oil will cause lubrication issues. Check the oil’s condition and replace it if it’s old, dirty, or contaminated.

Next, check for dirt or debris inside the transmission cover plate. If there’s dirt or debris lodged inside, use an air compressor to clean it.

If sticking and grinding issues persist, examine the shift linkage and adjust it correctly. Then replace any worn or broken parts, such as the lock nuts.

Stability Problems

Instability is one of the most common Coleman UTV 400 problems. The UTV feels unstable while cornering or driving at low speeds. This UTV does not have a wide turning radius and reliable steering to provide stability when cornering.

Unfortunately, this manufacturer issue will affect new and old Coleman UTV 400 models. Luckily, a few modifications can help you resolve stability problems.

Effective Fixes:

Install larger aftermarket tires to make your UTV more stable while driving. Larger tires will provide a wider turning radius to allow smooth cornering without spinning out of control.

If your UTV feels unstable while negotiating rugged terrain, install aftermarket shocks that can absorb bumps.

Rattling and Squeaking While Driving

Over time, your Coleman UTV 400 might make an unusual noise while driving. Since this UTV operates on rugged or challenging terrain, parts can become loose, rattle, and squeak.

Parts will rattle and squeak when some nuts and bolts become loose or go missing. Other possible causes of rattling and squeaking in this UTV are:

  • Worn-out rubber bushings
  • Worn-out or damaged shocks and struts
  • Insufficient lubricant in moving parts

Effective Fixes:

Examine the bolts and nuts on various parts, such as the tailgate, dump bed, cage, and seat. If you find loose nuts and bolts, tighten them fully. If some bolts and nuts are missing, install new ones.

Next, check the rubber bushings and replace them if worn or damaged. You’ll also need to replace worn or damaged shocks and struts that cause the UTV to squeak and rattle.

Lastly, inspect the moving parts to see if they’re well-lubricated. If not, check the oil level and refill the reservoir with high-quality oil. If you find worn or broken moving parts, replace them.

Clutch Problems

The Coleman UTV 400 uses a wet clutch that can fail over time. While this clutch helps prolong the transmission’s life, parts can wear out or get damaged due to excessive use.

You can notice clutch failure if the UTV moves slower while revving. This issue occurs due to worn or damaged clutch shoes that cause the clutch to slip. Other causes of clutch failure in your UTV are:

  • Worn or broken clutch disc
  • Weak or broken clutch springs
  • Driving at low speeds while in high gear
  • Hauling heavy loads in high gear

Effective Fixes:

If the clutch is acting up, remove the clutch assembly and check for worn or broken parts. Replace worn or damaged clutch shoes and the clutch disc. If the clutch springs are weak, the clutch will slip due to a lack of proper tension. So, replace the springs if they appear weak or broken.

After fixing the clutch, add high-quality oil for wet clutches to lubricate the parts. Then, avoid driving at low speeds or hauling heavy loads while in high gear.

Coleman UTV 400 problems

Are Coleman UTV 400 Problems a Deal Breaker?

Despite having several problems, the Coleman UTV 400 is a tried-and-tested partner around farms and plains. Its engine is powerful to tackle even the most challenging terrains or haul heavy objects.

Thankfully, this article saves you much trouble if you encounter Coleman UTV 400 issues. Troubleshoot each problem as detailed above to enjoy the most out of your UTV. Lastly, avoid neglecting your UTV’s routine maintenance, as this will prevent most issues from occurring.