5 Major Hisun 400 UTV Problems and solutions 

The most common Hisun 400 utv problems are starting issues, transmission problems, clutch issues, brake issues and steering problems.

Here we explore these Hisun utv problems in detail and provide the easy solutions.

Hisun 400 utv Problems and solutions 

Now we are going to discuss the most common problems of Hisun 400 utv with their easy solutions. Also explore the Hisun 500 UTV Problems.

1. Starting Problems

Hisun UTV starting issues


Here are some problems of Hisun UTV related to the starting.  

1. Battery Issues

One of the most common reasons for starting problems is a weak or dead battery. When the battery is not providing sufficient power, the engine won’t crank, leaving you stranded. This issue is often due to poor maintenance, age, or extreme temperatures affecting battery performance.

To diagnose and resolve battery-related issues, start by performing a battery voltage check using a multimeter. A completely charged 12V battery usually shows about 12.6 volts. If the reading is below 12.4 volts, the battery likely needs charging or replacement. 

Next, charge the battery with an appropriate charger, ensuring the charging voltage does not exceed 14.4 volts to avoid overcharging and damage. If the battery still fails to hold a charge, it might be time for a battery replacement

Ensure the new battery meets the specifications required for the Hisun 400 UTV for optimal performance. For more information on battery maintenance, visit Battery University.

2. Fuel System Problems

Insufficient fuel supply is another common cause of starting issues. If the engine isn’t receiving enough fuel, it can’t start. This can be due to an empty tank, clogged fuel filter, or a malfunctioning fuel pump.

Begin by checking the fuel level in the tank, ensuring it is at least half full. This simple step can sometimes solve the issue immediately. Next, inspect the fuel filter. When a fuel filter gets blocked, it slows down the fuel going to the engine.

If you notice this, swap it out for a new one. Additionally, test the fuel pump’s pressure. It should be in the range of 2.5-3.5 psi for the Hisun 400 UTV. ‘

If the fuel pump fails to deliver this pressure, it might need replacement. For detailed guidelines on fuel system maintenance, refer to the Automotive Fuel Association.

3. Ignition System Faults

Issues with the ignition system can prevent the spark plug from igniting the fuel mixture, which is crucial for starting the engine. Broken spark plugs or ignition coils are often to blame.

First, inspect the spark plug for signs of wear and carbon deposits. The spark plug gap should be around 0.6-0.7 mm. If the spark plug looks old or broken, put in a new one.

Next, test the ignition coil’s resistance using a multimeter. The primary coil should read between 0.4-0.6 ohms, and the secondary coil should read 7-12 k ohms. 

Replace the ignition coil if the readings are outside this range. To learn more about ignition system standards, visit SAE International.

4. Starter Motor Issues

A faulty starter motor can prevent the engine from cranking, leaving the UTV immobile. This problem can stem from issues with the starter relay or the motor itself.

First, check the starter relay for continuity using a multimeter. If the relay isn’t working right, you should swap it out for a new one.

Next, inspect the starter motor. If the starter motor does not spin when voltage is applied directly to it, it may require rebuilding or replacement.

For more detailed information on diagnosing starter motor issues, check out this guide on HowStuffWorks.

5. Electrical Connections

Loose or corroded electrical connections can cause starting issues by disrupting the flow of electricity necessary for engine ignition and operation.

Start with a thorough inspection of all wiring and connections from the battery to the starter motor and ignition system. Make sure all connections are snug and don’t have any rust or buildup on them.

If you find any corroded terminals, clean them with a wire brush and apply dielectric grease to prevent future corrosion. For a comprehensive guide on electrical connections and maintenance, refer to Electrical Safety Foundation International.

2. Transmission Problems 

Hisun 400 utv transmission problems

Here are some Hisun 400 utv transmission problems. Also explore the best offroad vehicles.

Hard Shifting

  • Problem: Owners often report difficulty in shifting gears. This can be due to improperly adjusted shift cables or worn-out shift forks.
  • Solution: Adjusting the shift cables to the correct tension can alleviate this issue. If the shift forks are worn, replacing them is necessary. Regular maintenance can prevent hard shifting. According to a survey by UTV Action Magazine, 65% of users who performed regular cable adjustments reported smoother shifting.

Gear Slippage

  • Problem: Gear slippage, where the transmission unexpectedly shifts out of gear, can be alarming and dangerous. This is frequently caused by worn clutch plates or low transmission fluid levels.
  • Solution: Inspect and replace worn clutch plates and ensure the transmission fluid is at the recommended level. Using a high-quality transmission fluid can significantly reduce slippage. Data from Hisun’s maintenance guide indicates that maintaining fluid levels can reduce slippage incidents by up to 70%.

Noisy Transmission

  • Problem: Unusual noises from the transmission, such as grinding or whining, typically indicate bearing or gear issues.
  • Solution: Conduct a thorough inspection to identify and replace faulty bearings or gears. Lubricating all moving parts with the appropriate grease can also reduce noise. A study by ATV.com found that 58% of noise-related issues were resolved through proper lubrication and part replacement.

Delayed Engagement

  • Problem: A delayed response when shifting into gear can be attributed to a worn transmission belt or incorrect tension.
  • Solution: Check the transmission belt for wear and replace it if necessary. Adjust the belt tension to the manufacturer’s specifications. Hisun’s technical manuals emphasize that correct belt tension can improve engagement times by 80%.

Overheating Transmission

  • Problem: Overheating can lead to severe transmission damage and is often caused by excessive load or inadequate cooling.
  • Solution: Reduce the load to within recommended limits and ensure the cooling system is functioning correctly. Installing additional cooling fans or upgrading the cooling system can also be beneficial. Research by UTV enthusiasts shows that improving the cooling system can extend transmission life by 50%.

According to the American Society of Mechanical Engineers (ASME), proper maintenance and timely interventions can prolong the lifespan of UTV transmissions by up to 40%.

Hisun’s own technical support team recommends routine checks every 500 miles or six months, whichever comes first, to ensure optimal performance.

3. Clutch Problems

hinsun utv clutch

Here are some issues related to the clutch of you UTV. Also explore the Hisun 700 UTV Problems.

  1. Slipping Clutch: One of the most common issues is clutch slipping. This can be identified when the engine revs increase without a corresponding increase in speed. The primary cause is often worn-out clutch plates.
  2. Sticking Clutch: A sticking clutch is another frequent problem, where the clutch does not disengage properly. This can make shifting gears difficult and is usually due to dirt or debris in the clutch mechanism or a misadjusted clutch cable.
  3. Noisy Clutch Operation: If you notice unusual noises such as grinding or squealing, it could indicate a problem with the clutch bearings or a misalignment in the clutch components.
  4. Overheating: Overheating is typically caused by excessive friction within the clutch. This can be due to low-quality clutch materials or an overly tight clutch adjustment.


  1. Replacing Worn-out Plates: If the clutch is slipping, inspect the clutch plates for wear. Replacement is the most effective solution. Ensure you use high-quality parts to prevent premature wear.
  2. Cleaning and Adjustment: For a sticking clutch, thoroughly clean the clutch mechanism to remove any dirt and debris. Make sure to adjust the clutch cable so that it moves in and out smoothly without any issues.
  3. Bearing Replacement: If the clutch operation is noisy, inspect the bearings. Replacing worn bearings can eliminate the noise and prevent further damage to the clutch system.
  4. Proper Adjustment and Quality Parts: To prevent overheating, ensure the clutch is properly adjusted and use high-quality, heat-resistant materials. Regular maintenance checks can help in early identification and prevention of this issue.

Quantitative Evidence

  • According to a survey by UTV Action, about 35% of UTV owners report clutch issues within the first three years of ownership.
  • Proper maintenance, including regular inspections and timely replacement of worn parts, can reduce clutch problems by up to 50%

4. Brake Problems

Hisun 400 utv brake issues

Here are the several Hisun 400 utv brake issues.

  • Brake Fade: Brake fade is a temporary reduction in braking power due to overheating. This can occur after prolonged use, especially in demanding terrains.
  • Spongy Brakes: Spongy brakes feel soft and less responsive, often caused by air in the brake lines or low brake fluid.
  • Brake Noise: Noise from the brakes, such as squealing or grinding, usually indicates worn brake pads or contaminated brake components.
  • Brake Pull: When the UTV pulls to one side during braking, it’s often due to uneven wear of brake pads or issues with the brake calipers.


1. Addressing Brake Fade
  • Allow the brakes to cool down periodically during extended use. Upgrading to high-performance brake pads designed for heavy-duty use can also help.
  • According to industry data, high-performance pads can reduce brake fade incidents by up to 30% .
2. Fixing Spongy Brakes
  • Bleed the brake lines to remove air pockets and ensure the brake fluid is at the proper level. Regularly check and top up the brake fluid.
  • Use DOT 3 or DOT 4 brake fluid, as recommended by Hisun.

“Ensuring the brake fluid is free of air bubbles can significantly improve braking performance” (Brake Manufacturers Association) 

3. Resolving Brake Noise
  • Inspect and replace worn brake pads. Clean the brake system to remove dirt and debris. If necessary, replace contaminated components.
  • Replacing brake pads can reduce brake noise by over 80% .
4. Correcting Brake Pull
  • Check for uneven wear on brake pads and replace them in pairs. Inspect and service brake calipers to ensure they are functioning correctly.
  • Uneven brake pad wear can be mitigated by regularly rotating and inspecting the pads.

5. Steering Problems 

steering problelms of honda pioneer 700

  1. Stiff Steering: One prevalent issue is stiff or hard-to-turn steering, often caused by inadequate lubrication or worn-out steering components.
  2. Steering Wheel Vibration: Excessive vibration can indicate misaligned wheels, imbalanced tires, or worn-out bearings.
  3. Steering Pulls to One Side: If the UTV veers to one side, it might be due to uneven tire pressure, misalignment, or suspension issues.
  4. Loose Steering: This could stem from worn tie rods or steering rack issues.


Regular Maintenance and Lubrication:
  • Ensure all steering components are well-lubricated. Use high-quality grease to minimize friction.
  • Periodically inspect and replace worn-out parts like tie rods and ball joints. A study found that regular maintenance can reduce the likelihood of steering issues by up to 50% (Source: ATV Maintenance Journal, 2022).
Wheel Alignment and Tire Maintenance:
  • Misaligned wheels are a common cause of steering problems. According to the National Highway Traffic Safety Administration (NHTSA), proper wheel alignment can improve handling and extend tire life by 30%.
  • Check tire pressure regularly. Uneven tire pressure can cause the UTV to pull to one side. Make sure the tires have the right amount of air according to what the manufacturer recommends.
Bearing and Suspension Checks:
  • Worn-out bearings can cause steering vibrations. Inspect and replace bearings as needed.
  • Check the suspension system for any worn or damaged parts. Properly functioning suspension components are essential for smooth steering.
Steering Rack and Pinion Inspection:
    • The steering rack and pinion should be checked for wear and tear. A faulty rack can lead to loose steering.
    • Tighten any loose connections and replace damaged parts. Expert mechanics suggest that timely replacement of these components can prevent major steering issues (Source: UTV Mechanic Insights, 2023)


By following this guide you can easily get rid from the Hisun 400 UTV problems because here I provide the complete information about it.

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