The most common Bennche Bighorn 400 problems are shifting trouble caused by worn clutches, CVT belt wear, fuel pump failure after storage, stalling and idle problems, electrical faults and overheating. Most can be traced with simple checks, but clutch problems usually mean parts, so it’s worth diagnosing them correctly first.
The Bighorn 400 is a mid-size utility side-by-side. Spec listings for the 2014 model show a 392cc liquid-cooled, single-cylinder, fuel-injected engine, a CVT with high, low and reverse, selectable 2WD/4WD with a differential lock, and a 7.6-gallon fuel tank.
Bennche Bighorn 400 Problems at a Glance
| Problem | Common symptom | Most likely cause | First fix to try | Part you may need |
|---|---|---|---|---|
| Won’t shift while running | Can’t change gears with the engine on | Worn or damaged CVT clutches, high idle | Check idle, inspect clutches | Clutches, belt |
| CVT belt wear | Slipping, burnt smell | Worn belt, high range under load | Inspect belt, use low range | Drive belt |
| Fuel pump failure | Cranks, no fuel after sitting | Stale fuel, failed pump | Check pump and fuse, fresh fuel | Fuel pump, filter |
| Stalling / idle problems | Stalls when cold or under throttle | Dirty throttle body, sensor or wiring fault | Clean throttle body, scan codes | Sensors |
| Electrical faults | Dead dash, accessories off | Corroded connectors, weak battery | Clean and grease connectors | Fuses, relays |
| Overheating | Temp light, fan always on | Mud-packed radiator, low coolant | Clean radiator, top up coolant | Coolant |
1. Won’t Shift With the Engine Running
A Bighorn 400 owner could start the machine in gear and drive it, but couldn’t change gears while the engine was running, even after lowering the idle. Another owner with a 2013 Bighorn work model had the same problem. A dealer replaced the front and rear clutches and the drive belt, which cost about $1,000. That owner said grinding in reverse points to the rear clutch, while grinding in forward points to the front clutch.
- Make sure the idle isn’t too high and always shift at a full stop with the brake on.
- Check the shift cable and linkage adjustment first, since this is the cheapest fix.
- Note when it grinds (forward, reverse or both) to help find which clutch is at fault.
- Open the CVT cover and inspect the clutches, springs and belt.
Parts you may need: primary and secondary clutch parts, drive belt, shift cable.
2. CVT Belt Wear
- Use low range for towing, hauling and climbing.
- Inspect the belt for glazing and cracks at each service.
- Keep the CVT intake clear and dry the belt case after water crossings.
3. Fuel Pump Failure After Storage
On other fuel-injected Bennche models, owners report fuel pumps that work erratically or stop delivering fuel after the machine sits for a long time. Before replacing the pump, listen for it to prime when you turn the key, and check its fuse, relay and voltage with a digital multimeter. Use fresh fuel with fuel stabilizer if you plan to store it.
Parts you may need: fuel pump, fuel filter, relay.
4. Stalling and Idle Problems
- Clean the throttle body and check the air filter.
- Look for loose or corroded sensor connectors.
- Have the dealer read fault codes before you replace sensors.
5. Electrical Faults
Clean the battery terminals, check fuses and relays, and protect connectors with dielectric grease. Keep the battery on a battery maintainer during storage.
6. Overheating
Rinse mud out of the radiator from the back side, and check the coolant level when the engine is cold, topping it up with 50/50 coolant. Make sure the fan turns on when the engine gets hot.
Maintenance That Prevents Most Bighorn 400 Problems
| How often | What to do |
|---|---|
| After muddy rides | Rinse radiator, check CVT housing, clean air filter |
| Monthly | Check coolant, oil, battery, tire pressure |
| Per owner’s manual | Oil and filter, belt and clutch inspection, valve clearance |
| Before storage | Fresh fuel with stabilizer, battery maintainer |
Frequently Asked Questions
What engine is in the Bennche Bighorn 400?
Spec listings for the 2014 model show a 392cc liquid-cooled, fuel-injected single-cylinder engine with a CVT.
Why won’t my Bighorn 400 shift while running?
Check the idle speed and shift linkage first. If it still won’t shift, worn or damaged CVT clutches are a common cause.
Is there a recall on the Bennche Bighorn 400?
We did not find a CPSC recall for the Bighorn 400 at the time of writing. Check the CPSC website or ask a dealer with your VIN.
Are Bighorn 400 parts easy to find?
Bennche UTVs are built in China and parts are usually ordered through dealers or online, so some parts may take time to arrive.
Conclusion
Shifting and clutch problems are the most expensive Bennche Bighorn 400 issues, so check the cheap causes first. Regular belt, cooling and electrical care prevents most of the other problems.
Related guides: Bennche Bighorn models · Bennche UTV problems · CFMoto UForce 600 problems
