5-22
Problem: Spark plug electrodes overheat or burn
Condition
Remedy
1.
Spark plug
incorrect (too hot)
2.
Engine
overheats
3.
Spark plug
loose
4.
Mixture
too lean (400/650)
1. Replace plug
2. Service cooling system
3. Tighten plug
4. Adjust carburetor
Problem: Magneto does not charge
Condition
Remedy
1.
Lead wires/connections
shorted - loose - open
2.
Magneto coils
shorted - grounded - open
3.
Regulator/rectifier
defective
1. Repair - replace - tighten lead wires
2. Replace magneto coils
3. Replace regulator/rectifier
Problem: Magneto charges, but charging rate is below the specification
Condition
Remedy
1.
Lead wires
shorted - open - loose (at terminals)
2.
Stator coils (magneto)
grounded - open
3.
Regulator/rectifier
defective
4.
Electrolyte
low
5.
Cell plates (battery)
defective
1. Repair - tighten lead wires
2. Replace stator coils
3. Replace regulator/rectifier
4. Add distilled water
5. Replace battery
Problem: Magneto overcharges
Condition
Remedy
1.
Internal battery
short circuited
2.
Regulator/rectifier resistor
damaged - defective
3.
Regulator/rectifier
poorly grounded
1. Replace battery
2. Replace resistor
3. Clean - tighten ground connection
Problem: Charging unstable
Condition
Remedy
1.
Lead wire
intermittently shorting
2.
Magneto
internally shorted
3.
Regulator/rectifier
defective
1. Replace lead wire
2. Replace magneto
3. Replace regulator/rectifier
Problem: Starter button not effective
Condition
Remedy
1.
Battery charge
low
2.
Switch contacts
defective
3.
Starter relay
defective
4.
Emergency stop - ignition switch
off
5.
Wiring connections
loose - disconnected
1. Charge - replace battery
2. Replace switch
3. Replace relay
4. Turn on switches
5. Connect - tighten - repair connections
Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)
Condition
Remedy
1.
Charging rate
too low - too high
2.
Battery electrolyte
insufficient
3.
Specific gravity
too low
4.
Battery
run-down - damaged
5.
Electrolyte
contaminated
1. Replace battery
2. Keep electrolyte to prescribed level
3. Charge battery - add distilled water
4. Replace battery
5. Replace battery
Problem: Battery discharges too rapidly
Condition
Remedy
1.
Electrolyte
contaminated
2.
Specific gravity
too low
3.
Charging system
not charging
4.
Cell plates
overcharged - damaged
5.
Battery
short-circuited
6.
Specific gravity
too low
1. Replace battery
2. Charge battery - add distilled water
3. Check magneto - regulator/rectifier - circuit connections
4. Replace battery - correct charging system
5. Replace battery
6. Charge battery
Problem: Battery polarity reversed
Condition
Remedy
1.
Battery
incorrectly connected
1. Reverse connections - replace battery - repair damage
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