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Problem: Engine noisy (Noise seems to come from clutch)
Condition
Remedy
1.
Clutch shoe(s)
worn
2.
Driven clutch hub
warped - worn
1. Replace clutch shoe(s)
2. Replace clutch
Problem: Engine noisy (Noise seems to come from crankshaft)
Condition
Remedy
1.
Bearing
worn - burned
2.
Lower rod-end bearing
worn - burned
3.
Connecting rod side clearance
too large
4.
Engine oil
low - incorrect grade
1. Replace bearing
2. Replace bearing
3. Replace thrust washer(s)
4. Fill crankcase with recommended engine oil
Problem: Engine idles poorly
Condition
Remedy
1.
Magneto
defective
2.
CDI unit
defective
3.
Spark plug
fouled -
gap
too wide
4.
Ignition coil
defective
5.
Float
level
out of adjustment
6.
Carburetor jets
obstructed
7.
Pilot screw setting
improper
1. Replace magneto
2. Replace CDI unit
3. Adjust gap - replace plug
4. Replace ignition coil
5. Adjust float height
6. Clean jets
7. Adjust pilot screw
Problem: Engine runs poorly at high speed
Condition
Remedy
1.
Spark plug gap
too narrow
2.
Ignition coil
defective
3.
Float level
too low
4.
Air cleaner element
obstructed
5.
Fuel hose
obstructed
6.
Carburetor jets
obstructed
7.
Air filter inlet pipe
obstructed
1. Adjust gap
2. Replace ignition oil
3. Adjust float arm height
4. Clean element
5. Clean - prime hose
6. Clean jets
7. Remove obstruction
Problem: Exhaust smoke dirty or heavy
Condition
Remedy
1.
Piston rings - cylinder
worn
2.
Cylinder wall
scored - scuffed
3.
Crankcase
over-full of oil
4.
Air filter
too much air filter element oil
5.
Carburetor jets
incorrect size (too big)
1. Replace - service rings - cylinder
2. Replace - service cylinder
3. Drain excess oil from crankcase - recheck oil level
4. Use recommended type and quantity air filter element oil
5. Use recommended carburetor jets
Problem: Engine lacks power
Condition
Remedy
1.
Piston ring(s)
- cylinder
worn
2.
Spark plug
fouled
3.
Spark plug gap
incorrect
4.
Carburetor jets
obstructed
5.
Float level
out of adjustment
6.
Air filter element
obstructed
7.
Intake manifold
leaking air
8.
Brake(s)
dragging
9.
Drive axle
bent - worn bearings
10.
Drive chain - sprockets
stretched - worn
1. Replace - service rings - cylinder
2. Clean - replace plug
3. Adjust gap - replace plug
4. Clean jets
5. Adjust float arm height
6. Clean element
7. Tighten - replace manifold
8. Adjust brake(s)
9. Straighten - replace axle
10. Replace sprocket - chain
Problem: Engine overheats
Condition
Remedy
1.
Carbon deposit (piston crown)
excessive
2.
Engine oil
low
3.
Octane
low -
gasoline
poor
4.
Oil pump
defective
5.
Oil filter/screen
obstructed
6.
Float level
low
7.
Intake manifold
leaking air
8.
Air filter element
obstructed
1. Clean piston
2. Add engine oil
3. Drain - replace gasoline
4. Replace pump
5. Clean filter/screen
6. Adjust float arm height
7. Tighten - replace manifold
8. Clean element
Manual
Table of Contents
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