51
8. Connect the gasline hose (A) to the carburetor; then
connect the crankcase breather hose (B) to the air fil-
ter housing.
YT004A
9. Connect the gear shift position switch connectors to
the main harness and secure to the frame with a
nylon tie.
10. Install the left-side footwell mounting plate to the
frame; then install the left and right footwells and
secure to the mountings and fenders. Tighten all
hardware securely.
11. Pour the recommended quantity of engine oil into the
crankcase; then install the level stick and fill the
transmission with the recommended amount of gear
lubricant. Install the level plug and fill plug.
TR028A
12. Start the engine and check for any fluid leaks. After a
short “test-ride,” shut off the engine and check the
fluid levels. Add fluids as required.
Troubleshooting
Problem: Engine will not start or is hard to start (Compression too low)
Condition
Remedy
1.
Piston rings
worn excessively
2.
Cylinder bore
worn
3.
Spark plug
seating poorly
4.
Starter motor
cranks too slowly - does not turn
5.
Valves
burned -
tappets
adjusted too tight
1. Replace rings
2. Replace - rebore cylinder
3. Tighten plug
4. See Electrical System section
5. Replace valves - adjust tappets
Problem: Engine will not start or is hard to start (No spark)
Condition
Remedy
1.
Spark plug
fouled
2.
Spark plug
wet
3.
Magneto
defective
4.
CDI unit
defective
5.
Ignition coil
defective
6.
High-tension lead
open - shorted
1. Clean - replace plug
2. Clean - dry plug
3. Replace magneto
4. Replace CDI unit
5. Replace ignition coil
6. Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the carburetor)
Condition
Remedy
1.
Gas tank vent hose
obstructed
2.
Carburetor inlet needle
defective
3.
Fuel hose
obstructed
4.
Fuel screens
obstructed
1. Clean vent hose
2. Replace needle
3. Clean - replace hose
4. Clean - replace inlet screen - valve screen
Problem: Engine stalls easily
Condition
Remedy
1.
Spark plug
fouled
2.
Magneto
defective
3.
CDI unit
defective
4.
Carburetor jets
obstructed
1. Clean plug
2. Replace magneto
3. Replace CDI unit
4. Clean jets
Problem: Engine noisy (Noise seems to come from piston)
Condition
Remedy
1.
Piston - cylinder
worn
2.
Combustion chamber
carbon buildup
3.
Piston pin - piston pin bore
worn
4.
Piston rings - ring groove(s)
worn
1. Replace - service piston - cylinder
2. Clean chamber
3. Replace - service pin - bore
4. Replace rings - piston