Section 03
ENGINE
Subsection 02
(TROUBLESHOOTING)
VMR2004_006_03_02A.FM
03-02-1
TROUBLESHOOTING
0
The following charts are provided to help in diagnosing the probable source of troubles. It should be used
as a guideline. This section pertains to engine mechanical components only. Some related problems can
come from other systems such as ignition system, fuel system etc. and have an impact on the engine.
Ensure to check the other systems prior to concluding that the engine is in fault.
COOLING SYSTEM
SYMPTOM
HIGH ENGINE OPERATING TEMPERATURE.
CONDITION
NORMAL USE.
Test/Inspection
1. Check coolant level.
a. Coolant less than recommended level.
Refill.
2. Check temperature sensor for electrical/mechanical failure.
a. Temperature sensor defective.
Replace.
3. Check thermostat (located on cylinder head).
a. Thermostat defective (does not open when engine gets hot).
Replace thermostat.
4. Check weep hole (water pump housing area) if coolant leaks.
a. Coolant leaking from weep hole means a damaged water pump rotary seal .
Replace rotary seal (refer to COOLING SYSTEM and MAGNETO COVER).
5. Check coolant bleeding screw on water pump housing.
a. Screw looses and/or gasket ring is missing.
Retighten screw and/or place gasket ring.
6. Check condition of hoses and hose clamps fixation.
a. Hoses are brittle and/or hard.
Replace.
b. Hose clamps are loose.
Retighten clamps.
7. Check condition of impeller located on the water pump shaft.
a. Impeller wings broken and/or impeller thread is damaged.
Replace.
8. Check gasket(s) on water pump housing.
a. Gasket on water pump housing leaks.
Retighten screws and/or replace gasket(s).
9. Check cylinder head and/or cylinder base gasket.
a. Worn out gasket(s) is(are) causing water leakage.
Replace.
10. Check cooling fan and connection.
a. Fan motor faulty.
Replace.
b. Wire harness is brittle or hard (no connection).
Replace.
Summary of Contents for DS 650
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Page 2: ...Shop Manual 2004 DS 650TM DS 650TM BAJA DS 650TM BAJA X ...
