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GENERAL INFORMATION
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at TDC but there is still a large amount of air escaping from
the engine, the crankshaft is off one revolution. Turn the
engine 360°and realign the TDC mark as described in Step 7,
then relock it as described in Step8.
a.
Air leaking through the exhaust pipe indicates a leaking exhaust valve.
b.
Air leaking through the throttle indicates a leaking intake valve.
c.
Air leaking through both the intake and exhaust valves indicates the engine is not set at
TDC on its compression stroke.
d.
Air leaking through the coolant filler neck indicates a leaking cylinder head gasket or a
cracked cylinder head or cylinder liner.
e.
Air leaking through the oil filler hole indicates the rings are not sealing properly in the
bore.
11. If the cylinder leak down is 10 percent or higher, further service is required.
12. Disconnect the test equipment and install all the parts previously removed.
ELECTRICAL TESTING
This section describes basic electrical testing and test equipment use.
Preliminary Checks and Precautions
Refer to the color wiring diagrams at the end of the manual for component and connector
identification; Use the wiring diagrams to determine how the circuit should work by tracing the current
paths from the power source through the circuit components to ground. Also, check any circuits that
share the same fuse (if used), ground or switch. If the other circuits work properly and the shared
wiring is good, the cause must be in the wiring used only by the suspect circuit. If all related circuits are
faulty at the same time, the probable cause is a poor ground connection or a blown fuse (if used).
As with all troubleshooting procedures, analyze typical symptoms in a systematic manner. Never
assume any thing and do not overlook the obvious like a blown fuse or an electrical connector that has
separated. Test the simplest and most obvious items first and try to make tests at easily accessible
points on the UTV.
Before starting any electrical troubleshooting, perform the following:
1. Check the fuse if the fuse is blown, replace it.
2. Inspect the battery. Make sure it is fully charged, and the battery leads are clean and securely
attached to the battery terminals.
3.
Disconnect each electrical connector in the suspect circuit and make sure there are no bent
terminals in the electrical connector
4.
Make sure the terminals on the end of each wire are pushed all the way into the connector. If not.
Carefully push them in with a narrow blade screwdriver
5.
Check the wires where they connect to the terminals for damage
6.
Make sure all terminals within the connector are clean and free of corrosion. Clean them. If
necessary. And pack the connectors with dielectric grease
7.
Push the connectors with dielectric grease. The connectors are fully engaged and locked
together
8.
Never pull the electrical wires when disconnecting an electrical connector-pull only on the
connector
