Cushman HAULER 1200, Repair Manual

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Repair and Service Manual
FAULT TESTING
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
653045
POWERTRAIN PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
STARTER DOES NOT
TURN Weak or bad battery Charge or replace as necessary
Terminals are loose or corroded Clean and tighten
Poor wiring connections Repair or replace wire and/or connections
Faulty ignition switch Repair or replace wire switch, and/or connections
Blown fuses Investigate cause and replace fuses
Solenoid faulty If no audible ‘click’ is heard, check power and ground. Replace
solenoid if power and ground is good
Starter terminals are loose or cor-
roded Tighten or clean
Leads are broken or faulty ground Repair or replace
Bad relay If no audible click is heard, replace engine start relay
STARTER TURNS
SLOWLY Terminals are loose or corroded Re-tighten or clean
Weak battery Charge battery
Leads are nearly broken or connec-
tions are faulty Check for any defect of leads at bend or joint. Replace leads
or repair connections
Mechanical problem inside
starter Replace starter.
Internal engine damage Inspect and repair
Crankcase over filled with oil Drain and fill to recommended level with approved oil
STARTER ROTATES BUT
VEHICLE WILL NOT
START OR HARD TO
START Weak battery Recharge or replace as necessary
Corroded or loose battery connec-
tions Clean and tighten battery connections.
Apply a coat of battery protectorate to
terminals
Check for adequate fuel level Fill with correct grade gasoline. See GENERAL SPECIFICA-
TIONS.
No spark at spark plugs. Broken or
disconnected spark plug wiring Check and replace if required. See GENERAL SPECIFICA-
TIONS.
Spark plugs fouled Clean or replace
Incorrect spark plug Check that spark plugs are the correct type. See GENERAL
SPECIFICATIONS.
Fuel pump faulty Repair or replace
Fuel line clogged or clamp loose Clean or replace if required
Cracked or broken fuel line Replace with new hose
Clogged fuel filter Check and replace if required
Engine flooded Clean/or replace spark plugs
Engine fuel starved Check fuel line
Clogged air filter Wash or replace as required
Plugged muffler or pipe Repair or replace
POOR LOW SPEED
PERFORMANCE Plugged gas tank vent Clean or repair
Fuel pump faulty Replace
Insufficient fuel level Add fuel
Spark plug fouled Clean or replace
Fig. 2 Powertrain Performance Troubleshooting
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