12. TROUBLESHOOTING
12-2
4.
Check wiring harness for cracks or other damages.
harness shows electrical failure and/or other damages. Replace/repair wiring harness.
LUBRICATION
Symptom: LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION
1.
Check oil level and search for leakage on crankcase and/or sealing parts.
Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts.
Use recommended oil (refer to technical specifications).
Crankcase is leaking due to loose screws. Retighten screws with recommended torque
Sealing rings, O-rings and/or gaskets are brittle, hard or damaged. Replace damaged parts.
Poston rings worn out (blue colored engine exhaust emission). Replace piston rings (refer
to cylinder and head).
Piston rings are broken (low compression). Replace piston rings (refer to cylinder and
head).
Valve stem seal damaged and/or sealing lip is hard and/or brittle. Replace all valve stem
seals.
2.
Check oil filter for contamination.
Oil filter clogged. Replace oil and oil filter at the same time. Use recommended oil (refer
to technical specifications).
3.
Check oil drain plug on engine bottom.
Plug is loose and/or gasket ring is missing. Retighten the plug and/or place gasket ring.
4.
Check leak indicator hole if oil leaks (in crankcase MAG side-water pump housing area).
Oil leaking from leak indicator hole means a damaged oil seal on water pump shaft.
Replace oil seal (refer to cooling system).
5.
Check oil pressure switch function.
Oil pressure switch damaged. Replace oil pressure switch.
6.
Check oil orifice(s) on the oil pump suction side.
Oil orifice(s) is (are) clogged. Clean from contamination. Replace oil and oil filter if
necessary (refer to maintenance or lubrication system).
7.
Check oil pump function.
Oil pump rotor is out of wear limit. Replace oil pump (refer to lubrication system).
Oil pump seized due to oil leakage and/or air inclusion. Replace oil pump (refer to
lubrication system).
Gears driving oil pump are broken or otherwise damaged. Replace gears.
Incorrect oil being used. Use recommended oil (refer to technical specifications).
8.
Check oil pressure regulator valve (spring) function.
Valve spring damaged (valve always open). Replace spring.
Valve piston is worn or broken. Replace valve piston (refer to lubrication system).
Valve piston stays open due to contamination. Clean or repair valve piston.
9.
Check plain bearings in crankcase for heavy wear.
plain bearings out of specification (increased clearance). Replace plain bearings (refer to
bottom end).
10.
Check engine oil strainer in crankcase.
Oil strainer is clogged due to contamination. Clean or replace strainer and diagnose
causes. Replace possible damaged parts (refer to bottom end).
Symptom: OIL CONTAMINATION (white appearance)
1.
Check leak indicator hole (in crankcase MAG side-water pump housing area) if water and oil
leaks.
Leakage of oil/water mixture from indicator bore means damaged water pump seal ring
and rotary seal. Replace sealing ring, rotary seal and change oil, oil filter and/or coolant
(refer to lubrication system, cooling system and bottom end).
2.
Check cylinder head and/or cylinder base gasket..
Gasket damaged or leaking. Retighten cylinder head with recommended torque and/or
replace gasket.
3.
Check tightening torque of cylinder head screws.
Screws not properly tightened. Retighten screws to recommended torque and replace oil.
4.
Check oil for particles (may indicate possible engine internal damages).
Oil contamination due to metal or plastic particles. Replace possibly damaged part(s)
including oil and oil filter. Use recommended oil (refer to technical specifications).
CYLINDER AND HEAD
