10. TROUBLESHOOTING
10-1
10. TROUBLESHOOTING
ELECTRICAL SYSTEM ····························· 10-1
COOLING SYSTEM ·································· 10-1
MAGNETO SYSTEM ································· 10-2
LUBRICATION ········································· 10-2
CYLINDER AND HEAD ······························ 10-3
CRANKSHAFT ········································· 10-3
GEARBOX ··············································· 10-3
COUPLING UNIT ······································ 10-4
CVT ······················································· 10-4
ENGINE GENERAL ··································· 10-6
ELECTRICAL SYSTEM
Symptom: NO SPARK OR POOR SPARK
1.
Refer to
ignition system
.
Symptom: STARTER DOES NOT TURN
1.
Refer to starting system.
Symptom: STARTER TURNS BUT DOES NOT CRANK THE ENGINE
1.
Refer to starting system.
2.
Check gear condition on electric starter.
◼
Worn and/or damaged starter gear. Replace electric starter and/or starter drive.
3.
Check condition of starter pinion gear.
◼
Worn and/or damaged starter pinion and/or ring gear. Replace starter drive and/or drive
pulley fixed sheave.
4.
Check splines on starter drive.
◼
Poor movement of pinion gear on splines. Clean and/or replace starter drive.
Symptom: STARTER TURNS BUT STARTER DRIVE DOES NOT MESH WITH RING GEAR
1.
Refer to starting system.
Symptom: STARTER KEEPS RUNNING
1.
Refer to starting system.
COOLING SYSTEM
Symptom: HIGH ENGINE OPERATING TEMPERATURE
1.
Check coolant level.
◼
Coolant level lower than recommended. Refill(refer to cooling system).
2.
Check for air bubbles in cooling system.
◼
Air in cooling system. Refill and bleed cooling system (refer to cooling system).
3.
Check temperature sensor for electrical/mechanical failure.
◼
Temperature sensor defective. Replace.
4.
Check thermostat.
◼
Thermostat defective (does not open when engine gets hot). Replace (refer to cooling
system).
5.
Check leak indicator hole (in crankcase MAG side-water pump housing area) if coolant leaks.
◼
Coolant leaking from indicator hole means a damaged water pump rotary seal. Replace
rotary seal (refer to cooling system)..
6.
Check condition of hoses and hose clamps fixation.
◼
Hoses are brittle and/or hard. Replace.
◼
Hose clamps are loose. Retighten clamps.
7.
Check condition of impeller located on the water pump shaft.
◼
Impeller wirings broken and/or impeller threads are damaged. Replace (refer to cooling
system).
8.
Check gasket on water pump housing.
◼
Gasket on water pump housing leaks. Retighten screws and/or replace gasket.
9.
Check cylinder head and/or cylinder base gasket.
◼
Worn out gasket(s) is (are) causing coolant leakage. Replace.
10.
Check coolant drain screw on water pump housing MAG side.
◼
Copper ring on drain screw leaks. Retighten screw and/or replace copper ring.
11.
Check intermediate gear(s) behind of PTO cover.
◼
Worn out and/or broken gear(s) is/are causing less coolant supply. Replace worn out
and/or broken gear(s) (refer to bottom end).