Service Manual

5.60
ENGINE
TROUBLESHOOTING
Engine
Spark Plug Fouling
• Restricted air filter (main or pre-cleaner) or breather
system
• Improperly assembled air intake system
• Restricted engine breather system
• Oil contaminated with fuel
• Fuel quality poor (old) or octane too high
• PVT system calibrated incorrectly/ components worn or
mis-adjusted
• Restricted exhaust
• Spark plug cap loose or faulty
• Incorrect spark plug heat range or gap
• Weak ignition (loose coil ground, faulty coil, or stator)
• Low compression
Engine Turns Over But Fails To Start
•No fuel
• Dirt in fuel line, filter, or injectors
• Fuel pump inoperative/restricted
• Fuel valve off or restricted flow
• Tank vent plugged or pinched
• Engine flooded
• Low compression (high cylinder leakage)
• No CPS signal (debris on CPS pole, damaged CPS
causing incorrect air gap)
• No spark (spark plug fouled) ignition component failure
Engine Does Not Turn Over
• Dead battery
• Starter motor does not turn
• Engine seized, rusted, or mechanical failure
Engine Runs But Will Not Idle
• Restricted fuel system
• Low compression (valves incorrectly adjusted)
• Crankcase breather restricted
Engine Idles But Will Not Accelerate
• Spark plug fouled / weak spark
• Broken throttle cable
• Air intake obstructed
• Air box removed (reinstall all intake components)
• Reverse speed limiter limiting speed
• Incorrect ignition timing
• Restricted exhaust system
• Camshaft worn excessively
• PVT not operating properly
Engine Has Low Power
• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage (check
compression)
• PVT not operating properly
• Restricted exhaust muffler
• Camshaft worn excessively
Piston Failure - Scoring
• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated (water)
Excessive Smoke and Carbon Buildup
• Excessive piston-to-cylinder clearance
• Worn rings, piston, or cylinder
• Worn valve guides or seals
• Restricted breather
• Air filter dirty or contaminated