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Range Rover Classic Engine Troubleshooting repair guide and PDF manual download

ENGINE OIL PRESSURE TEST

Service tools: LRT-12-0S2: Pressure test equipment

1. Check lubricant is to correct level.
2. Place vehicle on a ramp [hoist].
3. Disconnect battery negative lead. Remove oil pressure switch.
4. Fit the test gauge.
5. Reconnect battery negative lead.
6. Start and run engine to normal operating temperature.
7. At a steady engine speed of 2500 rev/min - engine oil pressure reading should be – 2.75 bar (40 Ibf/in 2).
8. If the pressure is low – Remove and overhaul oil pump

CYLINDER COMPRESSION – TEST

Equipment: Compression pressure gauge

1. Start and run engine until normal engine operating temperature is achieved (thermostat open).
2. Remove all spark plugs.
3. Disconnect both coil negative (WB) leads
4. Insert compression gauge, crank engine until reading stabilises.
5. Expected readings, throttle fully open, battery fully charged:
8.31:1 = 10.2-10.9 bar, 150-160Ibf/in2
9.35:1 = 11.5-12.2 bar, 170-180Ibf/in2

ENGINE NOISES

Excessive or obtrusive noise from the engine compartment originates from three main sources:
A. The exhaust system, which makes an unmistakable and easy to diagnose noise.
B. External components emit the greatest variety of noises, but are also easy to diagnose by simply removing the drive belt.
C. Engine internal mechanical noises which can vary in volume and pitch and may be a combination of, tapping – knocking or rumbling, are the most difficult to diagnose. The following is therefore a guide to diagnosis of engine internal mechanical noises only.

Engine internal mechanical noises.
Single or multiple, light tapping noise, particularly
when engine is cold. See Description and
operation, Description
1. Is engine oil level correct?
NO – Top up to correct level. See
LUBRICANTS, FLUIDSAND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES – Continue.
2. Is the lubricating pressure correct?
NO – See Engine OilPressure Test
YES – Suspect valve operating mechanism.
3. To confirm diagnosis, remove the rocker covers
and with the engine idling, insert a feeler gauge
of O,015mm between each rocker and valve
stem. A faulty valve operating mechanism will
emit a different noise when the feeler gauge is
inserted. See Repair, RockerShaft Renew
Heavy knocking noise (particularly on load and
when engine is hot). See Description and
operation, Description

1. Is engine oil level correct?
NO – Top up to correct level. See LUBRICANTS, FLUIDSAND  CAPACITIES, Information,Recommended Lubricants and Fluids
YES – Continue.
2. Is the lubricating pressure correct?
NO – See Engine OilPressure Test
YES – Drain engine oil and filter, and examine for metallic contamination.
3. Is the oil contaminated with metal particles?
YES – Suspect faulty big end bearings. To confirm diagnosis, short out the ignition to each spark plug in turn. The noise will disappear or be reduced when the
cylinder with the faulty big end is shorted out.
4. If noise is not conclusively diagnosed, check the security of the flywheel and crankshaft front pulley. Temporarily release the drive belt to reduce general noise level and use a stethoscope to locate source of noise. Heavy rumbling noise (particularly during hard acceleration). See Description and operation, Description
1. Is engine oil level correct?
NO – Top up to correct level. See LUBRICANTS, FLUIDSAND CAPACITIES, Information, Recommended Lubricants and Fluids
YES – Continue.
2. Is the lubricating pressure correct?
NO – See Engine OilPressure Test
YES – Drain engine oil and filter, and examine for metallic contamination.
3. Is the oil contaminated with metal particles?
YES – Suspect faulty main bearings. If noise is not conclusively diagnosed, check the security of the flywheel and crankshaft front pulley. Temporarily release the drive belt to reduce general noise level and use a stethoscope to locate source of noise.

ENGINE STARTING PROBLEMS

Engine fails to crank in park or neutral (Automatic Transmission)
1. Is battery in good state of charge?
NO – See INTRODUCTION, Information, Jump Starting
YES – Continue.
2. Is automatic transmission inhibitor switch faulty or gear selection linkage incorrectly adjusted?
YES – See AUTOMATIC GEARBOX, Repair, InhibitorSwitch,
NO – See Electrical Trouble Shooting Manual.
If problem is not diagnosed repeat tests, starting at 1.Engine fails to crank (Manual Transmission)
1. Is battery in good state of charge?
NO – See INTRODUCTION, Information,Jump Starting
YES – See Electrical Trouble Shooting Manual.
If problem is not diagnosed repeat tests, starting
at 1.

Engine cranks but fails to start

1. Is the cranking speed fast enough (120 rpm)?
NO – See INTRODUCTION, Information, Jump Starting If necessary also. See Electrical Trouble Shooting Manual.
YES – Continue.
2. Is there combustion in any cylinder?
NO – See ELECTRICAL, Fault diagnosis,Lucas Constant Energy Ignition System – VBi See Electrical Trouble Shooting Manual.
YES – Continue.
3. Are the fuel supply, tank, pump, ventilation and emission control systems in correct working order or the fuel contaminated?
NO – See FUEL SYSTEM, Repair, Fuel Filter See FUEL SYSTEM, Repair, Fuel Tank See FUEL SYSTEM, Repair, Fuel pump andSender Unit See EMISSION CONTROL, Description and operation, Emission control If problem is not diagnosed repeat tests, starting at 2.

ENGINE RUNNING PROBLEMS

Engine runs at high speed but will not idle (stops) Engine idle speed erratic Engine starts but stops immediately Engine stalls Engine misfireslhesitation

1. Multiport fuel injection. See Electrical Trouble Shooting Manual. See ELECTRICAL, Fault diagnosis, Lucas ConstantEnergy Ignition System – V8i

Check brake vacuum connections. See BRAKES, Description and operation, Brake Servo Unit

Check heater/ventilation unit vacuum connections. See HEATlNG AND VENTILATlON, Description and operation, Heating and Ventilation Unit If problem is not diagnosed continue.

2. Are HT leads correctly routed and clipped?
NO – See ELECTRICAL, Repair, Distributor- V8i
YES – Continue.

3. Is fuel supply, tank, pump, ventilation and emission control systems in correct working order or the fuel contaminated?

NO – See FUEL SYSTEM, Repair, Fuel Filter See FUEL SYSTEM, Repair, Fuel Tank See FUEL SYSTEM, Repair, Fuel Pump andSender Unit See EMISSION CONTROL, Description and operation, Emission Control

If problem is not diagnosed repeat tests, starting at 1.

Engine lacks powerlpoor performance

1. Is throttle travel restricted or cable incorrectly adjusted?

YES – Check thickness of carpets. See FUEL SYSTEM, Repair, Throttle Cable See FUEL SYSTEM, Repair, Accelerator Pedal
NO – Continue.

2. Are the Ignition and Multiport Fuel Injection systems in order?

NO – See Electrical Trouble Shooting Manual.A1 See ELECTRICAL, Fault diagnosis, Lucas Constant Energy Ignition System – VBi See ELECTRICAL, Repair, Distributor- VBi

YES – Continue.

3. Are fuel supply, tank, pump, ventilation and emission control systems in correct working order or the fuel contaminated?

NO – See FUEL SYSTEM, Repair, Fuel Filter See FUEL SYSTEM, Repair, Fuel Tank See FUEL SYSTEM, Repair, Fuel Pump andSender Unit

YES – Suspect valves held open by hydraulic tappets due to high oil pressure. See Engine OilPressure Test

4. Is oil pressure high?

YES – Remove oil filter and cooler adaptor and check pressure relief valve strainer gauze for blockage and that the relief valve is not stuck closed. See Description and operation, Description

NO – Carry out cylinder compression tests to determine condition of head gaskets and valves. See CylinderCompression – Test

5. Are cylinder compressions satisfactory?

NO – See Repair, Cylinder Heads – Renew

YES – Check brake vacuum connections. See BRAKES, Description and operation, Brake Servo Unit

Check heater/ventilation unit vacuum connections. See HEAT/NG AND VENT/LAT/ON, Description and operation, Heating and Ventilation Unit If problem is not diagnosed: Continue.

6. Are the brakes binding?
YES – Investigate cause of binding.
NO – Continue.

7. Automatic Transmission only. Is the Torque Converter and Transmission operating correctly? Carry out Road test, Static tests and Stall tests to determine condition of Automatic transmission.

If problem is not diagnosed: repeat tests starting at 1.

Engine backfires into exhaust system

1. Are there any leaking joints/connections or holes in the exhaust system?

YES – See MANIFOLD AND EXHAUST SYSTEM, Repair, Exhaust System Complete

NO – Continue.

2. Is distributorfitted correctly, HT leads in correct firing order and routed correctly?

NO – See ELECTRICAL, Repair, Distributor- V8i
YES – Continue.

3. Is air fuel ratio correct?

NO – Check multiport fuel injection. See Electrical Trouble Shooting Manual. Check brake vacuum connections. See BRAKES, Description and operation, Brake Servo Unit Check heater/ventilation unit vacuum connections. See HEAT/NG AND VENT/LAT/ON, Description and operation, Heating and Ventilation Unit Check the crank case and fuel tank ventilation system. See EMISSION CONTROL, Description and operation, Emission Control

YES – Continue.

4. Are cylinder compressions satisfactory?

NO – Carry out compression test to check for leaking gaskets valves etc. See CylinderCompression – Test See Repair, CylinderHeads – Renew

If problem is not diagnosed: repeat tests starting at 1.

Engine backfires into inlet system

1. Is the Distributor, HT connections and routing correct?

NO – See ELECTRICAL, Repair, Distributor – V8i YES – Continue.

2. Is air fuel ratio correct?

NO – Check multiport fuel injection. See Electrical Trouble Shooting Manual. Check brake vacuum connections. See BRAKES, Description and operation, Brake Servo Unit Check heater/ventilation unit vacuum connections. See HEAT/NG AND VENT/LAT/ON, Description and operation, Heating and Ventilation Unit Check the crank case and fuel tank ventilation system. See EMISSION CONTROL, Description and operation, Emission Control

YES – Continue.

3. Are cylinder compressions satisfactory?
NO – Carry out compression test to check for leaking gaskets valves etc. See CylinderCompression – Test For repair See Repair, CylinderHeads - Renew
If problem is not diagnosed: repeat tests starting at 1.

For more information, please download the relevant Range Rover Classic manual

Thomas T225 and T243-T245 HDS HDK Troubleshooting repair guide and PDF manual download

T243 HDS T245 HDS T245 HDK Protough 2200 FINAL DRIVE Troubleshooting repair guide

Problem 1 . Final drive noisy

Cause Corrective Action
No lubricating oil. Check the oil level. Check for leaks and cause.

Add 10W30 API SE / CD oil to correct level.

Chain loose. Replace chain and check tension every 150 hours.
Axles have too much

end play.

Check the axle end play. Replace damaged parts if

required and adjust end play.

Parking brake engaged

or out of adjustment.

Inspect and adjust or replace damaged parts.

Problem 2.  No drive on one side.

Drive chain failure. Inspect the chain. Replace damaged parts. Check

the chain tension every 150 hours.

Torque motor failure. Do pressure checks. Replace parts as required.
Hydrostatic drive failure. Do pressure checks. Replace parts as required.

Problem 3.  Lubricating oil leaking out the breather in the filler cap.

Lubricating oil level too

high.

Check oil level and drain excess.
Torque motor shaft seal

leaking.

Repair the hydraulic torque motor.

Problem 4.   Wheel studs shearing

Wheel nuts loose. Tighten nuts to 100 to 110 ft / lbs. (135 to 149

N.M.) Check wheel nuts every 8 hours.

Problem 5.    Wheel stud threads shearing.

Wheel nuts over torqued. Tighten nuts to 100 to 110 ft / lbs. (135 to 149

N.M.) Check wheel nuts every 8 hours.

T243 HDS T245 HDS T245 HDK Protough 2200 Hydraulic System Troubleshooting repair guide

Problem 1.  Loss of Hydraulic power (no flow from gear pump)

Cause Remedy
Reservoir low on fluid Replenish with 10W30 or

20W50 API SE/CD oil.

Check for hose or fitting

leaking

Universal joint between

engine and pump failure

Inspect and replace damaged

parts. Check for misalignment

between engine and

pumps

Spline coupling failure

between front and rear

hydrostatic pump

Inspect coupling for sheared

splines. Also check pump

shaft bearings.

Hydraulic gear pump

not functioning

Inspect and repair.

Problem 2.  Loss of hydraulic power (flow from gear pump)

Reservoir low on fluid Replenish with 10W30 or

20W50 API SE/CD oil.

Foot pedal linkage dis¬

connected or binding

Inspect and adjust.
Auxiliary Hydraulics

engaged

Disengage.
Relief valve failure in

control valve

Check pressure and adjust.
 

Problem 3.  Hydraulic action jerky

Reservoir low on oil Replenish with 10W30 or

20W50 API SE/CD oil.

Air in hydraulic system Check for leaks between the

reservoir and pump. Bleed

system by extending and

retracting lift cylinders sever¬

al times.

Anticavitation check

valve not functioning.

Check and repair or replace.
 

Problem 1.   No power on one side, both directions

Reservoir low on oil Replenish with 10W30 or 20W50

API SE/CD oil.

Check for hose or fitting leak.

Disconnected control

linkage

Reconnect and adjust linkage.
Bolt sheared on pump

pintle lever

Replace. Check pintle lever for

loose bolt or excessive play.

High pressure line failure Replace line. Ensure new line fits

without being forced. If necessary

stress relieve.

Drive chain failure Replace chain or connection link.

Adjust tightener tension.

Motor shaft or key failure Inspect and repair defective parts.

Check motor mounting bolts.

Problem 2.  No power on one side, one direction only

Defective relief valve Replace defective valve.

Problem 3.  Gradual loss of power as machine warms up

 
Excessive internal leakage

in pump and/or

motor

Consult dealer or Thomas Service

Dept.

Problem 4.  No power on both sides, also loss of hydraulic power

Reservoir low on oil Replace with 10W30 or 20W50

API SE/CD oil.

Check for hose or fitting leak.

Universal joint failure

between engine and

pump

Inspect and replace damaged parts.

Check for misalignment between

engine and pumps.

Drive coupling

between front and rear

pump failure

Inspect couplings for sheared

splines, replace. Also check support

bearings in pumps.

Check system pressure If low ,consult dealer or Thomas

Service Dept.

Problem 5.   System erratic and/or noisy

Air in system due to

low oil level in reservoir

Replenish with 10W30 or 20W50

API SE/CD oil.

Air in system due to

leak at suction fitting

Check fittings and tighten.
Internal pump or motor

wear caused by over-

speeding

Consult dealer or Thomas Service

Dept.

Excessive play in linkage or

pintle lever

Adjust linkage and tighten or

replace pintle lever.

Problem 6.    Machine will not travel in a straight line

Control levers binding Check that shields are not stopping

lever from full travel.

Adjust Tracking

Problem 7.   Final drive transmis sion noisy

 No lubricating oil Check and bring oil to the proper level. Use 10W30
  SE/CD Engine oil
Axles have too much Preload axle bearings removing
end play all end play.
Parking brake damaged Inspect and adjust or replace
or out of adjustment damaged parts,
Chain loose  
  Replace the chain.

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volkswagen vanagon official factory repair manual 1980 to 1991 including diesel, syncro and camper repair guide

Repair Service to Volkswagen owners is a top priority of Volkswagen organization and has always included the continuing development and introduction of new and expanded services. In line with this purpose, Volkswagen United States, Inc. has introduced this Volkswagen Official Factory Repair Manual.

This Vanagon manual covers the model years 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 including Air-cooled and Water-cooled Gasoline Engines, Diesel Engine, Syncro and Camper. This manual was specifically written to cover U.S. and Canada models only.For the Volkswagen owner with basic mechanical skills and for independent garages, this manual gives all the specifications and procedures that were available in an authorized Volkswagen service department as this manual went to press. In addition,the Volkswagen owner who has no intention of working on his or her vehicle may find that reading and owning this manual will make it possible to be better informed and to discuss repairs more intelligently with a professional automotive technician. This manual has been prepared from the repair information that the Volkswagen organization provides to its own factory-trained technicians and has been developed primarily with the professional automotive technician in mind. The aim throughout has been clarity and completeness with step-by-step procedures and accurate specifications. The Volkswagen owner intending to do maintenance and repair should have a set of metric wrenches and sockets, a torque wrench,screwdrivers, and feeler gauges, since these basic hand tools will be used for a majority of the repairs described in this manual. Usually, the text will note when a repair requires special tools. This manual is organized so that, whenever possible, when a change has been made within a model year, the vehicle identification number (VIN) of the first vehicle with this change is given. The digits you need to know for this parts and service information are taken from the seventeen digit VIN number. If, for example the VIN is WVWZZZ24ZBH000001, you will need only nine of the last eleven digits of this number—or, more specifically, the digits 24 B 000001. Your Volkswagen’s VIN is found on the left doorjamb and on a plate mounted on the driver’s side of the instrument panel padding where the number can be seen through the windshield. The VIMs assigned to Vanagon models for the years 1980 through 1991 which are covered by this manual are:

1980 25 A 000001 to    — ___„25_A_999999
1981 ___——25_B_000001 to    - 25„B_999999
1982 ______25_C_000001 to    — 25 C 999999
1983 ______25_D_CK)0001 to    - 25 D 999999
1984 ———__25_E_000001 to    - 26 E 999999
1985 _____24„F_000001 to    — 24 F 999999
25 F CK)0001 to    — 25—F—999999
1986 _„_„_24_G_000001 to    - _____24_G_999999
25 G 000001 to    - _____25_G—999999
1987 ______24_H_000001 to    - 24—H—999999
——25—H_000001 to   一 25 H 999999
1988 24 J000001 to    ■ _____24_J„999999
______25—J—000001 to    — —„__25_J_999999
1989 ___24_K_000001 to    - __„__24_K_999999
______25_K_000001 to    — _____25_K„999999
1990 ___    24 L 000001 to    - _____24_L_999999
________25J_—000001 to _____25_L_999999
1991 ______24_M_000001 to    - ______24_.M_999999
———25_M„000001 to    — _____25_M—999999

repair-guidebook.com have endeavored to ensure the highast degree of accuracy possible. When the vast army of data presented in this manual is taken into account, however, no claim to infallibility can be made. We therefore cannot be responsible for the result of any errors that may have crept into the text. The Publisher encourages comments from the readers of this manual in regard to any errors and, also, suggestions for improvement in the presentation of the technical material. These communications have been and will be carefully considered in the preparation of this and other manuals. Please write to Robert Bentiey, Inc., Cambridge, Massachusetts 02138. Volkswagen offers extensive warranties, especially on components of the fuel delivery and emission control systems. Therefore, before deciding to repair a Volkswagen that may still be covered wholly or in part by any warranties issued by Volkswagen United States, Inc., consult your authorized Volkswagen dealer. You may find that he can make the repair either free or at minimum cost. Regardless of its age, or whether it is under warranty, your Volkswagen is both an easy vehicle to service and an easy vehicle to get serviced. So if at any time a repair is needed that you feel is too difficult to do yourseff, a trained Volkswagen technician is ready to do the job for you.

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porche 911 cruise control Troubleshooting repair guide and repair manual download

porche 911  CRUISE CONTROL : The cruise control system consists o1 an electronic control unit, a cruise control servo, a control switch on the steering column, and switches at the brake and clutch pedals. The control module uses a signal from the speedometer to compare the car’s true speed to the speed selected by the driver via the column switch. The control unit then signals the servo to open or close the throttle via a cable. The system will maintain the set speed while going up and down hills within the engine’s power range. The set speed can be increased at any time by depressing the accelerator pedal. When the accelerator pedal is released the vehicle speed will return to the previously set speed. If either the clutch or brake pedal are depressed the system will be disengaged. If the vehicle speed drops below 15 mph at any time the system will automatically disengage. To disengage cruise control when the clutch pedal is depressed, a clutch pedal switch is used. To disengage cruise control when the brakes are used an extra connection at one of the brake light switches is used.

porche 911  Troubleshooting

—When troubleshooting cruise control system, first check for a faulty fuse 6 in the fuse/relay pane丨 in luggage compartment.

—To begin troubleshooting cruise control components and electrical circuit, access cruise control module as described later.

  • Remove Iresh air plenum in luggage compartment.
  • Detach electrical harness connector at cruise control module.
  • Proceed to tests in Table c.

—If no faults are found with cruise control components or electrical circuits, replace cruise control module.

Table c. Cruise control troubleshooting

Test (terminals at cruise control module harness connector)

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MAN D 2565 and D 2866 Series removing,repair guide and installing water pump and repair manual download

D2565 and D2866 Series Removing, repairing and installing water pump

Removing Figure 1

Drain coolant. Remove coolant lines. Depending on engine type remove surge tank with heat exchanger  (1), heat exchanger tank or fan. Remove V-belt, elbow (2), thermostat housing, cooling water connection (3) and bypass inserts / thermostats. Remove V-belt pulley (4).

Figure 1

Figure 2

Extract water pump hub using a 3-arm puller. Remove water pump screws and take off water pump.

Figure 2

Disassembly, repair

Figure 3

Remove circlip from water pump body.

Figure 3

Figure 4

Remove impeller from shaft using a suitable mandrel. Note: The impeller can also be extracted by means of a 3-arm puller. This is of advantage when the sea! only has to be replaced.

Figure4

Figure 5

Using a suitable mandrel press water pump shaft with bearing out of body. Shaft and bearing are encapsulated and can only be replaced together.

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Suzuki RG125 TROUBLESHOOTING repair guide and service manual download

ENGINE TROUBLESHOOTING

Complaint : Engine will  not start, or Is hard to start.

Symptom and passible causes Remedy
Plug not sparking

1. Fouled spark plug.

2. Wet spark plug.

3. Defective ignitiDn coil.

4 Open  or short in high-tension cord.

5. Defective pick-up coil, primary  coil or CDI unit.

Clean.

Clean and dry.

Hepisce.

RepJace.

Replace.

No fuel reaching the carburetor

1. Clogged hole in the fuel tank cap.

2, Clogged or defective fuel cock.

3, Defective carburetor   needle valve.

4, Clogged fuel pipe.

Clean.

Clean or replace

Replace.

clean.

Compression  too low

1. Excessively worn cvlinder or piston rings.

2. Stiff piston ring in place.

Gas leaks from the joint in crankcase, cvlinder

or cylinder head.

4. Damaged reed valve.

5. Spark plug too loose.

6. Worn crankshaft oil seal.

Replace

Repair or replace

Repair or replace

Replace

Retighten .

Replace.

Complaint : engine stalls easily.

1. Fouled    plug.

2- Defective pick-up coil— primary  or GDI unit

3. Clogged fuel pipe.

4- Clogged jets in carburetor.

Clean.

Replace.

Replace.

Clean.

Complaint : noisy engine.

Noise appears to cams from piston

1. Piston or Cylinder worn down.

2. Combustion chamber fouled with carbon.

3. Piston pin or piston pin bore worn,

4,Piston ring groove worn.

5, Piston pin bearing warn.

Replace

Clean.

Replace.

Replace.

Replace.

Noise seems to coma from clutch

1, Worn splines of countershaft or hub.

2. Worn teeth of clutch plates.

3. Distorted dutch plat as, driven and drive,

Replace.

Replace.

Replace.

Noise seems to come from crankshaft

1. Rattling bearings due lo wear.

2. Big-end bearings worn and burnt,

3, Journal bearing worn and burr�i.

Noise seems to came from Transmission

1, Gears worn or rubbing.

2- Badly worn splines,

3. Primarv gears warn or rubbing.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Complaint : slipping clutch.

t. Clutch control out of adjustment or loss of play.

2,  clutch springs,

3. Worn or distorted pressure plate.

4. Distorted clutch plates, driven and drive.

Adjust.

Replace.

Replace.

Replace.

Complaint :  Dragging clutch

1. Clutch control out of adjustment or too much play.

2. Some clutch springs weakened while others are not.

3. Distorted pressure plate or clutch plates.

Adjust.

Raplace.

Replaces.

Complaint :  Transmission will not shift

1. Broken gearshift cam,

2, Distorted gearshift forks.

3. Worn gearshift shaft.

Replace.

Replace.

Replace.

Complaint :  Transmission will not shift back

1. Broken return spring on gearshift shaft.

2. Fork shafts are rubbing or sticky.

Replace,

Repair or replace.

Complaint :  Transmission Jumps out of gear

1, Worn shifting gears on driveshaft or countershaft.

2. Distorted or worn gearshift forks.

3, Weakened stopper spring on gearshift stopper,

Replace.

Replace,

Replace.

Complaint :  Engine idles poorly.

1. Spark plug gaps too wide.

2. Defective ignition coil.

3, Defective pick-up coil primary coif or CDI unit.

4. Float-chamber fuel level out of adjustment in carburetor.

5. Clogged jets.

Adjust.

Replace,

Replace.

Adjust.

Clean or adjust.

Complaint :  Engine runs poorly in highspeed range.

1. Spark plug gaps too narrow.

2. Clogged jets.

3. Defective ignition coil.

4. Defective pick-up coil, primary coil or CDI unit.

5. Float-chamber fuel level too low.

6. clogged air cleaner element.

7. Clogged fuel pipe, resulting in inadequate fuel supply to

carburetor.

8. Exhaust value control out of adjustment.

9. Defective exhaust valve- control unit (CDI unit, actuator

or exhaust valve.

Acfpust,

Clean.

Replace.

Replace.

Adjust.

Clean.

Clean gnd prime,

Adjust.

Replace.

Complaint :  Dirty or heavy exhaust smoke.

1. Oil pump Qut of adjustment.

2. Damage or worn crankshaft oil seal.

Adjust,

Replace.

Complaint :  Engine locks power,

1. Worn piston rings or cylinder.

2. Spark plug gaps incorrect,

3, Clogged jets in carburetor.

4. Float-chamber fuel level out of adjustment,

S. Clogged air cleaner element.

6. Sucking air from intake pipe.

7. Supply— too much engine oiL

Replace.

Adjust  or replace.,

Clean.

Adjust.

Clean,

Retighten or replace.

Adjust oil pump.

Complaint : Engine overheats.

1. Heavy carbon deposit on piston crown.

2, Not enough oil supply.

3. Dcfeciive oil pump ar clogged oil circuir

4. Fuel level too low in float chamber.

5. Sucking air from intake pipe.

6. Using incorrect engine oil.

7. Defective cooling system.

Clean.

Adjust oil pump.

Replace or clean.

Adjust.

Retfghten or feplace,

Change.

See cooling section.

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