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Infolinks 2014

2001 Polaris Sportsman 400-500 DUSE & H.O. Troubleshooting repair guide

Engine Turn Over But Fail to Start
No fuel
Dirt in fuel line or filter
Fuel will not pas through fuel valve
Fuel pump inoperative/restricted
Tank vent plugged
Carb starter circuit
Engine flooded
Low compression (high cylinder leakage)
No spark (Spark plug fouled)
Engine Doe Not Turn Over
Dead battery
Starter motor doe not turn
Engine seized, rusted, or mechanical failure
Engine Run But Will Not Idle
Restricted carburetor pilot system
Carburetor misadjusted
Choke not adjusted properly
Low compression
Crankcase breather restricted
Engine Idle But Will Not Rev Up
Spark plug fouled/weak spark
Broken throttle cable
Obstruction in air intake
Air box removed (reinstall all intake components)
Incorrect or restricted carburetor jetting
ETC switch limiting speed
Reverse speed limiter limiting speed
Carburetor vacuum slide sticking/diaphragm damaged
Incorrect ignition timing
Restricted exhaust system
Engine Ha Low Power
Spark plug fouled
Cylinder, piston, ring, or valve wear or damage (check compression)
PVT not operating properly
Restricted exhaust muffler
Carburetor vacuum slide sticking/diaphragm damaged
Dirty carburetor
Piston Failure – Scoring
Lack of lubrication
Dirt entering engine through crack in air filter or ducts
Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup
Excessive piston-to-cylinder clearance
Wet sumping
Worn rings, piston, or cylinder
Worn valve guide or seals
Restricted breather
Air filter dirty or contaminated
Low Compression
Decompressor stuck
Cylinder head gasket leak
No valve clearance or incorrectly adjusted
Cylinder or piston worn
Piston ring worn, leaking, broken, or sticking
Bent valve or stuck valve
Valve spring broken or weak
Valve not seating properly (bent or carbon accumulated on sealing surface)
Rocker arm sticking
Backfiring
ETC or speed limiter system malfunction
Fouled spark plug or incorrect plug or plug gap
Carburetion faulty – lean condition
Exhaust system air leaks
Ignition system faulty:
Spark plug cap cracked/broken
Ignition coil faulty
Ignition or kill switch circuit faulty
Ignition timing incorrect
Sheared flywheel key
Poor connection in ignition system
System wiring wet
Valve sticking
Air leak in intake
Lean condition

Overheating
Low coolant level
Air in cooling system
Wrong type of coolant
Faulty pressure cap or system leaks
Restricted system (mud or debri in radiator fin or restriction to air flow, passage blocked in
radiator, lines, pump, or water jacket)
Lean mixture (restricted jets, vents, fuel pump or fuel valve)
Fuel pump output weak
Restricted radiator (internally or cooling fins)
Water pump failure
Cooling system restriction
Cooling fan inoperative or turning too slowly (perform current draw test)
Ignition timing misadjusted
Low oil level
Spark plug incorrect heat range
Faulty hot light circuit
Thermostat stuck closed or not opening completely
Temperature Too Low
Thermostat stuck open
Leak at Water Pump Weep Hole
Faulty water pump mechanical seal (coolant leak)
Faulty pump shaft oil seal (oil leak)

Fuel Starvation/Lean Mixture
Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low
power, spark plug erosion, engine run hot, surging, high idle, idle speed erratic.
No fuel in tank
Restricted tank vent, or routed improperly
Fuel line or fuel valve restricted
Fuel filter plugged
Carburetor vent line(s) restricted
Plugged or restricted inlet needle and seat screen or inlet passage
Clogged jet or passages
Float stuck, holding inlet needle closed or inlet needle stuck
Float level too low
Fuel pump inoperative
Air leak at impulse line
Restricted impulse line (kinked, pinched)
Intake air leak (throttle shaft, intake ducts, airbox or air cleaner cover)
Ruptured vacuum slide diaphragm, Vacuum slide stuck closed or sticky
Improper spring
Jet needle position incorrect
Incorrect pilot screw adjustment
Rich Mixture
Symptoms: Foul spark plugs, black, sooty exhaust smoke, rough idle, poor fuel economy, engine run rough/
misses, poor performance, bog, engine load up, backfire.
Air intake restricted (inspect intake duct)
Air filter dirty/plugged
Choke plunger sticking, incorrectly adjusted choke
Choke cable binding or improperly routed
Incorrect pilot air/fuel screw adjustment
Faulty inlet needle and seat
Faulty inlet needle seat O-Ring
Float level too high
Poor fuel quality (old fuel)
Loose jets
Worn jet needle/needle jet or other carburetor parts
Dirty carburetor (air bleed passage or jets)
Weak or damaged vacuum piston return spring
Fouled spark plug
Poor Idle
Symptoms: Idle too high.
Idle adjusted improperly/idle mixture screw damaged
Sticky vacuum slide
Throttle cable sticking, improperly adjusted, routed incorrectly
Choke cable sticking, improperly adjusted, routed incorrectly

Idle Too Low
Choke cable bending or incorrectly adjusted
Idle speed set incorrectly
Idle mixture screw misadjusted or damaged
Belt dragging
Ignition timing incorrect
Worn jet needle/needle jet
Erratic Idle
Choke cable bending or incorrectly adjusted
Throttle cable incorrectly adjusted
Air leaks, dirty carburetor passage (pilot circuit)
Pilot mixture screw damaged or adjusted incorrectly
Tight valves
Ignition timing incorrect
Belt dragging
Dirty air cleaner
Engine worn
Spark plug fouled
Idle speed set incorrectly (speed limiter)
Worn jet needle/needle jet

TROUBLESHOOTING CHECKLIST

Check the following item when shifting difficulty i encountered.
Idle speed adjustment
Transmission oil type/quality
Transmission torque stop adjustment
Engine torque stop adjustment
Drive belt deflection
Loose fastener on rod ends
Loose fastener on selector box
Worn rod ends, clevi pins, or pivot arm bushings
Linkage rod adjustment and rod end positioning
Shift selector rail travel
*Worn, broken or damaged internal transmission components

BRAKE TROUBLESHOOTING

Brake Squeal
Dirty/contaminated friction pads
Improper alignment
Worn disc
Worn disc splines
Poor Brake Performance
Air in system
Water in system (brake fluid contaminated)
Caliper/disc misaligned
Caliper dirty or damaged
Brake line damaged or lining ruptured
Worn disc and/or friction pads
Incorrectly adjusted lever
Incorrectly adjusted stationary pad
Worn or damaged master cylinder or components
Improper clearance between lever and switch
Lever Vibration
Disc damaged
Disc worn (runout or thicknes variance exceed service limit)
Caliper Overheat (Brake Drag)
Compensating port plugged
Pad clearance set incorrectly
Auxiliary brake pedal incorrectly adjusted
Brake lever or pedal binding or unable to return fully
Parking brake left on
Residue build up under caliper seals
Operator riding brakes
Brake Lock
Alignment of caliper to disc.

IGNITION SYSTEM TROUBLESHOOTING ELECTRICAL

No Spark, Weak or Intermittent Spark
Spark plug gap incorrect
Fouled spark plug
Faulty spark plug cap or poor connection to high tension lead
Related wiring loose, disconnected, shorted, or corroded
Engine Stop switch or ignition switch faulty
ETC switch misadjusted or faulty
Terminal board or connection wet, corroded
Poor ignition coil ground (e.g. coil mount loose or corroded)
Faulty stator (measure resistance of all ignition related windings)
Incorrect wiring (inspect color coding in connector etc)
Faulty ignition coil winding (measure resistance of primary and secondary)
Worn magneto (RH) end Crankshaft bearings
Sheared flywheel key
Flywheel loose or damaged
Trigger coil air gap too wide (where applicable) – should be .016-.040″ (.4-1.0 mm)
Excessive crankshaft runout on magneto (RH) end – should not exceed .0024″
Faulty CDI module

ELECTRICAL STARTER SYSTEM TROUBLESHOOTING

tarter Motor Doe Not Turn
Battery discharged – low specific gravity
Loose or faulty battery cable or corroded connection (see Voltage Drop Tests)
Related wiring loose, disconnected, or corroded
Poor ground connection at battery cable, starter motor or starter solenoid (see Voltage Drop
Tests)
Faulty starter button
Faulty ignition switch (Do other system function?)
Faulty starter solenoid or starter motor.
Engine problem – seized or binding (Can engine be rotated easily with recoil starter?)
tarter Motor Turn Over Slowly
Battery discharged – low specific gravity
Excessive circuit resistance – poor connection (see Voltage Drop Test below)
Engine problem – seized or binding (Can engine be rotated easily with recoil starter?)
Faulty or worn brushe in starter motor
Automatic compression release inoperative
tarter Motor Turn – Engine Doe Not Rotate
Faulty starter drive
Faulty starter drive gear or starter motor gear
Faulty flywheel gear or loose flywheel

 

KYMCO DINK CLASSIC 200 Troubleshooting repair guide

LUBRICATION SYSTEM  TROUBLESHOOTING repair guide

Oil level too low Poor lubrication pressure
• Natural oil consumption • Oil level too low
• Oil leaks • Clogged oil filter or oil passage
• Worn piston rings • Faulty oil pump
• Worn valve guide
• Worn valve guide seal
Oil contamination
• Oil not changed often enough
• Faulty cylinder head gasket
• Loose cylinder head bolts

CYLINDER HEAD/VALVES  TROUBLESHOOTING repair guide

TROUBLESHOOTING
• The poor cylinder head operation can be diagnosed by a compression test or by tracing engine
top-end noises.
Poor performance at idle speed White smoke from exhaust muffler
• Compression too low • Worn valve stem or valve guide
• Damaged valve stem oil seal
Compression too low
• Incorrect valve clearance adjustment Abnormal noise
• Burned or bend valves • Incorrect valve clearance adjustment
• Incorrect valve timing • Sticking valve or broken valve spring
• Broken valve spring • Damaged or worn camshaft
• Poor valve and seat contact • Worn cam chain tensioner
• Leaking cylinder head gasket • Worn camshaft and rocker arm
• Warped or cracked cylinder head
• Poorly installed spark plug
Compression too high
• Excessive carbon build-up in combustion
chamber

CYLINDER/PISTON TROUBLESHOOTING repair guide

• When hard starting or poor performance at low speed occurs, check the crankcase breather for
white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.
Compression too low or uneven
compression Excessive smoke from exhaust muffler
• Worn or damaged cylinder and piston rings • Worn or damaged piston rings • Worn, stuck or broken piston rings • Worn or damaged cylinder and piston
Compression too high Abnormal noisy piston
• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings
chamber or on piston head • Worn piston pin hole and piston pin

• Incorrectly installed piston

DRIVE AND DRIVEN PULLEYS/ KICK STARTER TROUBLESHOOTING repair guide

Engine starts but motorcycle won‘t move Lack of power
• Worn drive belt • Worn drive belt
• Broken ramp plate • Weak driven face spring
• Worn or damaged clutch lining • Worn weight roller
• Broken driven face spring • Faulty driven face
Engine stalls or motorcycle creeps
• Broken clutch weight spring

FINAL REDUCTION  TROUBLESHOOTING repair guide

Engine starts but motorcycle won‘t move
• Damaged transmission
• Seized or burnt transmission
Abnormal noise
• Worn, seized or chipped gears
• Worn bearing
Oil leaks
• Oil level too high
• Worn or damaged oil seal

A.C. GENERATOR/STARTER CLUTCH  TROUBLESHOOTING repair guide

Refer to page 1-27 for A.C. generator troubleshooting.
Starter motor rotates but engine does not start
• Faulty starter clutch
• Starter motor rotates reversely
• Weak battery

CRANKCASE/CRANKSHAFT  TROUBLESHOOTING repair guide

Excessive engine noise
• Excessive bearing play
• Excessive crankpin bearing play
• Worn piston pin and piston pin hole

COOLING SYSTEM TROUBLESHOOTING repair guide

Engine temperature too high Coolant leaks
• Faulty temperature gauge or thermosensor • Faulty pump mechanical (water) seal
• Faulty radiator cap • Deteriorated O-rings
• Faulty thermostat • Damaged or deteriorated water hoses
• Insufficient coolant
• Passages blocked in hoses or water jacket
• Clogged radiator fins
• Passages blocked in radiator
• Faulty water pump
Temperature gauge pointer does not register
the correct coolant temperature
• Faulty temperature gauge or thermosensor
• Faulty thermostat

FUELSYSTEM/CARBURETOR/FUEL PUMP TROUBLESHOOTING repair guide

Engine does not start Engine idles roughly, stalls or runs poorly
• No fuel in tank • Incorrect idle speed
• Restricted fuel line • Rich mixture
• Too much fuel getting to cylinder • Lean mixture
• Clogged air cleaner • Clogged air cleaner
• Contaminated fuel • Intake air leak
• Faulty fuel pump • Contaminated fuel
• Faulty air-cut off valve
• Damaged vacuum tube and connectors
• Damaged carburetor insulator

Throttle does not open fully, so engine stalls Rich mixture
• Damaged vacuum piston diaphragm • Auto bystarter valve opens excessively
• Clogged diaphragm hole • Faulty float valve
• Float level too high
Lean mixture • Clogged air jets
• Clogged fuel jets • Auto bystarter valve set plate installed in
• Clogged fuel tank cap breather hole the wrong groove
• Clogged fuel filter •Clogged air cleaner
• Bent, kinked or restricted fuel line
• Faulty float valve
• Float level too low
• Faulty fuel pump or insufficient output

STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING repair guide

Hard steering (heavy) Front wheel wobbling
• Excessively tightened steering stem top • Bent rim
cone race • Loose front axle
• Broken steering balls • Bent spoke plate
• Insufficient tire pressure • Faulty tire
Steers to one side or does not track straight • Improperly tightened axle nut
• Uneven front shock absorbers Soft front shock absorber
• Bent front fork • Weak shock springs
• Bent front axle or uneven tire • Insufficient damper oil
Poor brake performance Front shock absorber noise
• Worn brake pads • Slider bending
• Contaminated brake pad surface • Loose fork fasteners
• Deformed brake disk • Lack of lubrication
• Air in brake system
• Deteriorated brake fluid
• Worn brake master cylinder piston oil seal
• Clogged brake fluid line
• Unevenly worn brake caliper

REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER TROUBLESHOOTING repair guide

Rear wheel wobbling Poor brake performance
• Bent rim • Air in brake system
• Faulty tire • Deteriorated brake fluid
• Axle not tightened properly • Contaminated brake pad surface
• Worn brake pads
Soft rear shock absorber • Clogged brake fluid line
• Weak shock absorber spring • Deformed brake disk
• Damper oil leaks • Unevenly worn brake caliper
Rear wheel noise
• Worn rear wheel axle bearings
• Worn rear fork bearings
• Deformed rear fork

BATTERY/CHARGING SYSTEM TROUBLESHOOTING repair guide

No power Intermittent power
• Dead battery • Loose battery cable connection
• Disconnected battery cable • Loose charging system connection
• Fuse burned out • Loose connection or short circuit in
• Faulty ignition switch ignition system
Low power Charging system failure
• Weak battery • Loose, broken or shorted wire or connector
• Loose battery connection • Faulty regulator/rectifier
• Charging system failure • Faulty A.C. generator

IGNITION SYSTEM TROUBLESHOOTING repair guide

No spark at plug Engine starts but turns poorly
• Faulty spark plug • Ignition primary circuit • Poorly connected, broken or shorted wire —Faulty ignition coil • Faulty ignition switch —Poorly connected wire or connector • Faulty ignition coil —Poorly contacted ignition switch • Faulty CDI unit • Ignition secondary circuit • Faulty A.C. generator —Faulty ignition coil
—Faulty spark plug —Faulty high-tension wire
—Poorly insulated plug cap
• Improper ignition timing
—Faulty A.C. generator
—Stator not installed properly
—Faulty CDI unit

STARTING SYSTEM TROUBLESHOOTING repair guide

Starter motor won‘t turn Lack of power
• Fuse burned out • Weak battery
• Weak battery • Loose wire or connection
• Faulty ignition switch • Foreign matter stuck in starter motor
• Faulty starter clutch or gear
• Faulty front or rear stop switch
• Faulty starter relay Starter motor rotates but engine does
• Poorly connected, broken or shorted wire not start
• Faulty starter motor • Faulty starter pinion
• Starter motor rotates reversely
• Weak battery

SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS TROUBLESHOOTING repair guide

Lights do not come on when ignition Temperature gauge does not register
switch is “ON” correctly
• Burned bulb • Faulty temperature gauge
• Faulty switch • Faulty thermosensor
• Poorly connected, broken or shorted wire • Broken or shorted wire between
temperature gauge and thermosensor
Fuel gauge pointer does not move or
register correctly
• Faulty fuel gauge
• Faulty fuel unit
• Poorly connected wire between fuel
gauge and fuel unit
• Fuse burned out

EXHAUST EMISSION CONTROL SYSTEM TROUBLESHOOTING repair guide

High CO at idle speed
1. Damaged or clogged reed valve
2. Damaged or clogged air injection cut-off valve
3.Clogged air cleaner
Backfiring at sudden deceleration
1. Damaged reed valve (malfunction)
2. Faulty air injection cut-off valve (unable to close)
3.Carburetor incorrectly adjusted
4. Faulty air cut-off valve
5. Leaking vacuum tube
Exhaust muffler noise
1. Faulty air injection cut-off valve
2.Broken vacuum tube
3. Faulty reed valve

honda BF25D and BF30D LONG TILLER HANDLE INSTALLATION repair guide

BF25D and BF30D LONG TILLER HANDLE INSTALLATION
1)Set the long tiller handle assembly on the mount  frame and tighten the two 10 mm washers and two 10mm self-locking nuts.
2)Tighten the two 10 mm self-locking nuts to the speci- fied torque.
TORQUE: 34 N.m (3.5 kgf-m, 25 Ibf-ft)

[1] LONG TILLER HANDLE ASSEMBLY

1

 

3) Pass the tiller handle wire harness through the under case grommet A.

4) Pass the throttle cable and shift cable through the under case grommet A. · Pass the throttle cable through the inner side of the under case grommet A and the shift cable through the side close to the opening.

5) Set the throttle cable and shift cable in the cable plate by aligning the groove in each cable with the cutout in the cable set plate.

6) Set the under case grommet A, tiller handle wire harness, throttle cable and shift cable as a set in the engine under case.

7) Secure the tiller handle wire harness with the wire band clip.

Read the rest of this entry »

Polaris Outlaw 525 450 TROUBLESHOOTING repair guide

1. Polaris Outlaw 525 450 Brake Noise Troubleshooting

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, check the backing of each pad for worn spots allowing metal to metal contact. See table below:

Brake Noise Troubleshooting
Possible Cause Remedy
Dirt, dust, or imbedded material on pads or disc Spray disc and pads with a non–flammable aerosol brake

cleaner only! Remove pads and/or disc hub to clean imbedded

material from disc or pads.

Pad(s) dragging on disc (noise or premature pad wear)

Improper adjustment

Insufficient lever or pedal clearance

Master cylinder reservoir overfilled

Master cylinder compensating port restricted

Master cylinder piston not returning completely

Caliper piston(s) not returning

Operator error (riding the brake / park brake applied)

Adjust pad stop (front calipers)

Check position of controls & switches

Set to proper level

Clean compensating port

Inspect. Repair as necessary

Clean piston(s) seal

Educate operator

Loose wheel hub or bearings Check wheel and hub for abnormal movement
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
Noise is from other source (chain, axle, hub, disc or wheel) If noise does not change when brake is applied check other

sources. Inspect and repair as necessary

Wrong pad for conditions Change to a softer or harder pad

Brakes Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn disc splines
• Glazed brake pads
Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted lever
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Improper clearance between lever and switch
Lever Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)
• Caliper overheats (Brakes Drag)
• Compensating port plugged
• Pad clearance set incorrectly
• Auxiliary brake pedal incorrectly adjusted
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
• Fluid overfill of the reservoir
• Stuck caliper piston

2. Polaris Outlaw 525 450  Ignition System Troubleshooting

No Spark, Weak or Intermittent Spark
• No 12 volt power or ground to CDI
• Spark plug gap incorrect
• Fouled spark plug
• Faulty spark plug cap or poor connection to high
tension lead
• Related wiring loose, disconnected, shorted, or
corroded
• Faulty engine stop switch, ignition switch, or tether
switch
• ETC switch misadjusted or faulty
• Poor ignition coil ground (e.g. coil mount loose or
corroded)
• Faulty pulse coil (measure resistance of value of pulse
coil)
• Incorrect wiring (inspect color coding in connectors
etc)
• Faulty ignition coil winding (measure resistance of
primary and secondary)
• Sheared flywheel key
• Flywheel loose or damaged
• Excessive crankshaft runout on magneto (RH)
end – should not exceed .005”
• Faulty CDI module
• Faulty 5 Amp or 10 Amp circuit breaker

3.  Polaris Outlaw 525 450  Starter System Troubleshooting

Starter Motor Does Not Turn
• Battery discharged. Low specific gravity
• Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter motor
or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty kill switch
• Faulty neutral diode
• Faulty clutch switch
• Faulty starter solenoid or starter motor
• Engine problem – seized or binding (can engine be
rotated easily)?
Starter Motor Turns Over Slowly
• Battery discharged
• Excessive circuit resistance – poor connections (see
Voltage Drop Test)
• Engine problem – seized or binding (can engine be
rotated easily)?
• Faulty or worn brushes in starter motor
• Automatic compression release inoperative
Starter Motor Turns – Engine Does Not Rotate
• Faulty starter drive/one way clutch
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
• Possible engine damage

yamaha SXV70SJ VT70J CARBURETOR TUNING TROUBLESHOOTING repair guide

yamaha SXV70SJ VT70J CARBURETOR TUNING TROUBLESHOOTING

Trouble 1 Hard starting

Diagnosis Adjustment
Insufficient fuel Add gasoline.
Excessive   use   of   the

starter or choke

Return the starter lever to its seated position so that the

starter valve is fully closed.

Fuel  passage  is  clogged

or frozen

· Check and, if necessary, clean the fuel tank air vent, the

fuel filter and all of the fuel passages.

· Check and, if necessary, clean the carburetor air vents,

fuel passages and the float valve.

· Clean the float chamber of any ice or water.

Overflow Adjust the fuel level.

Trouble 2 Poor idling

· Poor  performance  atlow speeds

· Poor acceleration

· Slow   response    to throttle

· Engine tends to stall

Improper   idling   speed

adjustment

Adjust the engine idle speed.

Refer to “Low speed tuning”.

Damaged pilot screw Replace the pilot screw.
Clogged bypass hole Clean the bypass hole.
Clogged or loose pilot jet · Remove the pilot jet, clean it with compressed air and

then install it.

· Make sure that the pilot jet is fully tightened.

Air leaking into the carbu-

retor joint

Retighten  the  clamp  screws  on  the  carburetor  joints.
Defective   starter   valve

seat

Clean or replace the starter valve seat.
Overflow Adjust the fuel level.

Trouble 3 Poor   performance   at mid-range speeds:

· Momentary   slow   response to the throttle

· Poor acceleration

Diagnosis Adjustment
Clogged or loose pilot jet · Remove the pilot jet, clean it with compressed air, and

then install it.

· Make sure that the pilot jet is fully tightened.

Lean mixture Overhaul the carburetors.

Trouble 4  Poor   performance   at normal speeds:

· Excessive   fuel   consumption

· Poor acceleration

Clogged air vent Remove the air vent hose and clean it.
Clogged or loose main jet · Remove the main jet, clean it with compressed air, and

then install it.

· Make sure that the main jet is fully tightened.

Overflow Check and, if necessary, clean the float and float valve.

Trouble 5  Poor   performance   at high speeds:

· Power loss

· Poor acceleration

 

Starter valve is left open Return the starter lever to its seated position so that the

starter valve is fully closed.

Clogged air vent Remove and clean the air vent.
Clogged or loose main air

jet

· Remove the main jet, clean it with compressed air, and

then install it.

· Make sure that the main jet is fully tightened.

Clogged fuel line Clean or replace the fuel line.
Dirty fuel tank Clean the fuel tank.
Air leaks into the fuel line Tighten or replace the fuel line joint.
Low   fuel   pump   perfor-

mance

Repair or replace the fuel pump.
Clogged fuel filter Replace the fuel filter.
Clogged intake Remove any obstructions (e.g., ice).

Trouble 6  Abnormal combustion:

· Backfiring

Lean mixture Clean and adjust the carburetors.
Dirty carburetors Clean the carburetors.
Dirty or clogged fuel line Clean or replace the fuel line.

Trouble 7  Overflow:

· Poor idling

· Poor  performance  at low,   mid-range,   and high speeds

· Excessive   fuel   consumption

· Hard starting

· Power loss

· Poor acceleration

 

Clogged air vent Clean the air vent.
Clogged float valve · Disassemble and clean the float valve.

· Do not scratch the valve seat.

Scratched   or   unevenly

worn float valve or valve

seat

· Clean or replace the float valve and valve seat.

· The valve seat and body must be replaced as a set.

Broken float Replace the float.
Incorrect float level Check and, if necessary, replace the following parts:

· Float tang

· Float (entire assembly)

· Arm pin

2009 Polaris Scrambler SPORTSMAN XP 550 / XP 550 EPS TROUBLESHOOTING repair guide

Situation 1 : Engine RPM below specified operating range, although engine is properly tuned.

Probable Cause Remedy
-Wrong or broken drive clutch spring.

-Drive clutch shift weight too heavy.

-Driven clutch spring broken or installed in wrong

helix location.

-Replace with recommended spring.

-Install correct shift weight kit to match engine

application.

-Replace spring; refer to proper installation location.

Situation 2 :  Erratic engine operating RPM during acceleration or load variations.

-Drive clutch binding.

-Belt worn unevenly - thin / burnt spots.

-Driven clutch malfunction.

-Sheave face grooved.

A. Disassemble drive clutch; inspect shift weights for

wear and free operation.

B. Clean and polish stationary shaft hub; reassemble

clutch without spring to determine problem area.

Replace belt.

Inspect movable sheave for excessive bushing

clearance.

-Replace the clutch.

Situation 3:  Engine RPM above specified operating range.

-Incorrect drive clutch spring (too high spring rate).

-Drive clutch shift weights incorrect for application

(too light).

-Drive clutch binding.

-Driven clutch binding.

-Clutch sheaves greasy; belt slipage.

-Install correct recommended spring.

-Install correct recommended shift weights.

-Disassemble and clean clutch, inspecting shift weights

and rollers. Reassemble without the spring and move

sheaves through entire range to further determine

probable cause.

-Disassemble, clean, and inspect driven clutch.

-Clean sheaves with denatured alcohol or brake cleaner,

install new belt.

Situation 4:    Harsh drive clutch engagement.

 
-Drive belt worn too narrow.

-Excessive belt / sheave clearance with new belt.

-Replace belt.

-Perform belt / sheave clearance adjustment with shim

washers beneath spider.

Situation 5 : Drive belt turns over

-Wrong belt for application. -Replace with correct belt.
 

Situation 6 : Belt burnt, thin spots

-Abuse (continued throttle application when

vehicle is stationary, excess load)

-Dragging brake

-Slow, easy clutch engagement

-Caution operator to operate machine within guidelines.

-Vehicle operated with parking brake on.  Inspect brake

system.

-Fast, effective use of throttle for efficient engagement.

kubota b2320 b2620 b2920 b2320 NARROW ENGINE TROUBLESHOOTING repair guide

If something is wrong with the kubota b2320 b2620 b2920 b2320 NARROW engine, refer to the table below for the cause and its corrective measure.

Trouble 1 Engine is difficult to start orwon’t start.

Cause 1 : No fuel flow

Countermeasure: A Check the fuel tank and the fuel filter.Replace filter if necessary.

Cause 2 : Air or water is in the fuel system

Countermeasure:

  • Check to see if the fuel line coupler bolt andnut are tight.
  • Bleed the fuel system.(See “Bleeding Fuel System” in “SERVICE ASREQUIRED” in “PERIODIC SERVICE”section.)
  • Remove water from the system and replacethe fuel filter

Cause 3 : In winter, oil viscosity increases,and engine revolution is slow.

Countermeasure:

  • Use oils of different viscosities, depending onambient temperatures.
  • Use engine block heater. (Option)

Cause 4 :  Battery becomes weak and theengine does not turn over quickenough.

Countermeasure:

  • Clean battery cables and terminals.
  • Charge the battery.
  • In cold weather, always remove the batteryfrom the engine, charge and store it indoors.Install it on the tractor only when the tractor isgoing to be used.

Trouble 2 Insufficient engine power.

Cause 1 :  Insufficient or dirty fuel.

Countermeasure:   Check the fuel system.

Cause 2 : The air cleaner is clogged

Countermeasure:   Clean or replace the element.

Trouble 3 Engine stops suddenly.

Cause 1 :  Insufficient fuel.

Countermeasure:

  • Refuel.
  • Bleed the fuel system if necessary

Trouble 4 Exhaust fumes arecolored.

>>Black

Cause 1 :

  • Fuel quality is poor.
  • Too much oil.
  • The air cleaner is clogged

Countermeasure:

  •  Change the fuel and fuel filter.
  • Check the proper amount of oil.
  • Clean or replace the element.

>> Blue or white 

Cause 1 :

  • The inside of exhaust muffler isdumped with fuel.
  • Injection nozzle trouble.
  • Fuel quality is poor.

Countermeasure:

  • Heat the muffler by applying load to theengine.
  • Check the injection nozzle.
  • Change the fuel and fuel filter.

Trouble 5 Engine overheats.

Cause 1 :  Engine overloaded.

Countermeasure:  Shift to lower gear or reduce load.

Cause 2:   Low coolant level.

Countermeasure:  Fill cooling system to the correct level;check radiator and hoses for looseconnections or leaks.

Cause 3:   Loose or defective fan belt.

Countermeasure: Adjust or replace fan belt.

Cause 4:  A Dirty radiator core or grille screens.

Countermeasure: Remove all trash.

Cause 5:   Coolant flow route corroded.

Countermeasure: Flush cooling system.

If you have any questions, consult your local KUBOTA Dealer.

Bobcat x 225 excavator TROUBLESHOOTING repair guide and service manual pdf download

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.

PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged.

2. Battery connections are dirty or loose.

3. Battery is damaged.

4. The ground connection is not making a good contact.

5. The alternator is damaged.

6. The engine is locked.

7. The starter is damaged.

8. The wiring or the solenoid is damaged.

9. Check the fuses.

DISPLAY MODULE  Testing And Troubleshooting

Initial test (with Display Module installed in the Excavator.

NOTE:  If the display module has been removed from the excavator.

Turn the ignition key to the ON position (do not start the engine) [A]. The following display module conditions willexist.

N–02824

N–02824

Engine temperature bar graph will illuminate at the current engine temperature. If the engine temperature is below the minimum normal operating temperature warning light will blink on and off [B].

Fuel level bar graph will illuminate at the full F setting. At ten second intervals, the fuel level bar graph will drop one bar at a time until the actual fuel level in the tank is reached. If the fuel level is in the empty E range on the bar graph the low fuel warning light will blink on and off [B]. Engine oil pressure warning light will blink on and off continuously [B]. Voltage charging light will blink on and off continuously [B]. Pre heat indicator light will not be illuminated. The pre–heat indicator light will illuminate only when the ignition key is turned to the heat position [A]. Start the excavator [A]. With the excavator started, the display module will perform an internal module check. This will last for three seconds and the following display module conditions will exist. Engine temperature bar graph will illuminate at the current engine temperature. The engine temperature warning light will blink on and off for three seconds. After the three second check, if the engine temperature is below the minimum normal operating temperature (122°F–50°C), the engine warning light will continue to blink on and off until the engine reaches the normal operating temperature and the second bar graph illuminates. If the engine temperature at start up is above the minimum operating temperature, the warning light will not blink on and off.

Read the rest of this entry »

bobcat excavator 220 S/N 15001 & Above service repair Manual

This is the COMPLETE official full factory service repair manual for the bobcat excavator 220 S/N 15001 & Above. All pages allow you to print it out in its entirety or just the pages you need!!Dwonload bobcat excavator 220 S/N 15001 & Above Service Repair Manual for PDF

contents

  • safety instructions
  • serial number locations
  • delivery report
  • hydraulic excavator identification
  • preventive maintenance
  • hydraulic section
  • drive section
  • upper works & swing section
  • main frame & tracks
  • electrical system
  • engine service
  • technical data

Download 

HYDRAULIC FLOW CHART for model 220 Excavator (S/N 15001 & Above) PDF Download

The fluid flows by gravity from the reservoir 1 to the 3 section hydraulic gear pump 6 . The 3 section gear pumps are coupler driven from the engine. Each gear pump section is protected by a relief valve located in the control valve it supplies. Fluid from the hydraulic pump 6 (Engine flywheel end) is forced to the pressure reducing valve 17 and to the 6-spool hydraulic control valve 27 P1 port (Inlet). These control valve sections control R.H, travel. Boom and Bucket. Fluid from the center section hydraulic pump 6 is forced to the P2 port of the 6-spool hydraulic control valve 27 . These control valve sections control LH. travel. Arm and Auxiliary. Adjustable relief valves 28 29 are located at each end of the 6-spool hydraulic control valve 27 . With all spools in the neutral position the open center control valve allows fluid to flow to the oil cooler 35 . When a spool is activated, the fluid flows to the base or rod end of a cylinder 21 , 22 & 24 , The fluid on the other side of the cylinder flows back to the 6-spool hydraulic control valve 27 , When a cylinder reaches the end of the stroke the presjrp increases to 2450 PSI (16897 kPa) and opens the relief valve 28 or 29 , The oil then ftcws through the 6-spool hydraulic control valve 27 internally and back to the oil cooler 35 , The 6-spool hydraulic control valve has Port Relief Valves in both ports of the Boom section 30 & 31, the rod end of the Bucket section 32 and both ports of the Arm section 33 & 34. The auxiliary spool is hollow, and while in neutral, fluid flows through the center of the spool to the tank port of the valve. When the auxiliary spool is activated two pump flows are combined to supply more fluid to the auxiliary quick couplers 21 on the boom arm. The female coupler is pressure and the male coupler is return. The auxiliary fluid return flows through the 6-spoof hydraulic control valve 27 internally and back to the oil cooler 35 . Fluid from the end cap section of the hydraulic pump 6 flows to the inlet port PI of the 3-spool control 20 , Oil under pressure because of the buildup valve 0 is also directed to the joystick manifold 17 at 200 PSl (1379 kPa) to charge the accumulator 14 – The accumulator stores fluid under pressure 200 PSl (1379 kPa) to operate a joystick function if the engine stops, The console lock-out microswitch is located in the left console of all excavators. If the excavator is equipped with the ROPS Canopy, and addition microswitch is used in the right console to lock-out the fluid flow to the joysticks if the right console is raised to access the operators area. When the console(s) is lowered, the microswitch activates the joystick supply solenoid valve 16 and fluid is allowed to flow to the joysticks 18 and 19 .

 

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