Hi! workshop manual,service manual,repair manual [Sign in] [register]

Polaris Sportsman 800 Engine TROUBLESHOOTING GUIDE

Spark Plug Fouling
• Spark plug cap loose or faulty
• Incorrect spark plug heat range or gap
• PVT system calibrated incorrectly/ components worn or mis-adjusted
• Fuel quality poor (old) or octane too high
• Low compression
• Restricted exhaust
• Weak ignition (loose coil ground, faulty coil, stator, or  ETC switch)
• ETC switch mis-adjusted
• Restricted air filter (main or pre-cleaner) or breather  system
• Improperly assembled air intake system
• Restricted engine breather system
• Oil contaminated with fuel
Engine Turns Over But Fails To Start
•No fuel
• Dirt in fuel line or filter
• Fuel will not pass through fuel valve
• Fuel pump inoperative/restricted
• Tank vent plugged or pinched
• Engine flooded
• Low compression (high cylinder leakage)
• 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 carburetor pilot system
• Low compression
• Crankcase breather restricted
Engine Idles But Will Not Accelerate
• 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
• Incorrect ignition timing
• Restricted exhaust system
• Cam worn excessively
Engine Has Low Power
• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage (check  compression)
• PVT not operating properly
• Restricted exhaust muffler
• Cam worn excessively
Piston Failure – Scoring
• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated
Excessive Smoke and Carbon Buildup
• Excessive piston-to-cylinder clearance
• Wet sumping (Oil Level Too Full)
• Worn rings, piston, or cylinder
• Worn valve guides or seals
• Restricted breather
• Air filter dirty or contaminated
Piston Failure – Scoring
• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup
• Excessive piston-to-cylinder clearance
• Wet sumping due to over-full crankcase
• Worn rings, piston, or cylinder
• Worn valve guides or seals
• Restricted breather
• Air filter dirty or contaminated
Low Compression
• Cylinder head gasket leak
• No valve clearance ( cam wear )
• Cylinder or piston worn
• Piston rings 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
• Exhaust system air leaks
• Exhaust system air leaks
• Ignition system faulty: Spark plug cap cracked/broken, Ignition coil faulty, Ignition or kill switch circuit faulty,  Ignition poor connections in ignition system
• n timing incorrect, Sheared flywheel key
• Valve sticking

Cooling System
Overheating
• Low coolant level
• Air in cooling system
• Wrong type/mix of coolant
• Faulty pressure cap or system leaks
• Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines, pump, or water jacket, accident damage)

• Lean mixture (restricted jets, vents, fuel pump or fuel valve)
• Fuel pump output weak
• Electrical malfunction
• Water pump failure/ Loose impeller
• Thermistor failure
• Cooling fan inoperative or turning too slowly (perform current draw test)
• Ignition timing mis-adjusted
• Low oil level
• Spark plug incorrect heat range
• Faulty hot light circuit
• Thermostat stuck closed or not opening completely
• Possible diverter plate loose or missing inside radiator
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)

Related files:

468

Submit a Comment

Your email address will not be published.


*

You may use these HTML tags and attributes: <a href="" title=""> <abbr title=""> <acronym title=""> <b> <blockquote cite=""> <cite> <code> <del datetime=""> <em> <i> <q cite=""> <strike> <strong>