Troubleshooting
8-18
1. Support the UTV on a work stand with the rear wheels off the ground.
2. Remove the air filter assembly Open and secure the throttle so it is at its in the
wide-open position.
3. Remove the spark plug.
4. Install the threaded hose adapter from the leak down kit. Then install the leak down
gauge onto the hose.
5. Remove the ignition timing hole cap from the left crankcase cover.
6. Remove the crankshaft hole cap from the right crankcase cover.
Note:
Because the following test is performed with the cylinder head cover installed on
the engine, the camshaft lobes cannot be viewed to ensure that the engine is
positioned at TDC on its compression stroke. To determine when the engine is
approaching TDC on its compression stroke, or whether it is 360°off. Observe the
following two indicators to predict engine position. First, when aligning the index
marks in Step7, listen for pressure building inside the combustion chamber,
Indicating that the piston is moving to TDC on its compression stroke. Second,
view the gauge on the leak down tester when turning the engine. As the piston
moves toward TDC on its compression stroke, compression building inside the
combustion chamber may cause the gauge needle to move slightly. If the
crankshaft is 360°off, these indicators will not be present.
Note:
The decompression mechanism will click loudly once during each crankshaft
revolution. This is normal.
7. Use hex socket on the primary drive gear mounting bolt and turn the crankshaft
clockwise and align the TDC mark on the flywheel with the index mark on the left
crankcase cover Remove the hex socket from the primary drive gear.
8. Perform the following to lock the transmission so the engine remains at TDC on
its compression stroke when performing the leak down test:
Warning:
Do not attempt to lock the engine by trying to use a tool to hold the Allen bolt on
the end of the crankshaft. Once the combustion chamber becomes pressurized,
any crankshaft movement can throw the tool away from the engine under
considerable force, attempting to hold the tool can cause serious injury. Engine
damage may also occur to the crankshaft or right crankcase cover. Lock the
engine as described in this procedure.
a. Turn the drive sprocket by hand and shift the transmission into top gear
with the shift pedal.
b. Mount a holding tool or equivalent onto the drive sprocket. Use a wooden
block and clamp to hold the holding tool so it cannot move when the
combustion chamber becomes pressurized.
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