Page 10-3: Engine Troubleshooting
Boxxer 421
3.5. There is a mechanical problem with the engine. Have engine inspected by a qualified
engine service technician.
4.0. Starts then dies immediately
4.1. The oil pressure switch is activated. Check engine oil for proper level. If oil level is
okay, disconnect switch. If the engine starts, replace the switch.
4.1.1. Note: It is important to use only Briggs oil filters. Even though an after-market filter may
fit, the internal by-pass system may not be compatible with the Daihatsu engine
resulting in low oil pressure.
5.0. Will not come up to normal operating RPM
5.1. Throttle linkage is out of adjustment. Inspect for broken or loose linkage. Repair or
replace as necessary and adjust to proper RPM. Note: It is important to use an accurate
tachometer to adjust engine speed to 3000 RPM while it is under a vacuum load of
between 10"hg and 14"hg. Too high or too low will cause severe damage to machine
components.
5.2. There is excessive load on the engine due to the blower-to-recovery tank hose
becoming delaminated. Remove and inspect the inside of the hose. Replace as
necessary.
5.3. There is excessive back-pressure on the engine or blower exhaust. Check for
clogged blower heat exchanger.
6.0. Runs rough at medium or high speed
6.1. One or both spark plugs are defective. Remove and inspect spark plugs. Replace as
necessary.
6.2. A spark plug wire is loose at the spark plug or has been damaged. Inspect wire.
Replace wire and coil as necessary.
6.3. Low compression on one or both cylinders. Check compression. If low, check valve
adjustment. If incorrect, adjust to proper specs. This operation should be performed by a
qualified service technician.
6.3.1. If adjustment is okay, there is a possibility of burned valves, burned head gasket or worn
cylinders. Refer to qualified engine service technician.
6.4. Poor spark on one or both cylinders. Refer to qualified engine service technician.
10/7/2002
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