TABLE OF CONTENTS
ANTICORROSION TREATMENT.................................................................................... 48
CHECKLIST........................................................................................................... 48
03 TROUBLESHOOTING
01 – TROUBLESHOOTING CHART.............................................................................. 49
ENGINE WILL NOT START.......................................................................................... 49
ENGINE HARD TO START........................................................................................... 52
ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED.............................................................. 52
ENGINE MISFIRES,RUNS IRREGULARLY......................................................................... 53
ENGINE CONTINUALLY BACKFIRES............................................................................... 55
ENGINE DETONATION OR PINGING............................................................................... 55
ENGINE LACKS ACCELERATION OR POWER .................................................................... 56
ENGINE STOPS RUNNING .......................................................................................... 57
ENGINE CANNOT REACH MAXIMUM RPM ...................................................................... 57
ENGINE RUNS TOO FAST (VEHICLE CANNOT REACH ITS TOP SPEED)....................................... 58
ENGINE OVERHEATS................................................................................................ 58
O.P.A.S. SYSTEM FAULTS (GTX 4-TEC MODELS)................................................................. 59
ENGINE SMOKE IN THE EXHAUST(4-TEC SERIES).............................................................. 59
LOW OR NO ENGINE OIL PRESSURE (4-TEC SERIES) .......................................................... 60
ENGINE OIL CONTAMINATION (MILKY)(4-TEC SERIES) ........................................................ 60
UNUSUAL ENGINE NOISE AND/OR VIBRATION (4-TEC SERIES) ............................................... 61
ABNORMAL NOISE FROM PROPULSION SYSTEM.............................................................. 61
04 ENGINE (2-STROKE)
01 – LEAK TEST .................................................................................................... 63
GENERAL............................................................................................................. 63
PREPARATION ....................................................................................................... 63
TESTING PROCEDURE.............................................................................................. 63
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART.................................................................. 69
02 – REMOVAL AND INSTALLATION........................................................................... 71
GENERAL............................................................................................................. 71
ENGINE REMOVAL .................................................................................................. 71
CLEANING............................................................................................................ 76
INSTALLATION ....................................................................................................... 76
03 – MAGNETO SYSTEM......................................................................................... 83
DISASSEMBLY ....................................................................................................... 86
CLEANING............................................................................................................ 93
ASSEMBLY ........................................................................................................... 93
04 – TOP END....................................................................................................... 99
GENERAL........................................................................................................... 102
DISASSEMBLY ..................................................................................................... 104
CLEANING.......................................................................................................... 111
INSPECTION........................................................................................................ 112
USED PISTONMEASUREMENT.................................................................................. 113
ASSEMBLY ......................................................................................................... 116
ADJUSTMENT...................................................................................................... 125
05 – BOTTOM END ............................................................................................... 129
DISASSEMBLY ..................................................................................................... 132
CLEANING.......................................................................................................... 139
INSPECTION........................................................................................................ 140
ASSEMBLY ......................................................................................................... 144
II
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