35
Troubleshooting
Problem: Engine will not start or is hard to start (Compression too low)
Condition Remedy
1. Valve clearance out of adjustment
2. Valve guides worn
3. Valves mistimed
4. Piston rings worn - broken
5. Cylinder bore worn
6. Starter motor cranks too slowly - does not turn
1. Adjust clearance
2. Replace guides
3. Retime engine
4. Replace rings
5. Replace cylinder
6. See Electrical System
Problem: Engine will not start or is hard to start (No spark)
Condition Remedy
1. Spark plug fouled
2. Spark plug wet
3. Magneto defective
4. ECM defective
5. Ignition coil defective
6. High-tension lead open - shorted
1. Clean - replace plug
2. Clean - dry plug
3. Replace stator coil
4. Replace ECM
5. Replace ignition coil
6. Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)
Condition Remedy
1. Gas tank vent hose obstructed
2. Fuel hose obstructed
3. Fuel screens obstructed
4. Fuel pump defective
1. Clean vent hose
2. Clean - replace hose
3. Clean - replace inlet screen
4. Replace fuel pump
Problem: Engine stalls easily
Condition Remedy
1. Spark plug fouled
2. Magneto defective
3. ECM defective
4. Fuel injector obstructed
5. Valve clearance out of adjustment
1. Clean - replace plug
2. Replace stator coil
3. Replace ECM
4. Replace fuel injector
5. Adjust clearance
Problem: Engine noisy (Excessive valve chatter)
Condition Remedy
1. Valve clearance excessive
2. Valve spring(s) weak - broken
3. Rocker arm - rocker arm shaft worn
4. Camshaft worn
1. Adjust clearance
2. Replace spring(s)
3. Replace arm - shaft
4. Replace camshaft
Problem: Engine noisy (Noise seems to come from piston)
Condition Remedy
1. Piston - cylinder worn
2. Combustion chamber carbon buildup
3. Piston pin - piston pin bore worn
4. Piston rings - ring groove(s) worn
1. Replace cylinder - service piston
2. Clean cylinder head and piston
3. Replace - service pin - bore
4. Replace rings - piston
Problem: Engine noisy (Noise seems to come from timing chain)
Condition Remedy
1. Chain stretched
2. Sprockets worn
3. Tension adjuster malfunctioning
1. Replace chain
2. Replace sprockets
3. Repair - replace adjuster
Problem: Engine noisy (Noise seems to come from crankshaft)
Condition Remedy
1. Main bearing worn - burned
2. Lower rod-end bearing worn - burned
3. Connecting rod side clearance too large
4. Centrifugal clutch loose
5. Rotor/flywheel loose
1. Replace bearing
2. Replace crankshaft assembly
3. Replace crankshaft assembly
4. Tighten - replace clutch
5. Tighten - replace flywheel - crankshaft
Problem: Engine noisy (Noise seems to come from transmission)
Condition Remedy
1. Gears worn - chipped
2. Splines worn
3. Primary gears worn - chipped
4. Bearings worn
5. Bushing worn
1. Replace gears
2. Replace shaft(s) - gears
3. Replace gears
4. Replace bearings
5. Replace bushing
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