Tracker Off-Road 800SX - Troubleshooting Engine Performance; Engine Starting Problems; Engine Noise Issues

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MOD392 MOD393
18. Install the drive clutch, drive belt, driven clutch and
clutch cover; then install the rear inner fenders and
cargo box.
19. Fill with coolant (see the Liquid Cooling System sec-
tion) and bleed the cooling system; then connect the
battery connections.
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 — seated poorly
3. Valves mistimed
4. Piston rings worn excessively
5. Cylinder bore worn
6. Starter motor cranks too slowly — does not turn
1. Adjust clearance
2. Repair — replace guides
3. Re-time valves
4. Replace rings
5. Replace — re-bore engine block
6. See Electrical System — Troubleshooting
Problem: Engine will not start or is hard to start (No spark)
Condition Remedy
1. Spark plug fouled
2. Spark plug wet
3. ECM defective
4. Ignition coil defective
5. Spark plug wire(s) open — shorted
1. Clean — replace plug
2. Clean — dry plug
3. Replace ECM
4. Replace ignition coil
5. Replace spark plug wire(s)
Problem: Engine will not start or is hard to start (No fuel reaching the fuel injectors)
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 noisy (Excessive valve chatter)
Condition Remedy
1. Valve clearance too large
2. Valve spring(s) weak — broken
3. Camshaft worn
1. Adjust clearance
2. Replace spring(s)
3. 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 — service piston — engine block
2. Clean chamber
3. Replace — service pin — bore
4. Replace rings — piston
Problem: Engine noisy (Noise seems to come from crankshaft)
Condition Remedy
1. Bearings worn — burned 1. Replace bearings and/or crankshaft