Troubleshooting - Polaris SPORTSMAN 600 2003 Service Manual

TROUBLESHOOTING

Spark Plug Fouling
G
Spark plug cap loose or faulty
G
Choke cable adjustment or
plunger/cable sticking
G Foreign material on choke plunger
seat or plunger
G
Incorrect spark plug heat range or
gap
G
Carburetor inlet needle and seat
worn
G
Jet needle and/or needle jet worn
or improperly adjusted
G Excessive carburetor vibration
(loose or missing needle jet locating
clips)
G Loose jets in carburetor or
calibration incorrect for
altitude/temperature
G Incorrect float level setting
G PVT system calibrated incorrectly/
components worn or mis-adjusted
G Fuel quality poor (old) or octane too
high
G
Low compression
G Restricted exhaust
G Weak ignition (loose coil ground,
faulty coil, stator, or ETC switch)
G ETC switch mis-adjusted
G Restricted air filter (main or
pre-cleaner) or breather system
G
Improperly assembled air intake
system
G Restricted engine breather system
G Oil contaminated with fuel
Engine Turns Over But Fails to Start
G
No fuel
G
Dirt in fuel line or filter
G
Fuel will not pass through fuel valve
G Fuel pump inoperative/restricted
G Tank vent plugged or pinched
G Carb starter circuit plugged
3.56
G
Engine flooded
G Low compression (high cylinder
leakage)
G No spark (Spark plug fouled)
ignition component failure
Engine Does Not Turn Over
G Dead battery
G
Starter motor does not turn
G
Engine seized, rusted, or
mechanical failure
Engine Runs But Will Not Idle
G Restricted carburetor pilot system
G
Carburetor misadjusted
G Choke not adjusted properly
G
Low compression
G
Crankcase breather restricted
Engine Idles But Will Not Rev Up
G
Spark plug fouled/weak spark
G
Broken throttle cable
G Obstruction in air intake
G
Air box removed (reinstall all intake
components)
G Incorrect or restricted carburetor
jetting
G ETC switch limiting speed
G Reverse speed limiter limiting
speed
G Carburetor vacuum slide
sticking/diaphragm damaged
G Incorrect ignition timing
G
Restricted exhaust system
G Cam worn excessively
Engine Has Low Power
G Spark plug fouled
G Cylinder, piston, ring, or valve wear
or damage (check compression)
G PVT not operating properly
G
Restricted exhaust muffler
G Carburetor vacuum slide
sticking/diaphragm damaged
G
Dirty carburetor
G
Cam worn excessively
ENGINE ENGINE