Troubleshooting - Tracker Off-Road 800SX Service Manual

MOD392

Troubleshooting

Problem: Engine will not start or is hard to start (Compression too low)
Condition
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
Problem: Engine will not start or is hard to start (No spark)
Condition
1. Spark plug fouled
2. Spark plug wet
3. ECM defective
4. Ignition coil defective
5. Spark plug wire(s) open — shorted
Problem: Engine will not start or is hard to start (No fuel reaching the fuel injectors)
Condition
1. Gas tank vent hose obstructed
2. Fuel hose obstructed
3. Fuel screens obstructed
4. Fuel pump defective
Problem: Engine noisy (Excessive valve chatter)
Condition
1. Valve clearance too large
2. Valve spring(s) weak — broken
3. Camshaft worn
Problem: Engine noisy (Noise seems to come from piston)
Condition
1. Piston — cylinder worn
2. Combustion chamber carbon buildup
3. Piston pin — piston pin bore worn
4. Piston rings — ring groove(s) worn
Problem: Engine noisy (Noise seems to come from crankshaft)
Condition
1. Bearings worn — burned
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.
Remedy
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
Remedy
1. Clean — replace plug
2. Clean — dry plug
3. Replace ECM
4. Replace ignition coil
5. Replace spark plug wire(s)
Remedy
1. Clean vent hose
2. Clean — replace hose
3. Clean — replace inlet screen
4. Replace fuel pump
Remedy
1. Adjust clearance
2. Replace spring(s)
3. Replace camshaft
Remedy
1. Replace — service piston — engine block
2. Clean chamber
3. Replace — service pin — bore
4. Replace rings — piston
Remedy
1. Replace bearings and/or crankshaft
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