SANMEN COUNTY YONGFU MACHINE UTV650 Maintenance Manual

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UTV650

Maintenance Manual

SANMEN COUNTY YONGFU MACHINE CO.,LTD

Any copy or without written permission

or authorization of Yongfu is prohibited to use

the manual (version 1, Oct 2017).

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Summary of Contents for SANMEN COUNTY YONGFU MACHINE UTV650

Page 1 UTV650 Maintenance Manual SANMEN COUNTY YONGFU MACHINE CO.,LTD Any copy or without written permission or authorization of Yongfu is prohibited to use the manual (version 1, Oct 2017). All rights reserved...
Page 2 GROUP INDEX overhaul, maintenance, overhauling program, dismantling, assembling, troubleshooting and service data of UTV650 GENERAL INFORMATION This manual will help you know the vehicle beter so that you can assure your customers of fast and reliable PERIODIC MAINTENANCE service. This manual hass been prepareed on the basis of the COOLING SYSTEM latest specifications at the time of publication.If...
Page 3 1. GENERAL INFORMATION 1. GENERAL INFORMATION PRECAUTIONS ······································ 1-1 TECHNICAL SPECIFICATIONS ·················· 1-3 TIGHTENING TORQUE ···························· 1-7 PRECAUTIONS Do not make engine under operation at a closed place or place with poor ventilation for a long time. If engine stops operation, please do not touch it or silencer to avoid burning. Due to high corrosiveness, battery fluid (dilute sulphuric acid)) may cause burns to skin and eyes.
Page 4 1. GENERAL INFORMATION 19. Please install a side dust proof bearing at correct direction. In installation of open or double-face dust proof bearing, pay attention to that marks of manufacturer shall be outward. 20. In cleaning and drying bearing, please keep bearing support still. Before installation, please carry out lubrication with oil or lubricating oil.
Page 5 1. GENERAL INFORMATION TECHNICAL SPECIFICATIONS Item Parameter Dimensions Overall length 2930mm Overall width 1400mm Overall height 1830mm Seat height 440mm Wheelbase 1916mm Ground clearance 300mm Engine Single cylinder,four stroke,four valves,water Type cooling+Oil cooling ,EFI Number of valves Cylinder diameter 96 mm Piston stroke 86 mm Compression ratio...
Page 6 1. GENERAL INFORMATION Size “A” Piston measurement 90.955 to 90.962mm Size “B” 90.962 to 90.970mm Size “A” Cylinder measurement 90.995 to 91.003mm Size “B” 91.003 to 91.010mm Clearance of cylinder - piston 0.033 to 0.048mm Service limit 0.090mm Piston ring type Upper compression ring, rectangular Lower compression ring, tapered face Oil scraper ring...
Page 7 1. GENERAL INFORMATION Transmission type Continuously variable ratio Drive belt width Service limit Gearbox type Gearbox oil Capacity Gear ratio Type Maximum load Capacity of cooling liquid Capacity of water tank Cooling liquid temperature Valve opening thermostat Fan opening Magneto generator output Crankshaft position sensor value of resistance Type Pressure...
Page 8 1. GENERAL INFORMATION Electrical Ignition system Type Maintenance Free Battery Voltage capacity 30AH Lock(fist shift) Light relay Fuses Main relay Lock(second shift) Reserve power Driving lamp Head lamp Fog light Tail light 12V 21W/5W Indicator light Turn light 12V 10W...
Page 9 1. GENERAL INFORMATION TIGHTENING TORQUE Locking devices ( e.g.: locking tabs, elastic stop nuts ,self-locking fasteners ,etc.) must be installed or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the following recommended torque value: Torque( N·m)
Page 10 1. GENERAL INFORMATION Magneto stator bolt 12.5(1.3) One way bolt 30(3.1) Engine oil drain plug 20(2.0) Gearbox oil drain plug 20(2.0) Decompression valve plug 20(2.0) Cylinder head bolt 60(6.1） Cylinder head bolt 12.5(1.3) Connecting rod bolt 50(5.1) Timing chain wheel bolt 30(3.1) Front output shaft flange bolt 30(3.1)
Page 11 2. PERIODIC MAINTENANCE 2. PERIODIC MAINTENANCE MAINTENANCE SCHEDULE ······················ 2-1 AIR CLEANER ········································· 2-3 VALVE CLEARANCE ································· 2-4 SPARK PLUG ··········································· 2-8 THROTTLE CABLE PLAY ··························· 2-8 ENGINE OIL ············································ 2-9 FRONT REDUCER OIL ······························· 2-11 REART REDUCER OIL ······························· 2-12 STEERING SYSTEM ··································...
Page 12 2. PERIODIC MAINTENANCE INTIAL EVERY Whichever month Comes first ITEM ROUTINE 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) hours ●Check operation/brake wear/fluid leakage. ●Brake fluid needs to be above the lowest Brake* position. ●Correct if necessary. Replace pads/disk if worn to the limit.
Page 13 2. PERIODIC MAINTENANCE AIR CLEANER In case of driving in dusty environment, air filter shall be cleaned regularly. It is of great possibility to accelerate wear to engine if there is not filtering element or worn filtering element is used. So, please keep air filter under good conditions all the time.
Page 14 2. PERIODIC MAINTENANCE Blow low pressure compressed air on filter element to clean it. Properly reinstall removed parts in the reverse order of their removal. pay attention to the seal gasket of air filter housing is not skew. CAUTION 1.If liquid /deposits are found, squeeze and dry the foam filter. Replace filter element if damaged. 2.Do not start engine if liquid or deposit are found.
Page 15 2. PERIODIC MAINTENANCE Remove the plug screw and O-ring of magneto cover. Remove the crankshaft position sensor. 1. Crankshaft position sensor 2. Screw Valve clearance of cylinder 2 Use a 14 mm Allen key to turn crankshaft until piston 2, rear is at TDC ignition.
Page 16 2. PERIODIC MAINTENANCE CAUTION Securely tighten the locknut after completing adjustment. Valve clearance adjuster locknut:12N.m Valve clearance of cylinder 1 Using a 14 mm Allen key, turn crankshaft 280 ° counterclockwise. 1. Allen key 14mm 2. Turn crankshaft 280°counterclockwise At TDC ignition, the printed marks on the camshaft timing gear have to be parallel to cylinder head base as per following illustration.
Page 17 2. PERIODIC MAINTENANCE SPARK PLUG In case of serious wear or burn to electrode or burn to insulator by spark plug or damage to thread etc, please replace it with new spark plug In case of carbon deposit, please use proper tools for cleaning. Spark plug gap Use clearance gauge to measure clearance of spark plug.
Page 18 2. PERIODIC MAINTENANCE Loose throttle cable (bracing cable).Turn adjuster to adjust free play of throttle pedal. After adjustment, tighten nut. If free play after adjustment cannot reach designated requirement or there is viscosity for throttle valve, replace it with new throttle cable. ENGINE OIL Oil level verification Strictly follow this procedure, otherwise wrong oil...
Page 19 2. PERIODIC MAINTENANCE Replace engine oil Prior to change the oil, ensure vehicle is on a level surface. Oil and oil filter must be replaced at the same time. Oil change and oil filter replacement should be done with a warm engine. WARNING The engine oil can be very hot.
Page 20 2. PERIODIC MAINTENANCE classification engine oil, Oil change capacity with filter 1850mL. 17. Check the oil level with the dipstick. Refer to OIL LEVEL VERIFICATION above. 18. Run engine to ensure oil filter and drain plug areas are not leaking. CAUTION In order to expand service life of vehicle, please use grade SJ standard engine oil conforming to...
Page 21 2. PERIODIC MAINTENANCE STEERING SYSTEM Park vehicle at flat ground and hold steering wheel for wobbling to up, down, left and right.Check whether there is loosing. In case of wobbling, tighten nut or dismantle steering column for further inspection. Park vehicle at flat ground and turn handle left or right slowly to see whether it can be turned flexibly. In case of obstacles, check whether it is caused by main cable or other wiring installation.
Page 22 2. PERIODIC MAINTENANCE Brake pedal adjustment The brake pedal stroke is 30～40mm. If less than equal 30mm, it will be a hidden dangers, must adjust the brake pin connecting the brake pedal. Parking brake adjustment Pull the parking brake lever up to engage the parking brake.
Page 23 2. PERIODIC MAINTENANCE GEAR SHIFT Check the shift lever as to change gearshift from P to R N H L and reverse smoothly. Also the meter display is correct. The shift lever should be vertical when the gear is in neutral.
Page 24 2. PERIODIC MAINTENANCE Check the level of cooling water in fluid reservoir (auxiliary radiator) is between upper and lower critical levels. WARNING To avoid potential burns, do not remove the radiator cap or loosen the cooling drain plug if the engine is hot. Never drain or refill cooling system when engine is hot.
Page 25 2. PERIODIC MAINTENANCE Unscrew bleed screws on top of thermostat housing. Both cylinders must be bled. Fill up the radiator with coolant, when the coolant comes out by the thermostat housing hole, install the bleed screws with its gasket ring and torque to 10 N.m. Refill coolant tank up to upper level mark.
Page 26 2. PERIODIC MAINTENANCE Tire thread. When the tire groove decreases to 6 mm (0.24 in) due to wear, replace the tire. ENGINE COMPRESSION PRESSURE The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on results of a compression test.
Page 27 2. PERIODIC MAINTENANCE ENGINE OIL PRESSURE Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. The engine oil pressure test should be done with a warm engine 90℃ and the recommended oil. Remove left and right seats, gear shift handle and engine shield.
Page 28 3. Cooling system 3. COOLING SYSTEM FAULT OVERHAULING ····························· 3-1 COOLING SYSTEM TEST ··························· 3-2 THERMOSTAT ········································· 3-3 RADIATOR AND CAP ································ 3-3 COOLANT TANK ······································ 3-4 RADIATOR FAN ········································ 3-4 WATER PUMP HOUSING ···························· 3-6 WATER PUMP IMPELLER ··························· 3-6 WATER PUMP SHAFT AND SEALS ···············...
Page 29 3. Cooling system COOLING SYSTEM TEST ! WARNING To avoid potential burns, do not remove the radiator cap or loosen the cooling drain plug if the engine is hot. Open the upper cover of engine hood and remove the radiator cap. Install the test cap and a small hose pincher on overflow hose.
Page 30 3. Cooling system THERMOSTAT The thermostat is a single action type. The thermostat is located on the top of cylinder head, on intake side. Remove: ◼ thermostat housing screws and pull thermostat cover 1. Thermostat cover 2. Screws ◼ thermostat with gasket out of the hole. Thermostat Test To check thermostat, put in water and heat water.
Page 31 3. Cooling system Radiator Installation For installation, reverse the removal procedure. Pay attention to the following detail. Fill radiator. Refer COOLANT REPLACEMENT, in this section. Check for any coolant leakage from radiator and hoses. COOLANT TANK The coolant expands as the temperature (up to 100-110℃) and pressure rise in the system.
Page 32 3. Cooling system Radiator Fan Installation For the installation, reverse the removal procedure...
Page 33 3. Cooling system WATER PUMP HOUSING ! WARNING It is located on the engine MAG side. To avoid potential burns, do not remove Water Pump Housing Removal the radiator cap or loosen the cooling drain plug if the engine is hot . Drain cooling system.
Page 34 4. FUEL SYSTEM 4. FUEL SYSTEM FUEL PRESSURE TEST ······························ 4-2 FUEL FILTER ··········································· 4-2 FUEL PUMP ············································· 4-3 FUEL TANK ············································· 4-3 The fuel system of a fuel injection system holds much more a pressure than on carbureted vehicle. Prior to disconnecting a hose or to removing a component from the fuel system, follow the recommendation described here.
Page 35 4. FUEL SYSTEM FUEL PRESSURE TEST The pressure test will show the available pressure at the fuel pump outlet. It validates the pressure regulator, the fuel pump and leaks in the system. Before proceeding to the pressure test ensure the battery is fully charged. Battery voltage must be over 12 volts. Ensure there is enough gas in fuel tank.
Page 36 4. FUEL SYSTEM FUEL PUMP Fuel pump electrical test. When turning ignition key ON, the fuel pump should run for 5 seconds to build up the fuel pressure in the system. If the pump does not work, disconnect the connector from the fuel pump.
Page 37 5. DRIVE TRAIN 5. DRIVE TRAIN FRONT DRIVE ········································· 5-6 REAR DRIVE ··········································· 5-6 FRONT PROPELLER SHAFT ···················· 5-6 REAR PROPELLER SHAFT ······················ 5-6 FRONT WHEEL HUB ······························ 5-6 REAR WHEEL HUB ································ 5-6 FRONT DRIVE SHAFT ···························· 5-6 REAR DRIVE SHAFT ······························ 5-6 FRONT DIFFERENTIAL ··························...
Page 38 5. DRIVE TRAIN Removal Raise the front of vehicle, support it securely on jack stands and remove front wheel. Remove cotter pin, castellated nut and belleville washer. Remove the caliper from knuckle. Pull the wheel hub to remove it. Inspection Check wheel hub for cracks or other damages.
Page 39 5. DRIVE TRAIN Check if the bearing in kunckle move freely and smoothly. If not, replace them. Installation Apply grease to the splines and insert the end of drive shaft in differential and pull joint a little to make sure that the stop ring is locked in differential side gear groove.
Page 40 5. DRIVE TRAIN REAR PROPELLER SHAFT Removal Place vehicle on PARK position and select 4WD. Remove left and right seats, gear shift handle and engine shield. Unscrew propeller shaft bolt on engine side. Inspection Inspect the propeller shaft for wear or damage. If any defects are found, replace the propeller shaft with new one.
Page 41 5. DRIVE TRAIN Check the ring at teh end of drive shaft. If wear is apparent, replace the wear ring. Ring Check if the bearing in kunckle move freely and smoothly. If not, replace them. Installation Apply grease to the splines and insert the end of drive shaft in differential and pull joint a little to make sure that the stop ring is locked in differential side gear groove.
Page 42 5. DRIVE TRAIN Tire replacement Use jack to support vehicle and ensure its no dropping. Remove the wheels. After removing the air valve cap, release the tire pressure by depressing the valve. Dismount the bead from the rim completely. Separate the tire from the rim by using a set of tire levers and rim protectors.
Page 43 6. STEERING SYSTEM 6. STEERING SYSTEM STEERING WHEEL ··································· 6-1 STEERING LINKAGE ································· 6-1 STEERING GEARBOX ······························· 6-1 STEERING ALIGNMENT ···························· 6-2 Inspect the tie rod for distortion or damage. If any damage are found, replace the tie rod with a new one. Inspect the tie ends for smooth movement.
Page 44 6. STEERING SYSTEM STEERING ALIGNMENT Park vehicle on flat ground, make sure the tire pressure for right and left tires is same and set to the proper specification, set the front wheels in the straight position, then place a load of 75kg on the seat. Measurethe distance A and B of the front wheels and calculate the difference.
Page 45: Table Of Contents
7. SUSPENSION SYSTEM 7. SUSPENSION SYSTEM FRONT SUSPENSION ································ 7-1 REAR SUSPENSION ·································· 7-4 REMOVAL AND DISASSEMBLY ··············· 7-1 REMOVAL AND DISASSEMBLY ··············· 7-4 INSPECTION········································· 7-2 INSPECTION ········································· 7-4 SHOCK ABSORBER ···························· 7-2 SHOCK ABSORBER ····························· 7-5 KNUCKLE ········································· 7-2 KNUCKLE ·········································...
Page 46: Suspension System
7. SUSPENSION SYSTEM INSPECTION Shock absorber Inspect the shock absorber for oil leakage or damage, inspect the bushing for wear or damage. If any damage are found, replace the front shock absorber with a new one. Extend and compress the piston several times over its entire stroke.
Page 47: Lower Suspension Arm
7. SUSPENSION SYSTEM Lower Suspension Arm Inspect the suspension arm and for damage or distortion. If any damages or distortion are found, replace the suspension arm with a new one. Move suspension arm from side to side. There should be no noticeable loose. Replace bushing if necessary. Move suspension arm up and down.There should be no noticeable loose.
Page 48: Rear Suspension
7. SUSPENSION SYSTEM REAR SUSPENSION The procedure explained below is the same for the RH and LH sides unless otherwise noted. During assembly or installation, use the torque values and service products as in the torque table REMOVAL AND DISASSEMBLY Loosen wheel nut of the appropriate.
Page 49: Knuckle
7. SUSPENSION SYSTEM Knuckle Inspect the knuckle for damage. If any damages are found, replace the knuckle with a new one. Check bearing and seal for damage or wear, If any damages or wear are found, replace a new one. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Lower Suspension Arm...
Page 50 8. BRAKES SYSTEM 8. BRAKES SYSTEM BRAKE FLUID REPLACMENT ···················· 8-2 BRAKE PADS REPLACMENT ······················ 8-3 BRAKE DISC ··········································· 8-3 BRAKE CALIPER ······································ 8-4 BRAKE LIGHT SWITCH ····························· 8-4 BRAKE HOSE ·········································· 8-5 PARKING BRAKE MECHANISM ·················· 8-5 This brake system is filled with an ethylene glycol-based DOT4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based brake fluids.
Page 51: Brakes System
8. BRAKES SYSTEM BRAKE FLUID REPLACMENT Place the vehicle on a level surface. Remove the master cylinder reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with new brake fluid. Remove the dust cap of air bleeder valve. Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.
Page 52: Brake Disc
8. BRAKES SYSTEM BRAKE PADS REPLACMENT Remove the wheel. Remove the brake caliper mounting bolt and brake pads mounting pins. Remove the brake pads. Make sure that pad spring is in position. Install the new brake pads. Brake pads Install pad pins by pushing in the pads against pad mounting pins spring to align pad slots in the pads and caliper body.
Page 53: Brake Light Switch
8. BRAKES SYSTEM Maxmum warpage of brake disc:0.3mm. Reassembly and remounting Reassemble snd remount the brake disc in the reverse order of removal and disassembly. Pay attention to the following points: Install the disc to the wheel hub with the punching letters on the disc showed up. Make sure that the disc is clean and free of any greasy matter.
Page 54: Brake Hose
8. BRAKES SYSTEM Inspection Fist ensure brake light is good. Check switch for dirt or corrosion. Make sure it is operating properly. Depress brake pedal and check for brake light to turn on. Repeat with the brake pedal. Test Disconnect switch connectors. Check switch operation as follows.
Page 55 8. BRAKES SYSTEM PARKING BRAKE MECHANISM Parking brake cable removal Remove left and right seats, gear shift handle. Remove engine shield. Detach parking brake cable from pulley as follows: Ensure parking brake is released. Unscrew nut securing parking brake cable on parking brake support.
Page 56 8. BRAKES SYSTEM The installation is the reverse of the removal procedure. However, pay attention to the following. Adjust parking brake cable. Pull the parking brake lever up to engage the parking brake. To release the unit, press button on front end of parking lever then push the parking lever to the bottom.
Page 57 9. ELECTRICAL SYSTEM 9. ELECTRICAL SYSTEM WIRING DIAGRAMS ··································· 9-2 CAUTIONS IN SERVICING·························· 9-8 LOCATION OF ELECTRICAL COMPONENTS ··· 9-2 IGNITION SYSTEM ··································· 9-8 STARTING SYSTEM ···································· 9-4 LAMPS ··················································· 9-8 INDICATOR LIGHT ····································· 9-8 SWITCHES ·············································· 9-8 BATTERY ·················································· 9-8 CHARGING SYSTEM ·································...
Page 58 9. ELECTRICAL SYSTEM Resistance of generator coil Measure the resistance between three wires; If the resistance is not within the specified value, replace the stator coil. Check the generator core whether it is insulated. Install multimeter 1×10Ω. Resistance of generator coil: 0.9-1.5Ω (color: yellow) Insulation resistance ∞Ω...
Page 59 9. ELECTRICAL SYSTEM Regulator / Rectifier Measure the resistance between terminals with multimeter. If the resistance is not within the range of specified values, replace the regulator / rectifier. NOTE: If the probe is not connected and the multi meter reading is lower than 1.4V, replace the multi meter battery.
Page 60 9. ELECTRICAL SYSTEM Starting system Starter motor Bracket Brush holder Brush spring O-Ring Washer Motor housing Washer Armature coil Washer supporting tools Inner bracket O-Ring...
Page 61 9. ELECTRICAL SYSTEM Brush Check the brush on the brush holder whether it is worn abnormal, cracked or not smooth. Worn, cracked, or not smooth: → Replace Rectifier Check the rectifier whether it is discolored, abnormal wear or concave. Abnormal wear or damage: → Replace If the rectifier is discolored, grind it with sanding paper, then wipe it with a clean fabric.
Page 62 9. ELECTRICAL SYSTEM Starter relay Inter-terminal voltage is 12V. Test the direct connection of positive and negative poles with the multimeter. If the starter relay clicks and connected, the starter relay is OK. When there is no voltage of 12V, they are not connected, the starter relay is OK.
Page 63 9. ELECTRICAL SYSTEM Ignition system Ignition coil Primary peak voltage of ignition coil Remove the spark plug cap as shown in the right figure. Install the new spark plug to the cap. The cylinder is connected to grounding. Connect the multimeter and the peak voltage adapter as follows: +Probe: Green wire or grounding wire -Probe: Black / yellow wire...
Page 64 9. ELECTRICAL SYSTEM Primary peak voltage of ignition coil: ≥150V Note: Do not touch the test probes or spark plug, in case of electric shock. If the voltage is lower than the standard value, check the ignition coil and coupling coil. Resistance of ignition coil Disconnect the ignition coil wires and spark plug cap.
Page 65 10. TROUBLESHOOTING 10. TROUBLESHOOTING ELECTRICAL SYSTEM ····························· 10-1 COOLING SYSTEM ·································· 10-1 MAGNETO SYSTEM ································· 10-2 LUBRICATION ········································· 10-2 CYLINDER AND HEAD ······························ 10-3 CRANKSHAFT ········································· 10-3 GEARBOX ··············································· 10-3 COUPLING UNIT ······································ 10-4 CVT ······················································· 10-4 ENGINE GENERAL ··································· 10-6 ELECTRICAL SYSTEM Symptom: NO SPARK OR POOR SPARK 1.
Page 66 10. TROUBLESHOOTING 12. Check if water pump shaft is seized. ◼ Water pump shaft does not turn. Replace defective part(s). 13. Check cooling fan and connection. ◼ Fan motor faulty. Replace. ◼ Wire harness is brittle or hard (no connection). Replace. 14.
Page 67 10. TROUBLESHOOTING ◼ Valve spring damaged (valve always open). Replace spring. ◼ Valve piston is worn or broken. Replace valve piston (refer to lubrication system). ◼ Valve piston stays open due to contamination. Clean or repair valve piston. 9. Check plain bearings in crankcase for heavy wear. ◼...
Page 68 10. TROUBLESHOOTING ◼ Tooth of gears are damaged and/or worn. Replace respective gears. Symptom: GEAR INDICATION FAILS. 1. Check contact screws on gear housing center. ◼ Check contact screw outside for contamination and wetness. Clean contact screw and screw for wiring harness. ◼...
Page 69 10. TROUBLESHOOTING at the same time (lever kit). ◼ Roller(s) is (are) worn and/or damaged. Replace governor cup assembly. 3. Check drive/driven pulley sliding sheave for free axial movement. ◼ Sliding sheave is stuck. Replace damaged part(s). 4. Check condition of drive/driven pulley spring. ◼...
Page 70 10. TROUBLESHOOTING 1. Check tightening torque of drive pulley screw. ◼ Moving sliding sheave. Retighten screw. 2. Check fixed sheave bushings. ◼ Excessive gap between bushings and fixed sheave shaft, thus restraining sliding sheave movements. Replace fixed sheave assembly. 3. Check if slider shoes are present and/or placed in correct position. ◼...
Page 71 10. TROUBLESHOOTING plugs or replace. 3. Check for fuel on spark plugs. ◼ Flooded engine (spark plugs wet when removed). Activate engine drowned mode and crank engine with rags over the spark plug holes. 4. Check battery voltage. ◼ Battery is discharged and starter works not properly. Charge battery. 5.
Page 72 10. TROUBLESHOOTING ◼ Snow/water intrusion through intake system into combustion chamber. Clean intake system and replace defective part(s). 4. Melted and/or perforated piston dome; melted section at ring end gap. ◼ Spark plugs heat range is too hot. Install recommended spark plugs (refer to TECHNICAL SPECIFICATIONS).
Page 73 10. TROUBLESHOOTING ◼ Low fuel pressure. Perform fuel pressure test (refer to FUEL SYSTEM). Check air intake system. ◼ Air filter is clogged due to contamination. Replace air filter. Check if EMS (engine management system) is in limp home mode. Check fault codes in B.U.D.S.