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18-24 APPENDIX
Troubleshooting Guide
NOTE
○
This is not an exhaustive list, giving every
possible cause for each problem listed. It
is meant simply as a rough guide to assist
the troubleshooting for some of the more
common difficulties.
Engine Doesn’t Start, Starting Difficulty:
Starter motor not rotating:
Neutral switch trouble
Starter motor trouble
Battery voltage low
Relays not contacting or operating
Wiring open or shorted
Main switch trouble
Fuse blown
Starter motor rotating but engine doesn’t
turn over:
Starter motor trouble
Pinion or ring gear worn
Engine won’t turn over:
Valve seizure
Rocker arm seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end s eizure
Camshaft seizure
No fuel flow:
No fuel in tank
Fuel tank air vent obstructed
Fuel injection pump trouble
Fuel filter clogged
Fuel line clogged
Compression low:
Fuel injection nozzle l oose
Glow plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston rings bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Poor Running at Low Speed:
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or miss-
ing
Fuel tank air vent obstructed
Fuel injection pump trouble
Compression low:
Fuel injection nozzle loose
Glow plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston w orn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Other:
Engine oil viscosity too high
Front final gear case oil viscosity too high
Drive train trouble
Brake dragging
Poor Running or No Power at High Speed:
Fuel/air mixture incorrect:
Air c leaner clogged, poorly sealed, or miss-
ing
Fuel tank air vent obstructed
Fuel line clogged
Fuel injection pump trouble
Compression low:
Fuel injection nozzle loose
Glow plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston w orn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
- Utility Vehicle 1
- Service Manual 1
- Quick Reference Guide 3
- LIST OF ABBREVIATIONS 6
- COUNTRY AND AREA CODES 6
- EMISSION CONTROL INFORMATION 7
- (US Model only) 8
- Foreword 9
- General Information 11
- 1-2 GENERAL INFORMATION 12
- GENERAL INFORMATION 1-3 13
- 1-4 GENERAL INFORMATION 14
- GENERAL INFORMATION 1-5 15
- 1-6 GENERAL INFORMATION 16
- GENERAL INFORMATION 1-7 17
- 1-8 GENERAL INFORMATION 18
- GENERAL INFORMATION 1-9 19
- 1-10 GENERAL INFORMATION 20
- GENERAL INFORMAT ION 1-11 21
- Periodic Maintenance 23
- 2-2 PERIODIC MAINTENANCE 24
- PERIODIC MAINTENANCE 2-3 25
- 2-4 PERIODIC MAINTENANCE 26
- PERIODIC MAINTENANCE 2-5 27
- 2-6 PERIODIC MAINTENANCE 28
- PERIODIC MAINTENANCE 2-7 29
- 2-8 PERIODIC MAINTENANCE 30
- PERIODIC MAINTENANCE 2-9 31
- 2-10 PERIODIC MAINTENANCE 32
- PERIODIC MAINTENANCE 2-11 33
- 2-12 PERIODIC MAINTENANCE 34
- PERIODIC MAINTENANCE 2-13 35
- 2-14 PERIODIC MAINTENANCE 36
- PERIODIC MAINTENANCE 2-15 37
- 2-16 PERIODIC MAINTENANCE 38
- PERIODIC MAINTENANCE 2-17 39
- 2-18 PERIODIC MAINTENANCE 40
- PERIODIC MAINTENANCE 2-19 41
- 2-20 PERIODIC MAINTENANCE 42
- PERIODIC MAINTENANCE 2-21 43
- 2-22 PERIODIC MAINTENANCE 44
- PERIODIC MAINTENANCE 2-23 45
- 2-24 PERIODIC MAINTENANCE 46
- PERIODIC MAINTENANCE 2-25 47
- 2-26 PERIODIC MAINTENANCE 48
- PERIODIC MAINTENANCE 2-27 49
- 2-28 PERIODIC MAINTENANCE 50
- PERIODIC MAINTENANCE 2-29 51
- 2-30 PERIODIC MAINTENANCE 52
- PERIODIC MAINTENANCE 2-31 53
- 2-32 PERIODIC MAINTENANCE 54
- PERIODIC MAINTENANCE 2-33 55
- 2-34 PERIODIC MAINTENANCE 56
- PERIODIC MAINTENANCE 2-35 57
- 2-36 PERIODIC MAINTENANCE 58
- PERIODIC MAINTENANCE 2-37 59
- 2-38 PERIODIC MAINTENANCE 60
- PERIODIC MAINTENANCE 2-39 61
- 2-40 PERIODIC MAINTENANCE 62
- PERIODIC MAINTENANCE 2-41 63
- 2-42 PERIODIC MAINTENANCE 64
- PERIODIC MAINTENANCE 2-43 65
- 2-44 PERIODIC MAINTENANCE 66
- PERIODIC MAINTENANCE 2-45 67
- 2-46 PERIODIC MAINTENANCE 68
- PERIODIC MAINTENANCE 2-47 69
- Fuel System 71
- 3-2 FUEL SYSTEM 72
- FUEL SYSTEM 3-3 73
- 3-4 FUEL SYSTEM 74
- FUEL SYSTEM 3-5 75
- 3-6 FUEL SYSTEM 76
- FUEL SYSTEM 3-7 77
- 3-8 FUEL SYSTEM 78
- FUEL SYSTEM 3-9 79
- 3-10 FUEL SYSTEM 80
- FUEL SYSTEM 3-11 81
- 3-12 FUEL SYSTEM 82
- FUEL SYSTEM 3-13 83
- 3-14 FUEL SYSTEM 84
- FUEL SYSTEM 3-15 85
- 3-16 FUEL SYSTEM 86
- FUEL SYSTEM 3-17 87
- 3-18 FUEL SYSTEM 88
- FUEL SYSTEM 3-19 89
- 3-20 FUEL SYSTEM 90
- FUEL SYSTEM 3-21 91
- 3-22 FUEL SYSTEM 92
- FUEL SYSTEM 3-23 93
- 3-24 FUEL SYSTEM 94
- FUEL SYSTEM 3-25 95
- 3-26 FUEL SYSTEM 96
- FUEL SYSTEM 3-27 97
- 3-28 FUEL SYSTEM 98
- FUEL SYSTEM 3-29 99
- 3-30 FUEL SYSTEM 100
- FUEL SYSTEM 3-31 101
- 3-32 FUEL SYSTEM 102
- Cooling S ystem 103
- 4-2 COOLING SYSTEM 104
- COOLING SYSTEM 4-3 105
- 4-4 COOLING SYSTEM 106
- COOLING SYSTEM 4-5 107
- 4-6 COOLING SYSTEM 108
- COOLING SYSTEM 4-7 109
- 4-8 COOLING SYSTEM 110
- COOLING SYSTEM 4-9 111
- 4-10 COOLING SYSTEM 112
- COOLING SYSTEM 4-11 113
- 4-12 COOLING SYSTEM 114
- COOLING SYSTEM 4-13 115
- 4-14 COOLING SYSTEM 116
- Engine Top End 117
- 5-2 ENGINE TOP END 118
- ENGINE TOP END 5-3 119
- 5-4 ENGINE TOP END 120
- ENGINE TOP END 5-5 121
- 5-6 ENGINE TOP END 122
- ENGINE TOP END 5-7 123
- 5-8 ENGINE TOP END 124
- ENGINE TOP END 5-9 125
- 5-10 ENGINE TOP END 126
- ENGINE TOP END 5-11 127
- 5-12 ENGINE TOP END 128
- ENGINE TOP END 5-13 129
- 5-14 ENGINE TOP END 130
- ENGINE TOP END 5-15 131
- 5-16 ENGINE TOP END 132
- ENGINE TOP END 5-17 133
- 5-18 ENGINE TOP END 134
- ENGINE TOP END 5-19 135
- 5-20 ENGINE TOP END 136
- ENGINE TOP END 5-21 137
- 5-22 ENGINE TOP END 138
- ENGINE TOP END 5-23 139
- 5-24 ENGINE TOP END 140
- Converter System 141
- 6-2 CONVERTER SYSTEM 142
- CONVERTER SYSTEM 6-3 143
- 6-4 CONVERTER SYSTEM 144
- CONVERTER SYSTEM 6-5 145
- 6-6 CONVERTER SYSTEM 146
- CONVERTER SYSTEM 6 -7 147
- 6-8 CONVERTER SYSTEM 148
- CONVERTER SYSTEM 6-9 149
- 6-10 CONVERTER SYSTEM 150
- CONVERTER SYSTEM 6-11 151
- 6-12 CONVERTER SYSTEM 152
- CONVERTER SYSTEM 6-13 153
- 6-14 CONVERTER SYSTEM 154
- CONVERTER SYSTEM 6-15 155
- 6-16 CONVERTER SYSTEM 156
- CONVERTER SYSTEM 6-17 157
- 6-18 CONVERTER SYSTEM 158
- CONVERTER SYSTEM 6-19 159
- 6-20 CONVERTER SYSTEM 160
- CONVERTER SYSTEM 6-21 161
- 6-22 CONVERTER SYSTEM 162
- CONVERTER SYSTEM 6-23 163
- 6-24 CONVERTER SYSTEM 164
- CONVERTER SYSTEM 6-25 165
- 6-26 CONVERTER SYSTEM 166
- CONVERTER SYSTEM 6-27 167
- Engine Lubrication S ystem 169
- 7-2 ENGINE LUBRICATION SYSTEM 170
- ENGINE LUBRICATION SYSTEM 7-3 171
- 7-4 ENGINE LUBRICATION SYSTEM 172
- Special Tools and Sealant 173
- 7-6 ENGINE LUBRICATION SYSTEM 174
- ENGINE LUBRICATION SYSTEM 7-7 175
- 7-8 ENGINE LUBRICATION SYSTEM 176
- ENGINE LUBRICATION SYSTEM 7-9 177
- Oil Pump 178
- Relief Valve 179
- Oil Pressure Measurement 180
- Oil Pressure Switch 181
- Oil Nozzle 182
- Engine Removal/Installation 183
- Exploded View 184
- Special Tool 186
- Crankshaft/Crankcase 191
- 9-2 C RANKSHAFT/CRANKCASE 192
- CRANKSHAFT/CRANKCASE 9-3 193
- 9-4 C RANKSHAFT/CRANKCASE 194
- CRANKSHAFT/CRANKCASE 9-5 195
- 9-6 C RANKSHAFT/CRANKCASE 196
- CRANKSHAFT/CRANKCASE 9-7 197
- 9-8 C RANKSHAFT/CRANKCASE 198
- CRANKSHAFT/CRANKCASE 9-9 199
- 9-10 CRANKSHAFT/CRANKCASE 200
- CRANKSHAFT/CRANKCASE 9-11 201
- 9-12 CRANKSHAFT/CRANKCASE 202
- CRANKSHAFT/CRANKCASE 9-13 203
- 9-14 CRANKSHAFT/CRANKCASE 204
- CRANKSHAFT/CRANKCASE 9-15 205
- 9-16 CRANKSHAFT/CRANKCASE 206
- CRANKSHAFT/CRANKCASE 9-17 207
- 9-18 CRANKSHAFT/CRANKCASE 208
- CRANKSHAFT/CRANKCASE 9-19 209
- 9-20 CRANKSHAFT/CRANKCASE 210
- CRANKSHAFT/CRANKCASE 9-21 211
- 9-22 CRANKSHAFT/CRANKCASE 212
- CRANKSHAFT/CRANKCASE 9-23 213
- 9-24 CRANKSHAFT/CRANKCASE 214
- CRANKSHAFT/CRANKCASE 9-25 215
- 9-26 CRANKSHAFT/CRANKCASE 216
- CRANKSHAFT/CRANKCASE 9-27 217
- 9-28 CRANKSHAFT/CRANKCASE 218
- CRANKSHAFT/CRANKCASE 9-29 219
- 9-30 CRANKSHAFT/CRANKCASE 220
- CRANKSHAFT/CRANKCASE 9-31 221
- 9-32 CRANKSHAFT/CRANKCASE 222
- CRANKSHAFT/CRANKCASE 9-33 223
- Transmission 225
- 10-2 TRANSMISSION 226
- TRANSMISSION 10-3 227
- 10-4 TRANSMISSION 228
- TRANSMISSION 10-5 229
- 10-6 TRANSMISSION 230
- TRANSMISSION 10-7 231
- 10-8 TRANSMISSION 232
- TRANSMISSION 10-9 233
- 10-10 TRANSMISSION 234
- TRANSMISSION 10-11 235
- 10-12 TRANSMISSION 236
- TRANSMISSION 10-13 237
- 10-14 TRANSMISSION 238
- TRANSMISSION 10-15 239
- 10-16 TRANSMISSION 240
- TRANSMISSION 10-17 241
- 10-18 TRANSMISSION 242
- TRANSMISSION 10-19 243
- 10-20 TRANSMISSION 244
- TRANSMISSION 10-21 245
- 10-22 TRANSMISSION 246
- TRANSMISSION 10-23 247
- 10-24 TRANSMISSION 248
- TRANSMISSION 10-25 249
- 10-26 TRANSMISSION 250
- TRANSMISSION 10-27 251
- 10-28 TRANSMISSION 252
- TRANSMISSION 10-29 253
- 10-30 TRANSMISSION 254
- TRANSMISSION 10-31 255
- 10-32 TRANSMISSION 256
- TRANSMISSION 10-33 257
- 10-34 TRANSMISSION 258
- TRANSMISSION 10-35 259
- Wheels/Tires 261
- 11-2 WHEELS/TIRES 262
- WHEELS/TIRES 11-3 263
- 11-4 WHEELS/TIRES 264
- WHEELS/TIRES 11-5 265
- 11-6 WHEELS/TIRES 266
- WHEELS/TIRES 11-7 267
- 11-8 WHEELS/TIRES 268
- WHEELS/TIRES 11-9 269
- 11-10 WHEELS/TIRES 270
- Final Drive 271
- 12-2 FINAL DRIVE 272
- FINAL DRIVE 12-3 273
- 12-4 FINAL DRIVE 274
- FINAL DRIVE 12-5 275
- 12-6 FINAL DRIVE 276
- FINAL DRIVE 12-7 277
- 12-8 FINAL DRIVE 278
- FINAL DRIVE 12-9 279
- 12-10 FINAL DRIVE 280
- FINAL DRIVE 12-11 281
- 12-12 FINAL DRIVE 282
- FINAL DRIVE 12-13 283
- 12-14 FINAL DRIVE 284
- FINAL DRIVE 12-15 285
- 12-16 FINAL DRIVE 286
- FINAL DRIVE 12-17 287
- 12-18 FINAL DRIVE 288
- FINAL DRIVE 12-19 289
- 12-20 FINAL DRIVE 290
- FINAL DRIVE 12-21 291
- 12-22 FINAL DRIVE 292
- FINAL DRIVE 12-23 293
- 12-24 FINAL DRIVE 294
- FINAL DRIVE 12-25 295
- 12-26 FINAL DRIVE 296
- FINAL DRIVE 12-27 297
- 12-28 FINAL DRIVE 298
- FINAL DRIVE 12-29 299
- 12-30 FINAL DRIVE 300
- FINAL DRIVE 12-31 301
- 12-32 FINAL DRIVE 302
- FINAL DRIVE 12-33 303
- 12-34 FINAL DRIVE 304
- FINAL DRIVE 12-35 305
- 12-36 FINAL DRIVE 306
- FINAL DRIVE 12-37 307
- 12-38 FINAL DRIVE 308
- FINAL DRIVE 12-39 309
- 12-40 FINAL DRIVE 310
- Table of Contents 311
- 13-2 BRAKES 312
- BRAKES 13-3 313
- 13-4 BRAKES 314
- BRAKES 13-5 315
- 13-6 BRAKES 316
- BRAKES 13-7 317
- 13-8 BRAKES 318
- BRAKES 13-9 319
- 13-10 BRAKES 320
- BRAKES 13-11 321
- 13-12 BRAKES 322
- BRAKES 13-13 323
- 13-14 BRAKES 324
- BRAKES 13-15 325
- 13-16 BRAKES 326
- BRAKES 13-17 327
- 13-18 BRAKES 328
- BRAKES 13-19 329
- 13-20 BRAKES 330
- BRAKES 13-21 331
- 13-22 BRAKES 332
- BRAKES 13-23 333
- Suspension 335
- 14-2 SUSPENSION 336
- SUSPENSION 14-3 337
- 14-4 SUSPENSION 338
- SUSPENSION 14-5 339
- 14-6 SUSPENSION 340
- SUSPENSION 14-7 341
- 14-8 SUSPENSION 342
- SUSPENSION 14-9 343
- 14-10 SUSPENSION 344
- SUSPENSION 14-11 345
- 14-12 SUSPENSION 346
- SUSPENSION 14-13 347
- 14-14 SUSPENSION 348
- Steering 349
- 15-2 STEERING 350
- STEERING 15-3 351
- 15-4 STEERING 352
- STEERING 15-5 353
- 15-6 STEERING 354
- STEERING 15-7 355
- 15-8 STEERING 356
- STEERING 15-9 357
- 15-10 STEERING 358
- STEERING 15-11 359
- 15-12 STEERING 360
- STEERING 15-13 361
- 15-14 STEERING 362
- STEERING 15-15 363
- 15-16 STEERING 364
- STEERING 15-17 365
- 15-18 STEERING 366
- STEERING 15-19 367
- 15-20 STEERING 368
- STEERING 15-21 369
- 15-22 STEERING 370
- STEERING 15-23 371
- 15-24 STEERING 372
- STEERING 15-25 373
- 15-26 STEERING 374
- STEERING 15-27 375
- 15-28 STEERING 376
- STEERING 15-29 377
- 15-30 STEERING 378
- STEERING 15-31 379
- 15-32 STEERING 380
- STEERING 15-33 381
- 15-34 STEERING 382
- STEERING 15-35 383
- 15-36 STEERING 384
- STEERING 15-37 385
- 15-38 STEERING 386
- STEERING 15-39 387
- 15-40 STEERING 388
- STEERING 15-41 389
- 15-42 STEERING 390
- STEERING 15-43 391
- 15-44 STEERING 392
- STEERING 15-45 393
- 15-46 STEERING 394
- STEERING 15-47 395
- 15-48 STEERING 396
- STEERING 15-49 397
- 15-50 STEERING 398
- STEERING 15-51 399
- 15-52 STEERING 400
- 16-2 FRAME 402
- FRAME 16-3 403
- 16-4 FRAME 404
- FRAME 16-5 405
- 16-6 FRAME 406
- FRAME 16-7 407
- 16-8 FRAME 408
- FRAME 16-9 409
- 16-10 FRAME 410
- FRAME 16-11 411
- 16-12 FRAME 412
- FRAME 16-13 413
- 16-14 FRAME 414
- FRAME 16-15 415
- 16-16 FRAME 416
- FRAME 16-17 417
- 16-18 FRAME 418
- FRAME 16-19 419
- 16-20 FRAME 420
- Electrical System 421
- 17-2 ELECTRICAL SYSTEM 422
- ELECTRICAL SYSTEM 17-3 423
- 17-4 ELECTRICAL SYSTEM 424
- ELECTRICAL SYSTEM 17-5 425
- 17-6 ELECTRICAL SYSTEM 426
- ELECTRICAL SYSTEM 17-7 427
- 17-8 ELECTRICAL SYSTEM 428
- ELECTRICAL SYSTEM 17-9 429
- 17-10 ELECTRICAL SYSTEM 430
- ELECTRICAL SYSTEM 17-11 431
- 17-12 ELECTRICAL SYSTEM 432
- ELECTRICAL SYSTEM 17-13 433
- 17-14 ELECTRICAL SYSTEM 434
- ELECTRICAL SYSTEM 17-15 435
- 17-16 ELECTRICAL SYSTEM 436
- ELECTRICAL SYSTEM 17-17 437
- 17-18 ELECTRICAL SYSTEM 438
- ELECTRICAL SYSTEM 17-19 439
- 17-20 ELECTRICAL SYSTEM 440
- ELECTRICAL SYSTEM 17-21 441
- 17-22 ELECTRICAL SYSTEM 442
- ELECTRICAL SYSTEM 17-23 443
- 17-24 ELECTRICAL SYSTEM 444
- ELECTRICAL SYSTEM 17-25 445
- 17-26 ELECTRICAL SYSTEM 446
- ELECTRICAL SYSTEM 17-27 447
- 17-28 ELECTRICAL SYSTEM 448
- ELECTRICAL SYSTEM 17-29 449
- 17-30 ELECTRICAL SYSTEM 450
- ELECTRICAL SYSTEM 17-31 451
- 17-32 ELECTRICAL SYSTEM 452
- ELECTRICAL SYSTEM 17-33 453
- 17-34 ELECTRICAL SYSTEM 454
- ELECTRICAL SYSTEM 17-35 455
- 17-36 ELECTRICAL SYSTEM 456
- ELECTRICAL SYSTEM 17-37 457
- 17-38 ELECTRICAL SYSTEM 458
- ELECTRICAL SYSTEM 17-39 459
- 17-40 ELECTRICAL SYSTEM 460
- ELECTRICAL SYSTEM 17-41 461
- 17-42 ELECTRICAL SYSTEM 462
- ELECTRICAL SYSTEM 17-43 463
- 17-44 ELECTRICAL SYSTEM 464
- ELECTRICAL SYSTEM 17-45 465
- 17-46 ELECTRICAL SYSTEM 466
- ELECTRICAL SYSTEM 17-47 467
- 17-48 ELECTRICAL SYSTEM 468
- ELECTRICAL SYSTEM 17-49 469
- 17-50 ELECTRICAL SYSTEM 470
- ELECTRICAL SYSTEM 17-51 471
- 17-52 ELECTRICAL SYSTEM 472
- ELECTRICAL SYSTEM 17-53 473
- 17-54 ELECTRICAL SYSTEM 474
- ELECTRICAL SYSTEM 17-55 475
- 17-56 ELECTRICAL SYSTEM 476
- ELECTRICAL SYSTEM 17-57 477
- 17-58 ELECTRICAL SYSTEM 478
- Appendix 479
- 18-2 APPENDIX 480
- APPENDIX 18-3 481
- 18-4 APPENDIX 482
- APPENDIX 18-5 483
- 18-6 APPENDIX 484
- APPENDIX 18-7 485
- 18-8 APPENDIX 486
- APPENDIX 18-9 487
- 18-10 APPENDIX 488
- APPENDIX 18-11 489
- 18-12 APPENDIX 490
- APPENDIX 18-13 491
- 18-14 APPENDIX 492
- APPENDIX 18-15 493
- 18-16 APPENDIX 494
- APPENDIX 18-17 495
- 18-18 APPENDIX 496
- APPENDIX 18-19 497
- 18-20 APPENDIX 498
- APPENDIX 18-21 499
- 18-22 APPENDIX 500
- APPENDIX 18-23 501
- 18-24 APPENDIX 502
- APPENDIX 18-25 503
- 18-26 APPENDIX 504
- APPENDIX 18-27 505
- □8B500001 506
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