DOWNLOAD 1. 98. 5 2. Suzuki ATV Quad Service Repair Manuals. TROUBLESHOOTING Engine. Engine Turns Over But Fails to Start No fuel Dirt in fuel line or filter Fuel will not pass through fuel valve Fuel pump inoperativerestricted Tank vent plugged Carb starter circuit Engine flooded Low compression high cylinder leakage No spark Spark plug fouledEngine Does Not Turn Over Dead battery Starter motor does not turn Engine seized, rusted, or mechanical failure. Engine Runs But Will Not Idle Restricted carburetor pilot system Carburetor misadjusted Choke not adjusted properly Low compression Crankcase breather restricted. Engine Idles But Will Not Rev Up Spark plug fouledweak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect or restricted carburetor jetting ETC switch limiting speed Reverse speed limiter limiting speed Carburetor vacuum slide stickingdiaphragm damaged Incorrect ignition timing Restricted exhaust system. Engine Has Low Power Spark plug fouled Cylinder, piston, ring, or valve wear or damage check compression PVT not operating properly Restricted exhaust muffler Carburetor vacuum slide stickingdiaphragm damaged Dirty carburetor. Piston Failure Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated. Excessive Smoke and Carbon Buildup Excessive piston to cylinder clearance Wet sumping Worn rings, piston, or cylinder Worn valves, guides or seals Restricted breather Air filter dirty or contaminated. Low Compression Decompressor stuck Cylinder head gasket leak No valve clearance or incorrectly adjusted Cylinder or piston worn Piston rings worn, leaking, broken, or sticking Bent valve or stuck valve Valve spring broken or weak Valve not seating properly bent or carbon accumulated on sealing surface Rocker arm sticking. Backfiring ETC or speed limiter system malfunction Fouled spark plug or incorrect plug or plug gap Carburetion faulty lean condition Exhaust system air leaks Ignition system faulty Spark plug cap crackedbroken Ignition coil faulty. Ignition or kill switch circuit faulty. Ignition timing incorrect. Sheared flywheel key Poor connections in ignition system System wiring wet Valve sticking Air leaks in intake Lean condition. Spark Plug Fouling Spark plug cap loose or faulty Choke cable adjustment or plungercable sticking Foreign material on choke plunger seat or plunger Incorrect spark plug heat range or gap Carburetor inlet needle and seat worn Jet needle andor needle jet worn or improperly adjusted Excessive carburetor vibration loose or missing needle jet locating pins Loose jets in carburetor or calibration incorrect for altitudetemperature Incorrect float level setting PVT system calibrated incorrectly or components worn or mis adjusted Fuel quality poor old or octane too high Low compression Restricted exhaust Weak ignition loose coil ground, faulty coil, stator, or ETC switch ETC switch mis adjusted Restricted air filter main or pre cleaner Improperly assembled air intake system Restricted engine breather system Oil contaminated with fuel Restricted oil tank vent. Cooling Troubleshooting. View and Download Polaris Sportsman 400 service manual online. Sportsman 400 Offroad Vehicle pdf manual download. Just showing a little trick you can use to get a proper float adjustment if your manuals adjustment settings arent working for you. Ussually he manual for. MIKUNI Carburetor, jets major parts listing. There seems to be a million parts available for Mikuni carburetors. Over the years they have become the most popular. This page contains information about carb choices on Spitfires. Most carburetor problems seem to come, as you might guess, after the machine has set idle for a while. The real cure is to use Gasoline Stabilizer in your gas. Overheating Low coolant level Air in cooling system Wrong type of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins or restriction to air flow, passages blocked in radiator, lines, pump, or water jacket Lean mixture restricted jets, vents, or fuel pump Fuel pump output weak Restricted radiator internally or cooling fins Water pump failure Cooling system restriction Cooling fan inoperative or turning too slowly Ignition timing misadjusted Low oil level Spark plug incorrect heat range Faulty hot light circuit Thermostat stuck closed or not opening completely Radiator is missing its internal diverter plate not allowing coolant to flow through entire radiator. Temperature Too Low Thermostat stuck open. Leak at Water Pump Weep Hole Faulty water pump mechanical seal coolant leak Faulty pump shaft oil seal oil leakTROUBLESHOOTINGFuel Starvation Lean Mixture. Hp 50G How To Install Programs In Linux. Symptoms Hard start or no start, bog, backfire, popping through intake exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic. No fuel in tank Restricted tank vent, or routed improperly Fuel lines or fuel valve restricted Fuel filter plugged Carburetor vent lines restricted Plugged or restricted inlet needle and seat screen or inlet passage Clogged jets or passages Float stuck, holding inlet needle closed or inlet needle stuck Float level too low Fuel pump inoperative Air leak at impulse line Restricted impulse line kinked, pinched Intake air leak throttle shaft, intake ducts, airbox or air cleaner cover Ruptured vacuum slide diaphragm, Vacuum slide stuck closed or sticky Improper spring Jet needle position incorrect Incorrect pilot screw adjustment. Rich Mixture. Symptoms Fouls spark plugs, black, sooty exhaust smoke, rough idle, poor fuel economy, engine runs rough misses, poor performance, bog, engine loads up, backfire. Air intake restricted inspect intake duct Air filter dirtyplugged Choke plunger sticking, incorrectly adjusted choke Choke cable binding or improperly routed Incorrect pilot airfuel screw adjustment Faulty inlet needle and seat Faulty inlet needle seat O Ring Float level too high Poor fuel quality old fuel Loose jets Worn jet needleneedle jet or other carburetor parts Dirty carburetor air bleed passages or jets Weak or damaged vacuum piston return spring Fouled spark plug. Idle Too High Idle adjusted improperlyidle mixture screw damaged Sticky vacuum slide Throttle cable sticking, improperly adjusted, routed incorrectly Choke cable sticking, improperly adjusted, routed incorrectly Plugged or restricted idle jet. Idle Too Low Choke cable bending or incorrectly adjusted Idle speed set incorrectly Idle mixture screw misadjusted or damaged Belt dragging Ignition timing incorrect Worn jet needleneedle jet Plugged or restricted idle jet. Erratic Idle Choke cable bending or incorrectly adjusted Throttle cable incorrectly adjusted Air leaks, dirty carburetor passages pilot circuit Pilot mixture screw damaged or adjusted incorrectly Tight valves Ignition timing incorrect Belt dragging Dirty air cleaner Engine worn Spark plug fouled Idle speed set incorrectly speed limiter Worn jet needleneedle jet Plugged or restricted idle jet. TROUBLESHOOTINGTroubleshooting Checklist. Check the following items when shifting difficulty is encountered. Idle speed adjustment PVT alignment Transmission oil typequality Transmission torque stop adjustment where applicable Engine torque stop adjustment where applicable Drive belt deflection Loose fasteners on rod ends Loose fasteners on selector box Worn rod ends, clevis pins, or pivot arm bushings Linkage rod adjustment and rod end positioning Shift selector rail travel Worn, broken or damaged internal transmission components. NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem, isolate the transmission by disconnecting linkage rod from transmission bellcrank. Manually select each gear range at the transmission bellcrank, and test ride vehicle. Suzuki Service Manuals. Download Manuals Below. Suzuki LT230S LT230GE LT250S Repair Manual. Suzuki LT80 Repair Manual. Suzuki LT250R. National Distributors of Mikuni Automotive Sidedraft Carburetors and Parts. Manufacturers of CV Axle Kits for Datsun 510s and Zcars. This is a brief introduction to the fairly touchy process of rejetting your carbs. The techniques discussed here are fairly universal to most carburated. Beware of what you ask for. One of our most loyal readers and prolific commentators, Educatornow of teachersDan, expressed his disgust at the Kcar Aries.