Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

TROUBLESHOOTING CHART
The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to show all causes for all problems. NOTE: On RFI models, always check for fault codes. If a fault code is detected, service the fault code and recheck operating conditions. Refer to DIAGNOSTIC PROCEDURES in ENGINE MANAGEMENT section.

ENGINE WILL NOT START

OTHER OBSERVATION POSSIBLE CAUSE Wrong safety lanyard DESS operation non functional REMEDY Use one that has been programmed If 2 short beeps are not heard when installing safety lanyard, refer to ELECTRICAL SYSTEM and ENGINE MANAGEMENT Replace Check wiring then replace fuse Check wiring, starting system solenoid and MPEM or ECM (RFI models) Check/recharge Check, refer to STARTING SYSTEM or ENGINE MANAGEMENT Check/clean/tighten Check/clean/repair Check, refer to MAINTENANCE Check, refer to ELECTRICAL SYSTEM Check, refer to ELECTRICAL SYSTEM Check/repair, refer to PTO HOUSING/MAGNETO Check/repair, refer to the appropriate ENGINE SHOP MANUAL Check, refer to PROPULSION SYSTEM Check fault codes, refer to ENGINE MANAGEMENT

Safety lanyard switch faulty or disconnected or harness damaged Burnt fuse: battery, starting system. Also fuel pump on RFI models Starting system fuse keeps on burning Discharged or disconnected battery Defective or disconnected start/stop switch Engine does not turn over Battery connections Poor/bad or corroded ground contacts (engine, starter etc.) Water/fuel hydro-lock Starter malfunction Starter solenoid Obstructed starter drive gear ass'y Seized or obstructed engine Seized jet pump Faulty sensor or ECM (RFI models)

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Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

OTHER OBSERVATION

POSSIBLE CAUSE Loose battery cable connections Discharged/weak battery Restriction in jet pump

REMEDY Check/clean/tighten Check/charge/replace Check/clean pump Inspect, refer to PROPULSION SYSTEM Check, refer to MAINTENANCE Check compression, refer to ENGINE Check, refer to ELECTRICAL SYSTEM Check for fault codes. Refer to DIAGNOSTIC PROCEDURES in ENGINE MANAGEMENT Release throttle lever Recharge or replace battery Check fuel pump pressure output

Engine turns slowly

Partial seizure in jet pump Partial engine hydro-lock Partial engine seizure Worn starter Faulty component in the fuel injection system (RFI models) Engine drowned mode is active (RFI models) Low battery voltage Low or no fuel pressure (RFI models)

Check fuel pump fuse Engine turns over Fuel injectors not working (RFI models) Check wiring harness Check fuel injector operation. Replace as necessary Check output signal from ECM No spark at the spark plug Defective MPEM or ECM Check spark plugs condition and replace as necessary Check ignition system and repair Replace MPEM or ECM (as applicable) Inverted spark plug cables (RFI models) Reposition cables properly.

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OTHER OBSERVATION

POSSIBLE CAUSE Defective CPS (RFI models) Water-contaminated fuel Dirty fuel filter Fouled or defective spark plug Water in engine Carburetion (carburetor models) Defective ignition circuit Flooded engine: Carburetor needle valve stuck open (carburetor models)

REMEDY Check operation of CPS and replace if necessary Check/siphon and refill Clean/replace Replace Check, refer to MAINTENANCE Check, refer to FUEL SYSTEM Check, refer to ELECTRICAL SYSTEM Check, refer to FUEL SYSTEM Check, refer to the appropriate ENGINE SHOP MANUAL Check, refer to the appropriate ENGINE SHOP MANUAL Check, refer to the appropriate ENGINE SHOP MANUAL Check, refer to MAGNETO SYSTEM in the appropriate ENGINE SHOP MANUAL Properly position flywheel and rotor, refer to MAGNETO SYSTEM in the appropriate ENGINE SHOP MANUAL Replace defective part(s) Replace MPEM Check spark plug condition Check, refer to ELECTRICAL SYSTEM Replace ECM

Engine turns over (cont'd)

Excessive rotary valve clearance Incorrect rotary valve timing Internal engine damage Defective trigger wheel (RFI models) Incorrectly aligned flywheel and rotor (RFI models) Insufficient engine compression Faulty rev limiter in MPEM (carburetor models)

No spark at spark plugs

Spark plug faulty, fouled or worn out Ignition Faulty ECM (RFI models)

NOTE: Prior to replacing an ECM, refer to the ENGINE MANAGEMENT section and read carefully the tests to do before replacing an ECM that could otherwise be good.

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Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

ENGINE HARD TO START

OTHER OBSERVATION POSSIBLE CAUSE Wrong TPS zero setting (RFI models) Throttle cable adjustment (RFI models) Air lock in fuel rail (RFI models) Water in fuel reservoir or contaminated fuel Mechanical engine failure REMEDY Refer to ENGINE MANAGEMENT Refer to ENGINE MANAGEMENT Refer to ENGINE MANAGEMENT Flush reservoir and refill with fresh gas Check cylinder compression Check for cylinder head leaks Check starting system Spark plug faulty, fouled or worn out Low fuel pressure (RFI models) Check spark plug condition Check fuel pump operation. Refer to FUEL SYSTEM Check fuel pressure regulator. Refer to FUEL SYSTEM Missing shim under CPS (RFI models) Refer to COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT

ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED

OTHER OBSERVATION POSSIBLE CAUSE The system is in limp home mode (RFI models) Broken or loose throttle cable REMEDY Refer to ENGINE MANAGEMENT and check the fault codes Change/readjust

ENGINE STARTS BUT RUNS ONLY ON ONE CYLINDER (RFI MODELS)

OTHER OBSERVATION POSSIBLE CAUSE In normal conditions engine runs only on one cylinder at idle after engine warm-up is completed. REMEDY Engine should run on both cylinders with 3 percent or more of throttle opening. Use the VCK (Vehicle Communication Kit) with B.U.D.S. software to validate.

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ENGINE RUNS ON BOTH CYLINDERS AT IDLE AFTER ENGINE IS WARM-UP (RFI MODELS)
OTHER OBSERVATION POSSIBLE CAUSE Water temperature sensor (WTS) and its circuit ECM parameters Closed TPS. REMEDY Refer to COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT.

ENGINE MISFIRES, RUNS IRREGULARLY

OTHER OBSERVATION POSSIBLE CAUSE Fouled, defective, worn spark plugs Faulty ECM (RFI models) Defective trigger wheel/CPS (RFI models) Weak spark Too much oil supplied to engine Bad ignition coil wiring Faulty ignition coil, or bad connector REMEDY Check/verify heat range/gap/replace Check, refer to ENGINE MANAGEMENT Check, refer to ENGINE MANAGEMENT Adjust oil injection pump Check wiring condition and proper grounding of ignition coil Check coil. Refer to ENGINE MANAGEMENT or ELECTRICAL SYSTEM Check/clean/repair

Poor engine ground

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Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

OTHER OBSERVATION

POSSIBLE CAUSE Low fuel level (carburetor models) Carburetion dirty (carburetor models) Low fuel pressure (RFI models) Check/refill

REMEDY

Check/clean, refer to FUEL SYSTEM Check pump, regulator and injectors. Replace if necessary Check if filter is plugged. Check if a hose pincher is still installed.

Lean fuel mixture Dry spark plug (except when water fouled)

Leaking crankshaft seal(s) or intake manifold (carburetor models) Restricted fuel valve (carburetor models) Loose carburetor (carburetor models) Stale or water fouled fuel Fuel filter dirty or restricted Clogged fuel injectors (RFI models) Defective sensor or ECM (RFI models) Flame arrester dirty or restricted Partially closed choke (carburetor models) Loose main jet (carburetor models) Faulty fuel injector(s) (RFI models)

Pressure check engine, to the appropriate ENGINE SHOP MANUAL Check/replace Tighten carburetor Check/siphon and refill Check/clean/replace Remove and clean fuel injectors Check faulty codes in ECM memory, refer to ENGINE MANAGEMENT Check/replace Check/adjust choke cable Check, refer to FUEL SYSTEM Remove and replace fuel injector(s), refer to ENGINE MANAGEMENT

Defective sensor or ECM (RFI models) Rich fuel mixture Fouled spark plug Rotary valve shaft seal leaking Oil injection pump adjustment Worn needles and seals (carburetor models) Excessive rotary valve clearance (if so equipped) Fuel pressure fluctuating (RFI models) High fuel pressure (RFI models)

Check faulty codes in ECM memory, refer to ENGINE MANAGEMENT Check/replace, refer to the appropriate ENGINE SHOP MANUAL Check/adjust, refer to LUBRICATION SYSTEM Check, refer to section FUEL SYSTEM Check, refer to the appropriate ENGINE SHOP MANUAL Inspect fuel pressure regulator. Refer to FUEL SYSTEM Check pump, regulator, injectors or if filter is plugged. Replace if necessary

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OTHER OBSERVATION

POSSIBLE CAUSE Check spark plug condition, check fault codes, check fuel pressure (RFI models). Bent or missing tooth on trigger wheel (RFI models)

REMEDY Check, refer to ENGINE MANAGEMENT and FUEL SYSTEM. Check, refer to MAGNETO SYSTEM in the appropriate ENGINE SHOP MANUAL Check, refer to ENGINE MANAGEMENT Check/adjust, refer to the appropriate ENGINE SHOP MANUAL Check, refer to the appropriate ENGINE SHOP MANUAL

Starts, but runs poorly

Also fuel injection misinjecting (RFI models)

Damaged fuel injector Incorrect rotary valve timing Excessive rotary valve clearance

NOTE: Prior to replacing an ECM, refer to the ENGINE MANAGEMENT section and read carefully the tests to do before replacing an ECM that could otherwise be good.

ENGINE CONTINUALLY BACKFIRES

OTHER OBSERVATION Weak spark Spark plugs POSSIBLE CAUSE Fouled, defective spark plugs Ignition coil leads or wiring reversed Incorrect setting Ignition timing Defective trigger wheel/CPS (RFI models) Rotary valve Carburetor (if so equipped) Incorrect timing Carburetion too lean Clean/replace Refer to WIRING DIAGRAM Check/reset, refer to ELECTRICAL SYSTEM Check, refer to ENGINE MANAGEMENT Check/reset, refer to the appropriate ENGINE SHOP MANUAL Check, refer to FUEL SYSTEM REMEDY

ENGINE DETONATION OR PINGING

OTHER OBSERVATION Ignition Spark plug heat range too high Engine/exhaust high temperature Engine overheats and exhaust overheats Fuel octane too low of poor fuel quality POSSIBLE CAUSE Timing too far advanced Check/reset Check/change to correct range Check, see ENGINE OVERHEATS in this section Use good quality fuel REMEDY

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Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

ENGINE LACKS ACCELERATION OR POWER

OTHER OBSERVATION POSSIBLE CAUSE Weak spark Carburetion, jetting too rich/lean (carburetor models) Throttle does not open fully Low compression Water in fuel Debris in carburetor needle valve (carburetor models) Impeller leading edge damaged Poor fuel quality Clogged fuel injectors (RFI models) Low fuel pressure (RFI models) Incorrect throttle position sensor (TPS) adjustment (RFI models) Overheated engine Engine revs lower than its maximum operational RPM Peak performance is delayed until higher RPM range is reached RAVE valve does not open (if so equipped) Limp home mode activated (RFI models) RAVE valve is stuck opened (if so equipped) REMEDY Check/replace, refer to ELECTRICAL SYSTEM Check/replace, refer to FUEL SYSTEM Check/readjust, refer to FUEL SYSTEM or ENGINE MANAGEMENT Check/repair, refer to the appropriate ENGINE SHOP MANUAL Check/siphon/replace Check/clean, refer to FUEL SYSTEM Check/replace, refer to PROPULSION SYSTEM Siphon then refill with fresh fuel Remove and clean fuel injectors Check fuel line and fuel pump pressure Check and adjust TPS, refer to ENGINE MANAGEMENT See ENGINE OVERHEATS in this chart Check, refer to the appropriate ENGINE SHOP MANUAL Refer to ENGINE MANAGEMENT Check, refer to the appropriate ENGINE SHOP MANUAL

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ENGINE STOPS RUNNING

OTHER OBSERVATION POSSIBLE CAUSE Spark plug heat range too high Engine dies during operation (piston seizure) Improper ignition timing Compression ratio is too high Poor injection oil quality Engine stalls at idle Engine start but stops after approximately 2 seconds Contaminated or inappropriate fuel Air in fuel rail (RFImodels) Engine running out of fuel Air in fuel rail (RFI models) REMEDY Check/change to correct range Check/reset Check combustion chamber volume Use proper XPS 2stroke oil Syphon reservoir and refill with fresh fuel Refill fuel tank Check fuel delivery system for proper fuel pressure and delivery Refill fuel tank

ENGINE CANNOT REACH MAXIMUM RPM

OTHER OBSERVATION POSSIBLE CAUSE RAVE valve does not open (if so equipped) Faulty water regulator valve (if so equipped) Low fuel pressure (RFI models) Jet pump related problem Limp home mode activated (RFI models) Exhaust system blockage/muffler damage Exhaust gases in bilge (leak) Battery voltage is too low (RFI models) REMEDY Check, refer to the appropriate ENGINE SHOP MANUAL and to COOLING SYSTEM Check, refer to COOLING SYSTEM Check fuel pump pressure Check propulsion components. Refer to JET PUMP Refer to ENGINE MANAGEMENT Check and repair Check exhaust system for leaks Check/repair, refer to CHARGING SYSTEM

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Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

ENGINE OVERHEATS
OTHER OBSERVATION POSSIBLE CAUSE Temperature sensor defective (RFI models) Monitoring beeper sounds continuously Cooling system restriction Grounded temperature sensor or sensor wire (carburetor models) REMEDY Check/replace. Refer to ENGINE MANAGEMENT Check/flush, refer to MAINTENANCE Check/repair/replace

VEHICLE CANNOT REACH ITS TOP SPEED

OTHER OBSERVATION Engine RPM to low Engine RPM too high POSSIBLE CAUSE Faulty rev limiter Improper impeller pitch Improper impeller pitch Damaged leading or trailing edge of impeller Jet pump cavitation Sealing of ride plate, jet pump support or jet pump REMEDY Check/replace MPEM or ECM Check/replace, refer to PROPULSION SYSTEM Check/replace, refer to PROPULSION SYSTEM Check/replace NOTE: Leading edge damage contributes to poor performance from start. Trailing edge damage contributes to poor top performance and stator vanes erosion. Check/reseal, refer to section PROPULSION SYSTEM or HULL/BODY

O.T.A.S. SYSTEM FAULTS

OTHER OBSERVATION Engine RPM does not increase when throttle lever is released and steering is turned. POSSIBLE CAUSE Improper sequence or timing of events when trying it. REMEDY Refer to O.T.A.S. SYSTEM

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Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

ABNORMAL NOISE FROM PROPULSION SYSTEM

OTHER OBSERVATION POSSIBLE CAUSE Weeds/debris caught in intake grate or impeller Low oil level in jet pump Worn anti-rattle system Damaged or bent drive shaft Idle speed too low Check/clean Check/troubleshoot source of leak/refill supply, refer to PROPULSION SYSTEM Check/replace pusher in cover, refer to PROPULSION SYSTEM Check/replace, refer to PROPULSION SYSTEM Adjust (carbureted models) Check fault codes (RFI models) Check/replace, refer to ENGINE REMEDY

Broken engine mounts

STEERING POLE IS HEAVIER THAN USUAL (3D SERIES)

OTHER OBSERVATION POSSIBLE CAUSE Steering pole return spring adjustment REMEDY Set the adjuster to reduce the weight at the handlebar. Refer to STEERING SYSTEM. Refer to STEERING SYSTEM.

Steering pole return spring is broken

STEERING POLE IS STIFFER THAN USUAL (3D SERIES)

OTHER OBSERVATION POSSIBLE CAUSE Dirty/damaged parts REMEDY Clean. If parts are damaged, refer to STEERING SYSTEM.

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