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Snowmobile Ski Doo REV SERIES (2004 year). Manual - part 17

Section 03 TROUBLESHOOTING
Subsection 01 (ENGINE)

ENGINE LEAK VERIFICATION FLOW CHART

PRESSURIZE ENGINE

IS ENGINE LEAKING?

CHECK ALL JOINTED SURFACES,

SCREW/STUD THREADS. MOUNTING

FLANGES ETC.

ANY LEAK FOUND?

CHECK SMALL OIL LINES OF

INJECTION PUMP

AIR BUBBLES FOUND

OR OIL MOVING

TOWARD PUMP?

REPLACE GASKET OR O-RING,

RE-SEAL LEAKING AREA

REPLACE INJECTION CHECK VALVE(S)

REMOVE BLEED SCREW ON CYLINDER HEAD

ARE ANY AIR BUBBLES IN COOLANT?

BLOCK HOSE OF PUMP SHAFT

GEAR

LUBRICATION SYSTEM

IS ENGINE STILL LEAKING?

REPLACE O-RING OF CYLINDER HEAD

AND/OR CYLINDER BASE GASKET

PRESSURIZE PUMP SHAFT GEAR

RESERVOIR IN CRANKCASE

ARE SEALS LEAKING?

CHECK CRANKSHAFT OUTER

SEAL OF PTO AND

MAG SIDES

PRESSURIZE PUMP SHAFT GEAR

RESERVOIR IN CRANKCASE

IS RESERVOIR LEAKING?

UNSEAL PTO CYLINDER AND MAG

CYLINDER SEPARATELY

IS RESERVOIR LEAKING?

CHECK LEAKAGE AT DRAIN HOLE

BELOW COOLANT PUMP HOUSING

ANY LEAK FOUND?

REPLACE DEFECTIVE SEAL(S)

REPLACE OIL SEAL OF PUMP

SHAFT, BESIDE CERAMIC

COOLANT SEAL

REPLACE DEFECTIVE O-RING

REPLACE DEFECTIVE PARTS

CHECK OIL PUMP

MOUNTING AREA FOR LEAKS

IS O-RING LEAKING?

CAREFULLY INSPECT ENGINE CASTINGS,

PARTICULARLY THE THREAD HOLE AREAS

ANY LEAK FOUND?

ENGINE IS PERFECTLY SEALED

INTERNALLY

YES

ENGINE LEAK VERIFICATION

FLOW CHART

A32C1KS

YES

A32C1KS

mmr2004-Rev

Section 03 TROUBLESHOOTING

Subsection 02 (FUEL AND OIL SYSTEMS)

FUEL AND OIL SYSTEMS

The following chart is provided to help diagnose the probable source of troubles. It should be used as a
guideline. Some causes or corrections may not apply to a specific model.

NOTE: For the SDI fuel system troubleshooting, also refer to appropriate ENGINE MANAGEMENT sub-
section.

SYMPTOM

HIGH FUEL CONSUMPTION OR RICH MIXTURE (MODELS WITH CARBURETOR ONLY).

CONDITION

NORMAL USE

1. Check fuel tank.

a. Perforated fuel tank.

Replace fuel tank.

2. Check fuel pump, reservoir and carburetor fittings.

a. Leaking fittings.

Replace defective part.

3. Check choke adjustment.

a. Fuel flows through choke circuit while engine runs.

Readjust choke.

4. Check float height in carburetor(s).

a. Fuel level is too high in float bowl(s).

Adjust according to specifications (refer to TECHNICAL DATA).

TEST/INSPECTION

5. Check needle valve on each carburetor.

a. Foreign particles prevent needle valve from closing and/or pounded seating area.

Clean or replace needle valve, then clean seating area.

SYMPTOM

FUEL LEAKS IN ENGINE BASE WHEN ENGINE IS STOPPED (MODELS WITH CARBURETOR ONLY).

CONDITION

NORMAL USE

1. Check items 3, 4 and 5 of HIGH FUEL CONSUMPTION.

TEST/INSPECTION

2. Check fuel pump diaphragm.

a. Cracked diaphragm.

Replace.

mmr2004-Rev

Section 03 TROUBLESHOOTING
Subsection 02 (FUEL AND OIL SYSTEMS)

SYMPTOM

ENGINE LACKS POWER OR STALLS AT HIGH RPM (MODELS WITH CARBURETOR ONLY).

CONDITION

NORMAL USE

1. Check fuel tank vent hose.

a. Kinked or clogged hose.

Relocate or replace.

2. Check fuel filter.

a. Clogged filter.

Replace.

3. Check fuel lines.

a. Kinked or clogged lines.

Relocate or replace.

4. Check fuel pump flow.

a. Check impulse hose.

Replace.

b. Dried diaphragm.

Replace.

TEST/INSPECTION

5. Check if carburetor(s) is (are) clean.

a. Varnish.

Clean.

SYMPTOM

HIGH INJECTION OIL CONSUMPTION (SDI AND CARBURETOR MODELS ONLY).

CONDITION

NORMAL USE

1. Check oil injection pump adjustment.

a. Oil injection pump adjusted too rich.

Adjust.

2. Check injection pump identification.

a. Wrong pump.

Replace with the appropriate pump. Refer to OIL INJECTION SYSTEM.

3. Check injection oil lines and their fitting.

a. Leaking lines and/or cover.

Replace defective part(s).

4. Check injection pump cover gasket.

a. Broken gasket.

Replace.

5. Check nipple check valve.

a. Check valve stuck open.

Replace.

6. Check pump.

a. Defective pump.

Replace pump or connecting cable.

TEST/INSPECTION

7. Test pump shaft gear reservoir for leaks.

a. Leaking seal(s).

Replace seal(s).

mmr2004-Rev

Section 03 TROUBLESHOOTING

Subsection 02 (FUEL AND OIL SYSTEMS)

SYMPTOM

ENGINE LACKS FUEL (SDI MODELS ONLY).

CONDITION

NORMAL USE

1. Check fuel filter inline.

a. Corrosion due to oxidation.

Replace fuel filter.

2. Check if lines are perforated, kinked, or if they leak at fittings.

Replace lines.

TEST/INSPECTION

3. Check fuel pump pressure and flow.

a. Dirt clogging fuel filter or pump.

b. Wrong position of fuel pickup in the tank.

c. Regulator defect.

d. Pickup clogged due to dirt or contamination.

Change fuel pickup or replace them.

Change regulator.

Perform bleed procedure..

SYMPTOM

DPM SEEMS TO BE DEFECTIVE (MODELS WITH CARBURETOR ONLY).

CONDITION

NORMAL USE

1. Check electrical connections.

a. Corroded terminals.

Clean or replace.

2. Fuel mixture is too rich or too poor.

a. Possible damage to DPM.

If DPM does not operate properly, unplug compensation solenoid connector while engine is running. The

carburetion is now identical to that of carburetors without a DPM, provided that all pipe fittings are tight and

that solenoid is in good condition, (it must not be half-open). If problem is resolved with this procedure,

DPM is faulty.

TEST/INSPECTION

3. Check for DPM manifold leaking.

a. DPM manifold is leaking.

Repair or replace.

mmr2004-Rev

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