910113-0625 Tohatsu BOLT

Troubleshooting Problem List
The Engine Crankshaft Will Not Turn When The Start Switch Is On.
The Engine Will Not Start.
The Engine Is Misfiring Or The Engine Is Running Rough.
The Engine Stalls At Low RPM.
The Engine Has Sudden Changes In Engine RPM.
Engine With Dashpot Governor Is Slow To Correct Speed Or Engine Hunts (Changes Speed Constantly).
The Engine Does Not Have Enough Power.
The Engine Has Too Much Vibration.
The Engine Has A Loud Combustion Noise (Knock).
The Engine Has a Valve Train Noise (Clicking).
Oil Is In The Cooling System.
Mechanical Noise (Knock) Is In The Engine.
Fuel Consumption Is Too High.
A Loud Noise Is In The Valve Train.
Too Much Valve Lash Is Present.
The Valve Rotocoil Or The Spring Lock Is Free.
Oil Is At The Exhaust.
Little Valve Lash Or No Valve Lash Is Present.
The Engine Has Early Wear.
Coolant Is In The Lubrication Oil.
Too Much Black Smoke Or Gray Smoke Is Present.
Too Much White Smoke Or Blue Smoke Is Present.
The Engine Has Low Oil Pressure.
The Engine Uses Too Much Lubrication Oil.
The Engine Coolant Is Too Hot.
The Exhaust Temperature Is Too High.
The Air Starting Motor Does Not Turn.
The Alternator Provides No Charge.
The Alternator Charge Rate Is Low. The Alternator Charge Rate Is Not Regular.
The Alternator Charge Rate Is Too High.
The Alternator Has Noise.
The Rack Solenoid Does Not Stop The Engine. Troubleshooting Problems
Problem 1
The Engine Crankshaft Will Not Turn When The Start Switch Is On.Probable Cause
Low Output Of The Battery Refer to "Problem 27".
Defective Wires Or Defective Switches Refer to "Problem 27".
Defective Starter Motor Solenoid Refer to "Problem 27".
Problem With The Air Starting Motor Refer to "Problem 27".
An Internal Problem Prevents The Turning Of The Engine Crankshaft. If the crankshaft cannot be turned after disconnecting the driven equipment, inspect the cylinders for fluid while the crankshaft is being turned. If fluid in the cylinders is not the problem, the engine must be disassembled. After disassembling the engine, inspect the engine for other internal problems. Possible internal problems include the following conditions:
bearing seizure
piston seizure
valve and piston contactProblem 2
The Engine Will Not Start.Probable Cause
A Slow Turning Starter Motor Refer to "Problem 27" and refer to "Problem 28".
Dirty Fuel Filter Install a new fuel filter.
Dirty Fuel Line Or Broken Fuel Line Clean the fuel lines or install new fuel lines, as required.
Fuel Transfer Pump At the starting rpm, the minimum fuel pressure from the fuel transfer pump must be 35 kPa (5 psi). Change the fuel filter element if the fuel pressure is less than 35 kPa (5 psi). Look for air in the fuel system. Install a new fuel transfer pump if the fuel pressure is still low.
No Fuel To Cylinders Put fuel in the tank. Remove the air and/or remove the low quality fuel from the fuel system (prime).
Low Quality Fuel Remove the fuel from the fuel tank. Install a new fuel filter element. Fill the fuel tank with a good grade of clean fuel.
Wrong Fuel Injection Timing Make adjustment to timing. Refer to Testing And Adjusting, "Fuel System".
Defect In the Shutoff Solenoid The solenoid must get electricity to stop the engine. Operate the control for the shutoff solenoid. Listen to make sure that the solenoid makes a noise (clicking sound). If this sound can be heard and the engine will not start, remove the shutoff solenoid. Try and start the engine. If the engine starts, the shutoff solenoid is bad. Replace the shutoff solenoid.Problem 3
The Engine Is Misfiring Or The Engine Is Running Rough.Probable Cause
Low Fuel Pressure The fuel pressure at the outlet of the fuel filter housing must be a minimum of 230 35 kPa (33 5 psi) at full load speed. If fuel pressure is lower than 140 kPa (20 psi), check the following items:
plugged fuel filters
fuel transfer pumpMake sure that there is fuel in the fuel tank. Look for leaks or bends in the fuel line between the fuel tank and the fuel transfer pump. Look for air in the fuel system. Also look for a defective return fuel pressure regulating valve.
Air In Fuel System Find the air leak in the fuel system and correct the air leak. If there is air in the fuel system, the air generally enters the fuel system on the suction side of the fuel transfer pump.
Leakage Or Breakage In Fuel Line Between Fuel Manifold And Cylinder Head Install a new fuel line.
Wrong Valve Clearance Make an adjustment to the valve clearance. Refer to Testing And Adjusting, "Air Inlet And Exhaust System".
Defect In Fuel Injector Run the engine at a rpm that causes the engine to misfire or run the engine at a rpm that causes the engine to run rough. Loosen a fuel injection line nut at the valve cover base for each cylinder. Loosen a fuel injection line nut one at a time. Locate the cylinder that does not change the operation of the engine. Test the injection pump and test the injection nozzle for that cylinder. Install new parts, as required.
Wrong Fuel Injection Timing Make adjustment to timing. Refer to Testing And Adjusting, "Fuel System".
Bent Pushrod Or Broken Pushrod Make a replacement of pushrod, if necessary.
Fuel Has Cloud Point Higher Than Atmospheric Temperature. Cloud Point Is The Temperature When Wax Is Formed In The Fuel. Drain the fuel tank, fuel lines and fuel manifolds. Change the fuel filter. Fill the tank with fuel that has the correct cloud point. Remove the air from the system with the priming pump.Problem 4
The Engine Stalls At Low RPM.Probable Cause
Low Fuel Pressure The fuel pressure at the outlet of the fuel filter housing must be a minimum of 230 35 kPa (33 5 psi) at full load speed. If fuel pressure is lower than 140 kPa (20 psi), check the following items:
plugged fuel filters
fuel transfer pumpMake sure that there is fuel in the fuel tank. Look for leaks or bends in the fuel line between the fuel tank and the fuel transfer pump. Look for air in the fuel system. Also look for a defective return fuel pressure regulating valve.
Low Engine Idle RPM Make adjustment to the governor. Ensure