| (1) Engine doesn't start or is difficult to start
Starter motor doesn't rotate
•Engine kill switch OFF.
•Fuse blown. Check main fuse and starter circuit .
•Battery voltage low. Check and recharge battery.
•Starter motor defective.
Make sure the wiring to the starter is secure. Make sure the starter relay clicks when the start button is pushed. If the relay clicks, then the fault is in the wiring or motor.
Starter relay faulty. Check it accordingly.
•Starter switch not contacting. The contacts could be wet, corroded or dirty. Disassemble and clean the switch.
•Wiring open or shorted. Check all wiring connections and harnesses to make sure that they are dry, tight and not corroded.
Also check for broken or frayed wires that can cause a short to ground (earth).
•Ignition (main) switch defective. Check the switch. Replace the switch with a new one if it is defective.
•Engine kill switch defective. Check for wet, dirty or corroded contacts. Clean or replace the switch as necessary.
•Faulty side stand switch. Check the wiring to the switch itself.
Starter motor rotates but engine does not turn over.
•Starter motor clutch defective. Inspect and repair or replace.
•Damaged idler or starter gears. Inspect and replace the damaged parts.
Starter works but engine won't turn over (seized)
•Seized engine caused by one or more internally damaged components. Failure due to wear, abuse or lack of lubrication.
Damage can include seized valves, followers, camshafts, pistons, crankshaft, connecting rod bearings, or transmission gears or bearings.
No fuel flow
•No fuel in tank.
•Fuel pump failure or in-line filter blockage.
•Fuel tank breather hose or valve obstructed.
•Fuel line clogged. Pull the fuel line loose and carefully blow through it.
•Float needle valve clogged. For all of the valves to be clogged, either a very bad batch of fuel with an unusual additive has been used, or some other foreign material has entered the tank. Many times after a machine has been stored for many months without running, the fuel turns to a varnish-like liquid and forms deposits on the inlet needle valves and jets. The carburettors should be removed and overhauled if draining the float chambers doesn't solve the problem.
Engine flooded.
•Float height too high. Check.
•Float needle valve worn or stuck open. A piece of dirt, rust or other debris can cause the valve to seat improperly, causing excess fuel to be admitted to the float chamber. In this case, the float chamber should be cleaned and the needle valve and seat inspected. If the needle and seat are worn, then the leaking will persist and the parts should be replaced with new ones.
•Starting technique incorrect. Under normal circumstances (ie, if all the carburettor functions are sound) the machine should start with little or no throttle. When the engine is cold, the choke should be operated and the engine started without opening the throttle.
When the engine is at operating temperature, only a very slight amount of throttle should be necessary.
No spark or weak spark
•Ignition switch OFF.
Engine kill switch turned to the OFF position.
•Battery voltage low. Check and recharge the battery as necessary.
•Spark plugs dirty, defective or worn out. Locate reason for fouled plugs using spark plug condition chart and follow the plug maintenance procedures.
Spark plug caps or secondary (HT) wiring faulty. Check condition. eplace either or both components if cracks or deterioration are evident.
Spark plug caps not making good contact. Make sure that the plug caps fit snugly over the plug ends.
•Ignition control module defective. Check the module.
•Pick-up coil defective. Check the unit.
•Ignition HT coils defective. Check the coils.
•Ignition or kill switch shorted. This is usually caused by water, corrosion, damage or excessive wear. The switches can be disassembled and cleaned with electrical contact cleaner. If leaning does not help, replace the switches.
•Wiring shorted or broken between:
a) Ignition (main) switch and general relay
b) General relay and engine kill switch (or blown fuse)
c) Engine Kill switch and ignition HT coils
d) Ignition HT coils and spark plugs
e) Ignition control module and pick-up coils
f) Ignition control unit and HT coils
Make sure that all wiring connections are clean, dry and tight. Look for chafed and broken wires.  |