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16-26 APPENDIX
Troubleshooting
NOTE
This is not an exhaustive list, giving every
possible cause for each problem listed. It
is meant simply as a rough guide to assist
the troubleshooting for some of the more
common difficulties.
Engine Doesn’t Start, Starting Difficulty
Starter motor not rotating:
Starter lockout switch or gear position sen-
sor trouble
Starter motor trouble
Battery voltage low
Starter relay, starter circuit relay not con-
tacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn’t
turn over:
Starter motor clutch trouble
Torque limiter trouble
Engine won’t turn over:
Valve seizure
Valve lifter s eizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end, big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Balancer bearing seizure
No fuel flow:
No fuel in tank
Fuel tank air vent obstructed
Fuel tap clogged
Fuel tap valve trouble
Fuel tap vacuum hose clogged
Fuel line clogged
Carburetor float valve clogged
Starting technique faulty (When flooded,
crank the engine with the throttle fully
opened to allow more air to reach the
engine.)
Engine flooded:
Fuel level in carburetor float bowl too high
Float valve worn or jammed with foreign
matter
Starting technique faulty (When flooded,
crank the engine with the throttle fully
opened to allow more air to reach the
engine.
Fuel/air mixture incorrect:
Pilot screw and/or idle adjusting screw im-
properly adjusted
Pilot jet or air passage clogged
Air cleaner element clogged, poorly sealed,
or missing
Starter jet clogged
No spark; spark weak:
Ignition switch, engine stop switch OFF
Clutch lever not pulled in or gear not in neu-
tral
Battery voltage low
Spark plug dirty, broken, or improperly ad-
justed
Spark plug cap or high tension wiring trou-
ble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect heat value
IC igniter trouble
Crakshaft sensor trouble
Ignition coil trouble
Ignition switch, engine stop switch shorted
Gear position sensor, starter lockout switch,
or side stand switch trouble.
Wiring shorted or open
Fuse blown
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valvespringbrokenorweak
Valve spring not seating properly (valve
bent, deformed, worn, or c arbon accu-
mulation on the seating surface)
Poor Running at Low Speed
Spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trou-
ble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect heat value
IC igniter trouble
Crakshaft sensor trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Pilot screw improperly adjusted
Pilot jet or air passage clogged
Needle jet holder air passage clogged
Pilot jet air passage clogged
Air cleaner element clogged, poorly in-
stalled, or missing
428


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