23. TROUBLESHOOTING
Contents
1. Faulty PGM FI system page 5 13 YES GOTO STEP 6 23 5 TROUBLESHOOTING 6 IACV Inspection Check the IACV operation Does the IACV operates normally Faulty IACV POOR PERFORMANCE AT HIGH SPEED 23 6 1 Ignition Timing Inspection Check ignition timing Is the ignition timing correct Faulty ECM Faulty sensor Faulty sensor YES GOTO STEP 2 Fuel Pump Inspection Inspect the fuel flow Is the fuel pump unit operation normal Faulty fuel pump unit YES GOTO STEP 3 PGM FI System Inspection Check the PGM FI system Is the PGM FI system normal Faulty PGM FI system page 5 13 YES GOTO STEP 4 Valve Timing Inspection Check valve timing 15 the valve timing correct Cam sprockets not installed properly YES GOTO STEP 5 Valve Spring Inspection Check valve springs Is the valve spring free length within specification Faulty valve spring YES GOTO STEP 6 Camshaft Inspection Remove and inspect the camshaft Is the cam lobe height within specification Faulty camshaft YES Camshaft is OK TROUBLESHOOTING POOR HANDLING Steering is heavy e Steering top thread too tight e Damaged steering head bearings Low tire pressure Either wheel is wobbling e Excessive wheel bearing play Bent rim Improperly installed wheel hub e Excessively worn swingarm pivot bearings Bent frame Mo2. 23 TROUBLESHOOTING ENGINE DOES NOT START OR POOR PERFORMANCE AT IS HARD TO START 23 2 HIGH SPEED 23 6 ENGINE LACKS POWER 23 3 POOR HANDLING 23 7 POOR PERFORMANCE AT LOW AND IDLE SPEED 23 5 23 1 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 1 Fuel Line Inspection Check fuel flow to throttle body Does fuel reach the throttle body Clogged fuel line and strainer Clogged fuel tank breather e Faulty fuel pump unit page 5 58 YES GOTO STEP 2 2 Spark Plug Inspection Remove and inspect spark plugs Are the spark plugs in good condition Incorrect spark plug heat range e Incorrect spark plug gap e Dirty air cleaner YES GOTO STEP 3 3 Spark Test Perform spark test Is there weak or no spark YES Faulty spark plug Loose or disconnected ignition system wires Broken or shorted spark plug wire Faulty CKP sensor Faulty ignition coil Faulty engine stop relay Faulty ECM Faulty engine stop switch NO GOTO STEP 4 4 PGM FI System Inspection Check the PGM FI system Is the PGM FI system normal YES GOTO STEP 5 Faulty PGM FI system page 5 13 5 Cylinder Compression Test cylinder compression Is the compression low YES Valve clearance too small e Valve stuck open Worn cylinder and piston rings Damag
3. ed cylinder head gasket e Improper valve timing NO GOTO STEP 6 6 Engine Starting Condition Start engine by following normal procedure Does the engine start then stops YES Leaking intake manifold e Faulty IACV Improper ignition timing Faulty ECM CKP sensor TP sensor Contaminated fuel 23 2 TROUBLESHOOTING ENGINE LACKS POWER 1 Drive Train Inspection Raise wheel off the ground and spin it by hand Does the wheel spin freely NO Brake dragging Worn damaged wheel bearings YES GOTO STEP 2 Tire Pressure Inspection Check tire pressure Are the tire pressures low YES Faulty tire valve e Punctured tire NO STEP Clutch Inspection Accelerate rapidly shift from first to second Does the engine speed change accordingly when clutch is engaged Clutch slipping e Worn clutch discs plates e Warped clutch discs plates e Weak clutch spring e Additive in engine oil YES GOTO STEP 4 Engine Performance Inspection Accelerate lightly Does the engine speed increase NO Dirty air cleaner e Restricted fuel flow Clogged muffler Clogged fuel tank breather YES GOTO STEP 5 Engine Condition Inspection Accelerate or run at high speed Is there knocking YES Worn piston and cylinder Wrong type of fuel e Excessive carbon build up in combustion chamber e Ignition timing too advanced Faulty ECM NO STEP 6 S
4. park Plug Inspection Remove and inspect spark plugs Are the spark plugs in good condition Plugs serviced frequently enough e Incorrect spark plug heat range Incorrect spark plug gap YES GOTO STEP 7 23 3 TROUBLESHOOTING 23 4 7 10 11 12 Engine Oil Inspection Check oil level and condition Is there correct level and good condition Oil level too high Oil level too low Contaminated oil YES GOTO STEP 8 Ignition Timing Inspection Check ignition timing Is the ignition timing correct Faulty ECM Faulty CKP sensor Faulty TP sensor Improper valve timing YES GOTO STEP 9 Cylinder Compression Inspection Test cylinder compression Is the compression low YES Valve clearance too small Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Improper valve timing NO STEP 10 PGM FI System Inspection Check the PGM FI system Is the PGM FI system normal Faulty PGM FI system 5 13 YES GOTO STEP 11 Lubrication Inspection Remove cylinder head cover and inspect for proper lubrication Is the valve train lubricated properly Faulty oil pump Faulty oil pressure relief valve Clogged oil passage Clogged oil orifice YES GOTO STEP 12 Over Heating Inspection Check for engine over heating Is the engine over heating YES Coolant level too low e Fan motor not
5. torcycle pulled to one side e Front and rear wheels not aligned Bent fork Bent swingarm Bent axle Bent frame 23 7
6. working Thermostat stuck closed e Excessive carbon build up in combustion chamber e Use of poor quality fuel e Wrong type of fuel Clutch slipping NO GOTO STEP 13 TROUBLESHOOTING 13 Engine Knocking Inspection Accelerate or run at high speed Is the engine knocking YES Worn piston and cylinder Wrong type of fuel Thermostat stuck closed Excessive carbon build up in combustion chamber Ignition timing too advance Faulty ECM Faulty CKP sensor Engine does not knock POOR PERFORMANCE AT LOW AND IDLE SPEED 1 Intake Air Leak Inspection Check for leaking at insulators Are there leaks YES Loose insulator bands e Loose insulator mounting bolts e Damaged insulator e Faulty O ring NO STEP 2 Spark Test Perform spark test Is there weak or intermittent spark YES Faulty spark plug e Fouled spark plug e Loose or disconnected ignition system wires e Faulty CKP sensor e Faulty ignition coil e Faulty engine stop switch e Faulty ECM NO GOTO STEP Fuel Pump Inspection Inspect the fuel flow Is the fuel pump unit normal YES GOTO STEP 4 Faulty fuel pump unit 5 58 Ignition Timing Inspection Check ignition timing Is the ignition timing correct Faulty ECM e Faulty CKP sensor e Faulty TP sensor Improper valve timing YES STEP 5 PGM FI System Inspection Check the PGM FI system Is the PGM FI system normal
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