TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank Empty Clogged fuel filter Clogged fuel strainer Clogged fuel tank drain hose Clogged roll-over valve Clogged roll-over valve breather hose Deteriorated or contaminated fuel Fuel cock Clogged fuel hose Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked-in air Deformed float Worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Faulty starter plunger Improperly adjusted starter cable Air filter Clogged air filter element Fuel pump Faulty fuel pump Faulty fuel pump relay ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals severed Improper heat range Faulty spark plug cap Ignition coil Faulty spark plug lead Broken body Full-transistor system Faulty ignitor unit Faulty pickup coil Switch and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Starter motor Faulty starter motor Faulty starter relay Faulty circuit cut-off relay Faulty starter clutch
COMPRESSION SYSTEM Cylinder and cylinder head Loose spark plug Loose cylinder head or cylinder Faulty cylinder head gasket Worn, damaged or seized cylinder Improperly sealed valve Improper valve-to-valve seat contact Improper valve timing Faulty valve spring Piston and piston ring Improperly installed piston ring Worn, fatigued or broken piston ring Seized piston ring Seized or damaged piston Crankcase and crankshaft Improperly seated crankcase Seized crankshaft EB901000 POOR ENGINE IDLE SPEED PERFORMANCE POOR ENGINE IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Loose pilot jet Clogged pilot air jet Improperly synchronized carburetors Improperly adjusted idle speed (throttle stop screw) Improper throttle cable free play Flooded carburetor Electrical system Faulty battery Faulty spark plug Faulty ignitor unit Faulty pickup coil Faulty ignition coil Valve train Improperly adjusted valve clearance Air filter Clogged air filter element EB902000 POOR MEDIUM-AND HIGH-SPEED PERFORMANCE POOR MEDIUM-AND HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURE/HARD STARTING”. (Fuel system,electrical system,compression system and valve train) Carburetor Faulty diaphragm Improperly adjusted fuel level Clogged or loose main jet Air filter Clogged air filter element Fuel pump Faulty fuel pump
EB903000 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift pedal link Bent shift shaft Shift cam, shift fork Groove jammed with impurities Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Jammed impurities Incorrectly assembled transmission JUMPS-OUT-OF GEAR Shift shaft Improperly adjusted shift lever position Improperly returned stopper lever Shift fork Worn shift fork Shift cam Improper thrust play Worn shift cam groove Transmission Worn gear dog EB904000 FAULTY CLUTCH PERFORMANCE CLUTCH SLIPPING Clutch Improperly adjusted clutch cable Loose clutch spring Fatigued clutch spring Worn friction plate/clutch plate Incorrectly assembled clutch Engine oil Improper oil level Improper viscosity (low) Deterioration CLUTCH DRAGGING Clutch Warped pressure plate Unevenly tensioned clutch springs Bent push rod Broken clutch boss Burnt primary driven gear bushing Bent clutch plate Swollen friction plate Match marks not aligned Engine oil Improper oil level Improper viscosity (high) Deterioration
EB905000 OVERHEATING OVERHEATING Ignition system Improper spark plug gap Improper spark plug heat range Faulty ignitor unit Fuel system Improper carburetor main jet setting Improper fuel level Clogged air filter element Cooling system Faulty cooling fan Faulty thermo stat Faulty thermo switch Improper coolant level (low) Faulty radiator Faulty radiator cap Faulty water pump Compression system Heavy carbon build-up Engine oil Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag OVERCOOLING OVERCOOLING Faulty cooling fan Faulty thermo stat Faulty thermo switch EB906000 POOR BRAKING POOR BRAKING EFFECT Disc brake Worn brake pad Worn disc Air in brake fluid Leaking brake fluid Faulty cylinder cup kit Faulty caliper seal kit Loose union bolt Broken brake hose Oily or greasy brake disc/brake pad Improper brake fluid level EB907000 FAULTY FRONT FORK LEGS MALFUNCTION Bent, deformed or damaged inner tube Bent or deformed outer tube Damaged fork spring Worn or damaged slide metal Bent or damaged damper rod Improper oil viscosity Improper oil level OIL LEAKAGE Bent, damaged or rusty inner tube Damaged or cracked outer tube Damaged oil seal lip Improperly installed oil seal Improper oil level (too high) Loose damper rod holding bolt Broken cap bolt O-ring Loose drain bolt Damaged drain bolt gasket
UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Improperly installed or bent Steering Improperly installed handlebar crown Bent steering stem Improperly installed steering shaft (improperly tightened ring nut) Damaged ball bearing or bearing race Swingarm Worn bearing or busing Bent or damaged Rear shock absorber Faulty spring Oil and gas leakage Tire Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wear Front fork Uneven oil levels on both sides Uneven spring tension Broken spring Twisted front fork Wheel Incorrect wheel balance Deformed cast wheel Damaged bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged steering head tube Improperly installed bearing race EB909000 FAULTY LIGHTING AND SIGNAL SYSTEMS HEADLIGHT DOES NOT LIGHT Improper bulb Too many electric accessories Hard charging (broken stator coil wire, faulty rectifier /regulator) Incorrect connection Improperly grounded Poor contacts (main or light switch) FLASHER DOES NOT LIGHT Improperly grounded Discharged battery Faulty turn switch Faulty flasher relay Faulty wire harness Loosely connected coupler Burnt-out bulb Faulty fuse FLASHER BLINKS SLOWLY Faulty flasher relay Faulty main and/or turn switch Improper bulb BULB BURNT OUT Improper bulb Faulty battery Faulty rectifier/regulator Improperly grounded Faulty main and/or light switch Bulb life expired FLASHER REMAINS LIT Faulty flasher relay Burnt-out bulb FLASHER BLINKS QUICKLY Improper bulb Faulty flasher relay Burnt-out bulb HORN DOES NOT SOUND Faulty battery Faulty fuse Faulty main and/or horn switch Improperly adjusted horn Faulty horn Broken wire harness
