10
TROUBLESHOOTING
TROUBLESHOOTING.................................................................................... 10-1
GENERAL INFORMATION ...................................................................... 10-1
STARTING FAILURES ............................................................................. 10-1
INCORRECT ENGINE IDLING SPEED ................................................... 10-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .......................... 10-2
SHIFTING IS DIFFICULT ......................................................................... 10-2
SHIFT PEDAL DOES NOT MOVE ........................................................... 10-2
JUMPS OUT OF GEAR............................................................................ 10-2
CLUTCH SLIPS ........................................................................................ 10-2
CLUTCH DRAGS ..................................................................................... 10-2
OVERHEATING ....................................................................................... 10-2
OVERCOOLING ....................................................................................... 10-3
POOR BRAKING PERFORMANCE ......................................................... 10-3
FRONT FORK OIL LEAKING ................................................................... 10-3
FAULTY FRONT FORK LEGS ................................................................. 10-3
UNSTABLE HANDLING ........................................................................... 10-3
HEADLIGHT DOES NOT COME ON ....................................................... 10-4
HEADLIGHT BULB BURNT OUT............................................................. 10-4
TAILLIGHT DOES NOT COME ON ......................................................... 10-4
LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS........................... 10-5
TROUBLESHOOTING
10-3
Cooling system
1. Coolant
• Low coolant level
2. Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump
• Damaged or faulty water pump
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
Fuel system
1. Throttle body
• Damaged or loose throttle body joint
2. Air filter
• Clogged air filter element
Chassis
1. Brake(s)
• Dragging brake
Electrical system
1. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system
• Faulty ECU
• Faulty coolant temperature sensor
EAS2GBB416OVERCOOLING
Cooling system
1. Coolant temperature sensor
• Faulty coolant temperature sensor
EAS2GBB417POOR BRAKING PERFORMANCE
Chassis
1. Brake(s)
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Defective master cylinder kit
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS2GBB418FRONT FORK OIL LEAKING
Chassis
1. Front fork
• Bent, damaged, or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
EAS2GBB419FAULTY FRONT FORK LEGS
Chassis
1. Front fork
• Bent or damaged inner tube
• Bent or damaged outer tube
• Broken fork spring
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS2GBB420UNSTABLE HANDLING
Chassis
1. Handlebar
• Bent or improperly installed handlebar
2. Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg (s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly (-ies)
• Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire (s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
