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
10-2
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary coil
• Cracked or broken ignition coil
4. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
EAS2GBB409POOR MEDIUM-AND-HIGH-SPEED PER-
FORMANCE
Refer to “STARTING FAILURES” on page 10-
1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
2. Throttle body
• Defective throttle body
3. ECU
• Faulty ECU
EAS2GBB410SHIFTING IS DIFFICULT
Refer to “CLUTCH” on page 6-42.
EAS2GBB411SHIFT PEDAL DOES NOT MOVE
Engine
1. Shift shaft
• Bent shift shaft
2. Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
3. Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
EAS2GBB412
JUMPS OUT OF GEAR
Engine
1. Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
2. Shift forks
• Worn shift fork
3. Shift drum
• Incorrect axial play
• Worn shift drum groove
4. Transmission
• Worn gear dog
EAS2GBB413CLUTCH SLIPS
Engine
1. Clutch
• Improperly assembled clutch
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
EAS2GBB414CLUTCH DRAGS
Engine
1. Clutch
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Damaged clutch boss
• Burnt primary driven gear bushing
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS2GBB415OVERHEATING
Engine
1. Cylinder head and piston
• Heavy carbon buildup
• Clogged coolant passages
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
