> 21. TROUBLESHOOTING ENGINE DOES NOT START ORIS HARD TO START ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEEDS 24-1 24-2 21-3 POOR PERFORMANCE | ATHIGH SPEED 21-4 UNDERCHARGED BATTERY 21-4 OVERCHARGED BATTERY 215 215 NO SPARKS ENGINE DOES NOT START OR IS HARD TO START 1. Check if fuel is getting to the carburetor GETTING TO CARBURETOR 2. Try‘epark toot 5000 SPARKS: 4. Test cylinder compression COMPRESSION NORMAL, 4. Stert by following normal Starting procedure ENGINE DOES NOT FIRE ' 5. Remove spark plug RY + 6. Stert with cheke spplied NOT GETTING TO CARBURETOR WEAK OR NO SPARK» LOW COMPRESSION: ENGINE FIRES auT— SOON STOPS Probable cause + No fuel in fuel tank + Clegged fuct tube or fuel fiter or fuel strainer + Clogged float valve + Clegged fuel tank cep breather tube Faulty spark plug Fouled spark plug Faulty €.0.!, unt Broken or shorted high tension cord Faulty altarnator Broken or shorted ignition coil Faulty engine stop swite’ Faulty puise generator + Poorly connected, broken or short ed wires Valve clearance teo small Vave stuck oxen Worn cylinder and piston rings Damaged cylindar head gasket Impropar valve timing Stuck decompressor cam Faulty reverse decompressor cam one-way clutch + Seized velve + Choke excessively open + Carburetor alr screw excessively closed + Air leaking past intake pive + Impropar ignition timing (C.D unit or pulse generator faulty) Carburetor flooded + Carburetor choke axcessivaly closed Thvowtle valve excessively open Clogged air cleaner element 21-1TROUBLESHOOTING ous ENGINE LACKS POWER 1. Raise whael off graune! anci ‘sain by hand WHEEL SPINS FREELY 2. Check tre prosoure with tire gauge PRESSURE NORMAL 3. Trv rapid acceleration trom low te second ENGINE SPEED LOWERED WHEN CLUTCH IS RELEASED 4. Lightly aeeolerate engine ENGINE SPEED INCREASES 5. Check ignition timing using timing Highs CORRECT ©. Check valve clearance CORRECT 7. Test evlindor compression using compression geuge NORMAL 8, Check carburetor far clogging Nor cLogGeD 9. Rermove spark plug NOT FOULED OR DISCOLORED 21-2 Probable cause WHEEL DOES NOT SPIN». FREELY : PRESSURE TOO LW». ENGINE SPEED DOES NOT» - CHANGE WHEN CLUTCH IS, : RELEASED, . ENGINE SPEED DOES NoT——__»- INCREASE SUFFICIENTLY INCORRECT ————_______. INCORRECT: closaeo FOULED OR DISCOLORED——__+- Brake dragging Worn or damaged wheel bearing Wheel bearing reeds lubrication Drive chain too tight Axio nut excessively tightened Punczured tire Faulty tire valve Clutch slipping Worn clutch ciseiplate Warped clutch cise/plate Carburetor choke clesed Clogged cir cleaner Restricted fuel flow Clogged fuel tank breather tube Clogged muffler Faulty €.D.1. unit Faulty pulse generator Improper valve adjustment ‘Worn valve seat Valve stuck open Worn cylinder ard piston rings Leaking head gasket Improper valve timing Stuck decompressor car Fauty reverse decompressor cam one-way lurch Carburetor not serviced frequently enough Plug not serviced frequently enough Uso of plug with improper heet renge:TROUBLESHOOTING et 0 10, Remove cil lavel gauge and check ail level and for dirty of coRRECT 11, Remove the valve adjuster cover end inspect lubrication VALVE TRAIN LUBRICATED PROPERLY 12, Chock #f engine ovetheate 1, Adcelorate or run at high speed ENGINE DOES NOT KNOCK Probable cause OIL LEVEL INCORRECT Oi level too high i lavel too low VALVE TRAIN NOT» » LUBRICATED PROPERLY . Clogged ol passage Cloggad oil control orifice Contaminsted oil Fauity oil pump OVERHEATED ++ Excessive carbon build-up in com- bbuetion chamber Use of improper quality of fusl + Gluten stipping + Fue! air mixture too lean ENGINE KNOCKS————____» + + Fusl air mixture toe loan + Use of improper grace of cil + Excessive carton bulld-up in com: bustion chamber + Ignition timing too advanced (Faulty €.0.1. unith ‘Warn piston ring and cylinder POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1. Check ignition timing and valve clearance CORRECT 2. Check carburetor pilot screw adjustment CORRECT 3. Chaek if air is leaking past intake pipe NOT LEAKING . Try'spark test GOOD SPARK Possible Cause INCORRECT» + Improper valve clearance + Improper ignition tring (Faulty C.D Lurie) INCORRECT: + Fuel air mixture too lean (To correct, screw out) + Fuel air mixture too rich (Te corect, sarew in} LEAKING + Detetiorated insulator O-ring + Loose carburetor WEAK OR INTERMITTENT————» + SPARK Faulty, carbonized or wet spark plug + Faulty C.D, unit Faulty alternator + Faulty ignition coll + Faulty pulse generator 21-3TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Probable cause 1. Chock ignition timing and valve Incorrect + Improper valve clearance dearence + Faulty €.0.1. unit + Faulty pulse generator CORRECT 2, Diefonnect fuel tube a: carouretor FUEL FLOW RESTRICTED» Lack of fuel in tank + Clogged fuel tube + Clogged fuel tank breather tube + Clogged fuel valve + Clogged fuel etrainer 9. Remove carburetor and check for CLOGED. ————_—- lean clogged jet NoT cLaacen 4. Check valve timing InconrecT s+ cam sprocket not installed properly CORRECT 6. Check valve opring tension WEAK ++ Faulty spring NOT WEAKENED UNDERCHARGED BATTERY Probable cause 1. Parton the battery or electrical == LEAK». Loose, broken o shorted wits or inspection (page 18-4) connection + Faulty ignition switen NO LEAK 2. Staft tha angine and perform REGULATED. Faulty battery ‘the regulated voltoge inspection tpage 10-4) NOT REGULATED. 8. Chack the lternator stator oxil out oF ORDER — + Faulty steter coil continuity page 19-5) + Loose, broken or shorted yellaw wires or their connections NORMAL 4, Mozoure the voltage between (OUT OF ORDER ————*- Loose, brokan or shorted rediwhite the rediwhite (+) ane green (-) Cr green wires or their connections terminals of the veltage regulator! rectifier REGULATED. 5. Check the reguletetrectifier OUT OF ORDER ——————». Faulty voltage regulator, rectifier ‘continuity (page 16-6) and black + Loose connector terminal of the regulater/rectifior ‘comectar for loo NORMA; $e. Fauity stternator 21-4TROUBLESHOOTING OVERCHARGED BATTERY Probable cause 1. Measure the voltage berween the OUT OF NORMAL». black (+) and green (-) terminals of READINGS (11 ~12V) the voltage requlatoritectifier when ignition switch ON, NORMAL READINGS 2. Chdek the veltage reculatorirectifier LOOSE >. connector fot laase NOT LOOSE NO SPARKS 1. Replace the spark plug with good GOOD SPARK —________»+ NO SPARK 2. Chack the plug cap and high Loose ——___________». ‘tension cord for loose Nor Loose 3. Distonnect the black/white wire GOOD SPARK ———_____—»+ ‘terminal and check the sparke while engine cranking : NO SPARK inspection (page 17-31 ‘OUT OF ORDER NORMAL 6. Medaure the pulee generator (OUT OF STANDARD. . resistance (page 17-4) RESISTANCE NORMAL 7. Chetk the ignition ceil [pags 17-3) OUT OF ORDER noma 8. chi te cot nt oe 173) UT OF ORDER . noma worm Broken black or greon wiro harnase Loose connector Faulty voltage regulaior/rectifier Probable cause Fauity spark pluc Loose plug cap Faulty ignition switch of engine stop switch) Broien ar shorted Faulty excitor ecil Faulty pulse ganarator Faulty ignition e¢ Faulty CDI unit Loose terminal connection Out of order pulse generator air gap 21-5