Troubleshooting Guide ○Refer to the Fuel System chapter of the Service Manual for most of the DFI trouble shooting guide. ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting Difficulty Starter motor not rotating Ignition and engine stop switch not ON Starter lockout switch or neutral switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Ignition switch trouble Engine stop switch trouble Main 30 A or ignition fuse blown Starter motor rotating but engine doesn’t turn over Vehicle-down sensor DFI coming off Starter clutch trouble Starter idle gear trouble Engine won’t turn over Valve seizure Valve lifter seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark; spark weak Vehicle-down sensor DFI coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neutral Battery voltage low Spark plug dirty, broken, or gap maladjusted Spark plug incorrect Stick coil shorted or not in good contact Stick coil trouble ECU trouble Neutral, starter lockout, or sidestand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Starter system wiring shorted or open Main 30 A or ignition fuse blown Fuel/air mixture incorrect Bypass screw and/or idle adjusting screw maladjusted Air passage clogged Air cleaner clogged, poorly sealed, or missing Leak from oil filler cap, crankcase breather hose or air cleaner drain cap. Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder, piston worn Piston ring bad worn, weak, broken, or sticking Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak No valve clearance Valve not seating properly valve bent, worn, or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Stick coil trouble Stick coil shorted or not in good contact Spark plug dirty, broken, or maladjusted Spark plug incorrect ECU trouble Crankshaft sensor trouble Fuel/air mixture incorrect Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged, poorly sealed, or missing Fuel tank air vent obstructed Fuel pump trouble Throttle body assy holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad worn, weak, broken, or sticking Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent, worn, or carbon accumulation on the seating surface Camshaft cam worn Run-on dieseling Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loosen terminal of battery – cable or ECU ground lead Carbon accumulating on valve seating surface Engine overheating Other ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Clutch slipping Engine overheating Air suction valve trouble Air switching valve trouble Poor Running or No Power at High Speed Firing incorrect Spark plug dirty, broken, or maladjusted Spark plug incorrect Stick coil shorted or not in good contact trouble Stick coil trouble ECU trouble Fuel/air mixture incorrect Air cleaner clogged, poorly sealed, or missing Air cleaner duct loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad worn, weak, broken, or sticking Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent, worn, or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous Throttle valve won’t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worn Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating KLEEN Overheating Firing incorrect Spark plug dirty, broken, or maladjusted Spark plug incorrect ECU trouble Muffler overheating For KLEEN, do not run the engine even if with only one cylinder misfiring or poor running Request the nearest service facility to correct it For KLEEN, do not push-start with a dead battery Connect another full-charged battery with jumper cables, and start the engine using the electric starter For KLEEN, do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN, do not coast the motorcycle with the ignition switch off Turn the ignition switch ON and run the engine ECU trouble Fuel/air mixture incorrect Throttle body assy holder loose Air cleaner duct loose Air cleaner clogged, poorly sealed, or missing Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Gauge incorrect Water temperature gauge broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Gauge incorrect Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch release mechanism trouble Gear Shifting Faulty Doesn’t go into gear; shift pedal doesn’t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm broken Shift pawl broken Pawl spring broken Jumps out of gear Shift fork ear worn, bent Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Shift fork guide pin worn Drive shaft, output shaft, and/or gear splines worn Overshifts Neutral positioning pin spring weak or broken Pawl spring broken Abnormal Engine Noise Knocking ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring/groove clearance excessive Piston ring worn, broken, or stuck Piston ring groove worn Piston seizure, damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating KLEEN Abnormal Drive Train Noise Clutch noise Clutch damper weak or damaged Clutch housing/friction plate clearance excessive Clutch housing gear worn Transmission noise Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive chain worn Rear and/or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise Bracket, nut, bolt, etc. not properly mounted or tightened Oil Pressure Warning Indicator Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O-ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air cleaner duct loose Air cleaner poorly sealed or missing Handling and/or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped, or not balanced Wheel bearing worn Handlebar mounting bolt loose Steering stem nut loose Front, rear axle runout excessive Engine mounting nut loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft Tire air pressure too low Front fork oil insufficient and/or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork, rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn’t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble Also see Motorcycle Battery & Battery Charging Tips- Motorcycle Battery & Battery Charging Tips Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery cable making poor contact Load excessive bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator/rectifier trouble Battery overcharged Alternator trouble Regulator/rectifier trouble

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