Post by iconic944ss on Dec 14, 2011 21:07:22 GMT
With thanks to the power of the Internet 
Converted to PDF document:
dl.dropbox.com/u/26653469/Fault%20Finding/faultfinding.pdf
=======================================================
(1) Engine doesn't start or is difficult to start
Starter motor doesn't rotate
Starter motor rotates but engine does not turn over.
Starter works but engine won't turn over (seized)
or ..........
(1) Engine doesn't start or is difficult to start
Starter motor doesn't rotate
► Engine kill switch OFF.
► Fuse blown. Check main fuse and starter circuit .
► Battery voltage low. Check and recharge battery.
► Starter motor defective. Make sure the wiring to the starter is secure. Make sure the starter relay clicks when the start button is pushed. If the relay clicks, then the fault is in the wiring or motor.
œ Starter relay faulty. Check it accordingly.
œ Starter switch not contacting. The contacts could be wet, corroded or dirty. Disassemble and clean the switch.
œ Wiring open or shorted. Check all wiring connections and harnesses to make sure that they are dry, tight and not corroded. Also check for broken or frayed wires that can cause a short to ground (earth).
œ Ignition (main) switch defective. Check the switch. Replace the switch with a new one if it is defective.
œ Engine kill switch defective. Check for wet, dirty or corroded contacts. Clean or replace the switch as necessary.
œ Faulty side stand switch. Check the wiring to the switch itself.
Converted to PDF document:
dl.dropbox.com/u/26653469/Fault%20Finding/faultfinding.pdf
=======================================================
(1) Engine doesn't start or is difficult to start
Starter motor doesn't rotate
- Engine kill switch OFF.
- Fuse blown. Check main fuse and starter circuit .
- Battery voltage low. Check and recharge battery.
- Starter motor defective. Make sure the wiring to the starter is secure. Make sure the starter relay clicks when the start button is pushed. If the relay clicks, then the fault is in the wiring or motor.
- Starter relay (Solenoid) faulty. Check it accordingly.
- Starter switch or button not contacting. The contacts could be wet, corroded or dirty. Disassemble and clean the switch.
- Wiring open or shorted. Check all wiring connections and harnesses to make sure that they are dry, tight and not corroded.
Also check for broken or frayed wires that can cause a short to ground (earth). - Ignition (main) switch defective. Check the switch. Replace the switch with a new one if it is defective.
- Engine kill switch defective. Check for wet, dirty or corroded contacts. Clean or replace the switch as necessary.
- Faulty side stand switch. Check the wiring to the switch itself.
Starter motor rotates but engine does not turn over.
- Starter motor clutch defective. Inspect and repair or replace.
- Damaged idler or starter gears. Inspect and replace the damaged parts.
Starter works but engine won't turn over (seized)
- Seized engine caused by one or more internally damaged components. Failure due to wear, abuse or lack of lubrication.
Damage can include seized valves, followers, camshafts, pistons, crankshaft, connecting rod bearings, or transmission gears or
bearings.
or ..........
(1) Engine doesn't start or is difficult to start
Starter motor doesn't rotate
► Engine kill switch OFF.
► Fuse blown. Check main fuse and starter circuit .
► Battery voltage low. Check and recharge battery.
► Starter motor defective. Make sure the wiring to the starter is secure. Make sure the starter relay clicks when the start button is pushed. If the relay clicks, then the fault is in the wiring or motor.
œ Starter relay faulty. Check it accordingly.
œ Starter switch not contacting. The contacts could be wet, corroded or dirty. Disassemble and clean the switch.
œ Wiring open or shorted. Check all wiring connections and harnesses to make sure that they are dry, tight and not corroded. Also check for broken or frayed wires that can cause a short to ground (earth).
œ Ignition (main) switch defective. Check the switch. Replace the switch with a new one if it is defective.
œ Engine kill switch defective. Check for wet, dirty or corroded contacts. Clean or replace the switch as necessary.
œ Faulty side stand switch. Check the wiring to the switch itself.
