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Troubleshooting; Troubleshooting Guide - Kawasaki KLX110 Service Manual

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15-2 TROUBLESHOOTING

Troubleshooting Guide

NOTE
This is not an exhaustive list, giving every possi-
ble cause for each problem listed. It is meant sim-
ply as a rough guide to assist the troubleshooting
for some of the more common difficulties.
Engine Doesn't Start, Starting Difficulty:
Engine won't turn over:
Valve seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Camshaft seizure
Transmission gear or crankcase bearing seizure
Kickstarter return spring broken
Kick ratchet gear not engaging
No fuel flow:
No fuel in tank
Fuel tap turned off
Tank cap air vent obstructed
Tank cap clogged
Fuel line clogged
Float valve clogged
Engine flooded:
Fuel level too high
Float valve worn or stuck open
Starting technique faulty (When flooded, kick with the
throttle fully opened to allow more air to reach the
engine.)
No spark, spark weak:
Engine stop switch turned off
Spark plug dirty, damaged or maladjusted
Spark plug cap or high tension wiring damaged
Spark plug cap shorted or not in good contact
Ignition coil damaged
Stator coil damaged
Igniter broken
Flywheel magneto damaged
Engine stop switch shorted
Wiring shorted or open
Fuel/air mixture incorrect:
Idle adjusting screw maladjusted
Pilot jet, or air passage clogged
Air cleaner clogged, poorly sealed or missing
Air cleaner duct loose
Compression Low:
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
Cylinder head gasket damaged
Cylinder head not sufficiently tightened down
Cylinder head warped
Spark plug loose
No valve clearance
Valve spring broken or weak
Valve not seating properly (valve bent, worn or carbon
accumulation on the seating surface)
Poor Running at Low Speed:
Spark weak:
Spark plug dirty, damaged, or maladjusted
Spark plug cap or high tension wiring damaged
Spark plug cap shorted or not in good contact
Spark plug incorrect
Pickup coil trouble
Ignition coil damaged
Igniter broken
Flywheel magneto damaged
Fuel/air mixture incorrect:
Idle adjusting screw maladjusted
Pilot jet, or air passage clogged
Air cleaner clogged, poorly sealed, or missing
Air cleaner duct loose
Choke valve closed
Float level too high or too low
Fuel tank air vent obstructed
Carburetor holder loose
Compression low:
Cylinder, piston worn
Piston rings bad (worn, weak, broken or sticking
Piston ring/land clearance excessive
Cylinder head gasket damaged
Cylinder head not sufficiently tightened down
Cylinder head warped
No valve clearance
Spark plug loose
Valve spring broken or weak
Valve not seating properly (Valve bent, worn, or
carbon accumulation on the seating surface).
Crankshaft oil seal deteriorated or damaged
Other:
Throttle valve doesn't slide smoothly
Engine oil viscosity too high
Brake dragging
Poor Running or No Power at High Speed:
Firing incorrect:
Spark plug dirty, damaged, or maladjusted
Spark plug cap or high tension wiring damaged
Spark plug cap shorted or not in good contract
Spark plug incorrect
Ignition coil trouble
Pickup coil trouble
Stator coil shorted or open
Igniter trouble
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Jet needle or needle jet worn
Jet needle clip in wrong position
Fuel level too high or too low
Air jet or air passage clogged
Air cleaner clogged, poorly sealed or missing
Air cleaner duct poorly sealed
Carburetor holder loose
Fuel to carburetor insufficient
Water or foreign matter in fuel
Fuel tank air vent obstructed
Fuel line clogged
Fuel tap clogged
Air cleaner duct loose

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