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Dfi System Troubleshooting Guide - Kawasaki Vulcan900 Classic LT Service Manual

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DFI System Troubleshooting 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.
The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits checked out good, be sure to check the ECU for ground and power supply. If the ground
and power supply are checked good, replace the ECU.
Engine Doesn't Start, Starting Difficulty
Starter motor not rotating
Ignition and engine stop switches not ON
Starter lockout switch or neutral switch trouble
Starter motor trouble
Battery voltage low
Starter relays not contacting or operating
Starter button not contacting
Starter system wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Main 30 A or ignition fuse blown
Starter motor rotating but engine doesn't
turn over
Starter clutch trouble
Starter idle gear trouble
Engine won't turn over
Valve seizure
Rocker arm seizure
Cylinder, piston seizure
Camshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Crankshaft seizure
Transmission gear or bearing seizure
Balancer bearing seizure
No fuel flow
No or little fuel in tank
Fuel pump not rotating
Fuel injector trouble
Fuel tank air vent obstructed
Fuel filter or pump screen clogged
Fuel pressure regulator clogged
Fuel line clogged
Engine flooded
Spark plug dirty, broken or gap maladjusted
Starting technique faulty
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Symptoms or Possible Causes
manuals search engine
FUEL SYSTEM (DFI) 3-31
NOTE
Actions (chapter)
Turn both switches ON.
Inspect (see chapter 16).
Inspect (see chapter 16).
Inspect and charge (see chapter 16).
Inspect the starter relay (see chapter 16).
Inspect and replace (see chapter 16).
Inspect the wiring (see chapter 16).
Inspect and replace (see chapter 16).
Inspect and repair or replace (see chapter 16).
Inspect and replace (see chapter 16).
Inspect (see chapter 9).
Inspect (see chapter 9).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 9).
Inspect and replace (see chapter 9).
Inspect and replace (see chapter 9).
Inspect and replace (see chapter 9).
Inspect and replace (see chapter 9).
Supply fuel (see Owner's Manual).
Inspect (see chapter 3).
Inspect and replace (see chapter 3).
Inspect and repair (see chapter 3).
Inspect and replace fuel pump (see chapter 3)
Inspect and replace fuel pump (see chapter 3).
Inspect and repair (see chapter 3).
Clean spark plugs and adjust plug gap (see
chapter 2).
When flooded, don't crank engine with throttle
fully opened.

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