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Troubleshooting Guide - Kawasaki J300 Service Manual

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  • Contents

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17-26 APPENDIX

Troubleshooting Guide

NOTE
○
Refer to the Fuel System chapter for most
of 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
Side stand switch trouble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn't
turn over:
Starter clutch trouble
Starter idle gear trouble
Vehicle-down sensor (DFI) coming off
Engine won't turn over:
Valve seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Final gear or bearing seizure
Camshaft seizure
No fuel flow:
No fuel in tank
Fuel pump trouble
Fuel tank air vent obstructed
Fuel filter clogged
Fuel line clogged
Engine flooded:
Clean spark plug and adjust plug gap
Starting technique faulty
(When flooded, do not crank the engine with
the throttle fully opened. This promotes
engine flood because more fuel is supplied
automatically by DFI.)
No spark; spark weak:
Vehicle-down sensor (DFI) coming off
Ignition and engine stop switch not on
Battery voltage low
Spark plug dirty, broken, or gap malad-
justed
Spark plug cap or ignition coil cable trouble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect
ECU trouble
Side stand switch trouble
Crankshaft sensor trouble
Ignition coil trouble
Ignition switch or engine stop switch
shorted
Wiring shorted or open
Fuse blown
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or miss-
ing
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)
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Spark plug cap or ignition coil cable trouble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect
ECU trouble
Crankshaft sensor trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or miss-
ing
Fuel tank air vent obstructed
Fuel pump trouble
Intake manifold 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 warped
Cylinder head gasket damaged
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Table of Contents

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This manual is also suitable for:

J300 absJ300 2017Sc300ch 2017

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