Download  Print this page

Troubleshooting Guide - Kawasaki KLX110 Service Manual

Motorcycle.
Hide thumbs

Advertisement

Table of Contents
16-10 APPENDIX

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.
Engine Doesn't Start, Starting
Difficulty:
Starter motor not rotating:
Engine stop switch not ON
Starter lockout switch trouble (KLX110D)
Gear position switch trouble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Wiring open or shorted
Engine stop switch trouble
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
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end, big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Starter idle gear seizure
Kick shaft return spring broken
Kick ratchet gear not engaging
No fuel flow:
No fuel in tank
Fuel tank cap air vent obstructed
Fuel tap clogged
Fuel tap turned off
Fuel line clogged
Carburetor float valve clogged
Engine flooded:
Fuel level in carburetor float bowl too high
Float valve worn or jammed with foreign
matter
Starting technique faulty (When flooded,
crank the engine with the throttle fully
opened to allow more air to reach the
engine.)
Fuel/air mixture incorrect:
Pilot screw and/or idle adjusting screw mal-
adjusted
Pilot jet or air passage clogged
Air cleaner clogged, poorly sealed or miss-
ing
Starter jet clogged
No spark; spark weak:
Engine stop switch turned OFF
Spark plug dirty, broken or gap maladjusted
Spark plug cap or ignition coil lead trouble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect
Igniter trouble
Crankshaft sensor trouble
Ignition coil trouble
Engine stop switch shorted
Gear position switch trouble
Wiring shorted or open
Rotor damaged
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
Cylinder gasket damaged
Valve spring broken or weak
Valve not seating properly (valve bent, de-
formed, worn or carbon accumulation on
the seating surface)
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Spark plug dirty, broken or gap maladjusted
Spark plug cap or ignition coil lead trouble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect
Igniter trouble
Crankshaft sensor trouble
Rotor damaged
Ignition coil trouble
Wiring connector not in good contact
Fuel/air mixture incorrect:
Pilot screw and/or idle adjusting screw mal-
adjusted
Pilot jet or air passage clogged
Needle Jet or air passage clogged
Air cleaner clogged, poorly sealed or miss-
ing
Choke valve closed
Fuel level in carburetor float bowl too high
or too low
Fuel tank cap air vent obstructed
Fuel tap clogged
Carburetor holder loose
Air cleaner duct loose

Advertisement

Table of Contents

   Also See for Kawasaki KLX110

This manual is also suitable for:

Klx110l

Comments to this Manuals

Symbols: 0
Latest comments: