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Troubleshooting Guide - Kawasaki EN500 Vulcan 500 LTD Service Manual

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16-2 APPENDIX

Troubleshooting Guide

NOTE
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:
Starter lockout or neutral switch trouble
Starter motor trouble
Battery voltage low
Starter relays 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
Engine won't turn over:
Valve seizure
Rocker arm seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Alternator shaft bearing seizure
Balancer bearing seizure
No fuel flow:
No fuel in tank
Fuel tap vacuum hose clogged
Fuel tank air vent obstructed
Fuel tap clogged
Fuel line clogged
Float valve clogged
Engine flooded:
Fuel level in carburetor float bowl too high
Float valve worn or stuck open
Starting technique faulty
(When flooded, crank the engine with the
throttle fully opened to allow more air to
reach the engine.)
No spark; spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trou-
ble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect
IC igniter trouble
Neutral, starter lockout, or side stand switch
trouble
Crankshaft sensor trouble
Ignition coil trouble
Ignition or engine stop switch shorted
Wiring shorted or open
Fuse blown
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
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 high tension wiring trou-
ble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect
IC igniter trouble
Crankshaft sensor trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Pilot screw maladjusted
Pilot jet, or air passage clogged
Air bleed pipe, bleed holes clogged
Air cleaner clogged, poorly sealed, or miss-
ing
Choke plunger stuck open
Fuel level in carburetor float bowl too high
or too low
Fuel tank air vent obstructed
Carburetor holder loose
Air cleaner duct loose
Air cleaner O-ring damaged
Compression low:
Spark plug loose

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Vulcan 500 ltd

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  • Ricardo Paluan Apr 27, 2016 01:22:
    Adquiri recentemen​te uma moto vulcan 500 ano 1995. Tenho o 37 anos e iniciante no mundo motociclis​ta. Entretanto​, em razão só tempo e idade da moto, não tenho o manual do proprietá​rio, sendo este indispens