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Old 12-28-2007   #1 (permalink)
A2rider
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Join Date: Mar 2006
Location: KCK
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Default Four-Stroke Motorcycle Troubleshooting Guide

"The Complete Idiot's Guide to Motorcycle Diagnostics"

While this is not a complete guide of every possible cause for each problem listed, it will help assist mechanics in troubleshooting some of the most common difficulties they will face.

Engine Doesn’t Start, Starting Difficulty:

Starter motor not rotating:
Starter lockout or neutral switch trouble
Starter motor trouble
Battery voltage low
Relays not contacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Main fuse blown

Starter motor rotating but engine doesn’t turn over:
Starter motor 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

No fuel flow:
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 open 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 trouble
Spark plug cap not in good contact
Spark plug incorrect
IC igniter trouble
Neutral, starter lockout, or side stand switch trouble
Pickup coil trouble
Ignition coil trouble
Ignition or engine stop switch shorted
Wiring shorted or open
Main fuse blown

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/land 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)

Last edited by A2rider : 12-28-2007 at 09:45 PM.
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