Cable, Wire, and Hose Routing

APPENDIX 17-15

Cable, Wire, and Hose Routing

1. Throttle Cables

2. Ignition Switch

3. Clutch Cable

4. Route the speedometer cable through the clamp (5).

5. Clamp

6. Front Brake Hose

7. Band

8. Clamp

9. Choke Cable

10. Band (Fix the choke cable, clutch cable, left handlebar switch lead and ignition switch leads with

the band)

11. Band (Clamp the brake hose inside of the front fork inner tube, and shall not lap with the choke

cable, clutch cable and left handlebar switch lead.)

12. Front Fork

13. Cutting of the band position to forward.

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

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 trou­ble

Spark plug cap shorted or not in good con­tact

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 mal­adjusted

Pilot jet, or air passage clogged

Air cleaner clogged, poorly sealed, or miss­ing

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:

Spark plug dirty, broken, or maladjusted

Spark plug cap or high tension wiring trou­ble

Spark plug cap shorted or not in good con­tact

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 miss­ing

Starter 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

Cylinder head not sufficiently tightened

down No valve clearance