Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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17-20 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: Starter lockout switch or neutral 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 Vehicle-down sensor (DFI) coming off Engine won’t turn over: Valve seizure Valve lifter seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear 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 switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neutral Battery voltage low Spark plug dirty, broken, or gap maladjusted Stick coil shorted or not in good contact Stick coil trouble Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Neutral, starter lockout, or side stand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Wiring shorted or open Fuse blown Fuel/air mixture incorrect: Bypass screw and/or idle adjusting screw maladjusted Air passage clogged Air cleaner clogged, poorly sealed, or missing 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 Valvespringbrokenorweak 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 Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Stick coil trouble Fuel/air mixture incorrect: Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged, poorly sealed, or missing Fuel tank air vent obstracted Not For Resale www.SmallEngineDiscount.com Fuel pump trouble Throttle body assy holder loose
Not For Resale www.SmallEngineDiscount.com Troubleshooting Guide 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 Valvespringbrokenorweak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Other: IC igniter in ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Air suction valve trouble Vacuum switch valve trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed: Firing incorrect: Spark plug dirty, broken, or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect Camshaft postion trouble IC igniter in ECU trouble Crankshaft sensor trouble Stick coil trouble Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Air cleaner O-ring damaged Air cleaner duct loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient (DFI) Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble (DFI) Compression low: Spark plug loose Cylinder head not sufficiently down No valve clearance tightened APPENDIX 17-21 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.) Knocking: Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Miscellaneous: Throttle valve won’t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Air suction valve trouble Vacuum switch valve trouble Catalytic converter melt down due to muffler overheating (KLEEN) Overheating: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect IC igniter in ECU trouble
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© 2002 Kawasaki Heavy Industries,
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General Specifications GENERAL INFO
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Torque and Locking Agent PERIODIC M
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Torque and Locking Agent PERIODIC M
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Periodic Maintenance Procedures •
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Periodic Maintenance Procedures PER
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FUEL SYSTEM (DFI) 3-1 Fuel System (
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FUEL SYSTEM (DFI) 3-21 Troubleshoot
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DFI System Troubleshooting Guide FU
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Inlet Air Pressure Sensor (Service
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Subthrottle Valve Actuator (Service
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Fuel Line • Open the fuel tank ca
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Coolant COOLING SYSTEM 4-9 Pressure
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Camshaft, Camshaft Chain ENGINE TOP
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Cylinder, Pistons ENGINE TOP END 5-
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Clutch Cover CLUTCH 6-7 Clutch Cove
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• Install the engine ground cable
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Crankcase Splitting • Apply liqui
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Crankshaft and Connecting Rods •
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Crankshaft and Connecting Rods CRAN
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Transmission CRANKSHAFT/TRANSMISSIO
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ELECTRICAL SYSTEM 16-1 Electrical S
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Ignition System ELECTRICAL SYSTEM 1
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