Troubleshooting: General

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The troubleshooting section of the Owner's Manual is a guide to diagnose problems. Read the service manual before performing any work. Improper repair and/or maintenance could result in death or serious injury. (00080a)

The following checklist of possible operating troubles and their probable causes will be helpful in keeping your motorcycle in good operating condition. More than one of these conditions may be causing trouble and should be carefully checked.

Engine: Blast Models

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Starter Does Not Operate or Does Not Turn Engine Over

1. Engine run switch in OFF position.

2. Ignition switch not ON.

3. Discharged battery or loose or corroded connections (solenoid chatters).

Engine Turns Over But Does Not Start

1. Fuel tank empty.

2. Fuel valve turned OFF.

3. Fuel valve or filter clogged.

4. Discharged battery or loose or broken battery terminal connections.

5. Fouled spark plug.

6. Spark plug cable connections loose or in bad condition and shorting.

7. Loose or corroded wire or cable connection(s) at coil or battery.

8. Throttle held open.

Starts Hard

1. Spark plug in bad condition, has improper gap, or is partially fouled.

2. Spark plug cable in bad condition and leaking.

3. Battery nearly discharged.

4. Loose wire or cable connection(s) at one of the battery terminals or at coil.

5. Carburetor not adjusted correctly.

6. Engine oil too heavy (winter operation).

7. Fuel tank vent plugged or fuel line closed off, restricting fuel flow.

8. Water or dirt in fuel system.

Starts But Runs Irregularly or Misses

1. Spark plug in bad condition or partially fouled.

2. Spark plug cable in bad condition and leaking.

3. Spark plug gap too close or too wide.

4. Battery nearly discharged.

5. Damaged wire or loose connection at battery terminals or coils.

6. Intermittent short circuit due to damaged wire insulation.

7. Water or dirt in fuel system, filter or carburetor.

8. Fuel vent system plugged. See dealer.

A Spark Plug Fouls Repeatly

1. Fuel mixture too rich.

2. Incorrect spark plug.

Pre-ignition or Detonation (Knocks or Pings)

1. Incorrect fuel.

2. Incorrect spark plug.

Overheats

1. Insufficient oil supply or oil not circulating.

2. Heavy carbon deposit from lugging engine. See dealer.

3. Insufficient air flow over cylinder head during extended periods of idling or parade duty.

Excessive Vibration

1. Rear fork pivot shaft nuts loose. See dealer.

2. Front engine mounting bolts loose. See dealer.

3. Broken frame. See dealer.

4. Front chain or links tight as a result of insufficient lubrication or belt badly worn.

5. Wheels and/or tires damaged. See dealer.

6. Vehicle not properly aligned. See dealer.

Lubrication System

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Oil Does Not Return to Oil Tank

1. Oil tank empty.

2. Restricted oil lines or fittings. See dealer.

3. Restricted oil filter. See dealer.

4. O-ring at oil pump return missing or cut.

Engine Leaks Oil From Cases, Push Rods, Hoses

1. Loose parts. See dealer.

2. Imperfect seal at gaskets, push rod cover, washers, etc. See dealer.

3. Restricted oil return line to tank. See dealer.

Electrical System

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Alternator Does Not Charge

1. Module not grounded. See dealer.

2. Engine ground wire loose or broken. See dealer.

3. Loose or broken wires in charging circuit. See dealer.

Alternator Charge Rate is Below Normal

1. Weak battery.

2. Excessive use of add-on accessories.

3. Loose or corroded connections.

4. Extensive periods of idling or low speed riding.

Carburetor

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Carburetor Floods

1. Excessive rolling of hand throttle grip.

Transmission: Blast Models

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Transmission Shifts Hard

1. Bent shifter assembly. See dealer.

2. Transmission shifting mechanism needs adjustment. See dealer.

Transmission Jumps Out of Gear

1. Shifter mechanism improperly adjusted. See dealer.

2. Shifter forks (inside transmission) damaged. See dealer.

3. Worn shifter dogs in transmission. See dealer.

Clutch Slips

1. Clutch controls improperly adjusted. See dealer.

2. Worn friction discs. See dealer.

3. Insufficient clutch spring tension. See dealer.

Clutch Drags or Does Not Release

1. Clutch controls improperly adjusted. See dealer.

2. Insufficient clutch spring tension. See dealer.

3. Primary chaincase overfilled.

4. Clutch discs warped. See dealer.

Clutch Chatters

1. Friction discs or steel discs worn or warped. See dealer.

Brakes

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Brakes Do Not Hold Normally

1. Master cylinder low on fluid. See dealer.

2. Brake line contains air bubbles. See dealer.

3. Master or wheel cylinder piston worn. See dealer.

4. Brake pads contaminated with grease or oil. See dealer.

5. Brake pads badly worn. See dealer.

6. Brake disc badly worn or warped. See dealer.

7. Brake fades because of heat build up. Excessive braking or brake pads dragging. See dealer.

8. Brake drags. Insufficient hand lever free play. See dealer.