Kawasaki WORKHORSE 250 (2003) [319/322] Appendix 17 13

Kawasaki WORKHORSE 250 (2003) [319/322] Appendix 17 13
APPENDIX 17-13
Troubleshooting Guide
Fuel/air mixture incorrect:
Pilot screw and/or idle adjusting screw mal-
adjusted
Pilot jet, or air passage clogged
Starter plunger stuck open
Air cleaner clogged, poorly sealed, or miss-
ing
Fuel level too high or too low
Fuel tank air vent obstructed
Carburetor holder loose
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 gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Compression release mechanism trouble
Other:
Carburetor throttle valve doesn’t slide
smoothly
Engine oil viscosity too high
Brake dragging
Igniter trouble
Final gear case oil level too high
Final gear case oil viscosity too high
Poor Running or No Power at High Speed:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug cap or spark plug lead trouble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect
Crankshaft Sensor trouble
Igniter trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Jet needle or needle jet worn
Main air jet clogged
Needle jet clogged
Fuel level too high or too low
Air cleaner clogged, poorly sealed, or miss-
ing
Starter plunger stuck open
Water or foreign matter in fuel
Carburetor holder loose
Air cleaner duct loose
Fuel tank air vent obstructed
Fuel tap clogged
Fuel line clogged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston rings 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.)
Compression release mechanism trouble
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Igniter trouble
Miscellaneous:
Throttle valve won’t fully open
Carburetor throttle valve doesn’t slide
smoothly
Brake dragging
Clutch slipping
Overheating
Engine oil level too high
Engine oil viscosity too high
Balancer mechanism malfunctioning
Final gear case oil level too high
Final gear case oil viscosity too high
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
Igniter trouble
Fuel/air mixture incorrect:
Main jet clogged
Fuel level too low
Carburetor holder loose
Air cleaner poorly sealed, or missing
Air cleaner duct loose
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Brake dragging
Lubrication inadequate:
Engine oil level too low

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