Kappa Motorbikes

Cbr600 Trable Shooting

Engine cranks but won't start

• No fuel to carburetor -Clogged fuel filter

— Clogged fuel line

— Clogged fuel tank breather tube

• Too much fuel getting to the engine

— Clogged air cleaner

— Flooded carburetor

• Contaminated/deteriorated fuel

• Improper choke operation

• Improper throttle operation

• Fuel pump system malfunction

• No spark at plug (faulty ignition system —section 17)

Engine stalls, hard to start, rough idling

• Restricted fuel line

• Fuel mixture too lean/rich

• Contaminated/deteriorated fuel

• Misadjusted idle speed

• Misadjusted pilot screw

• Restricted fuel tank breather tube

• Clogged air cleaner

• Clogged slow circuit

• Starting enrichment valve open

• Fuel pump system malfunction

• Faulty EVAP CAV and/or EVAP purge control system (California type)

• Faulty ignition system (section 17)

Afterbum when engine braking is used

• Lean mixture in slow circuit

• Faulty air cut-off valve

• Faulty pulse secondary air injection (PAIR) system

• Faulty ignition system (section 17)

Lean mixture

• Clogged fuel jets

• Faulty float valve

• Restricted fuel line

• Restricted fuel tank breather tube

• Faulty vacuum piston

• Fuel pump system malfunction

• Faulty EVAP CAV control system (California type)

Rich mixture

• Starting enrichment valve open

• Clogged air jets

• Faulty float valve

• Float level too high

• Dirty air cleaner

• Faulty vacuum piston

• Faulty EVAP purge control system (California type)

Backfiring or misfiring during acceleration

• Faulty ignition system (section 17)

Poor performance (driveability)

• Clogged fuel system

• l-uel pump system malfunction

• Faulty EVAP CAV control system (California type)

• Faulty ignition system (section 175

Direct Air Induction (D.A.I.) system malfunction (49 STATE/CANADA type)

Turn the ignition switch ON with the engine stop switch to RUN and check the solenoid valve for operational sound located under the front side of the fuel tank (i.e. poping sound).

Sound

Remove the seat cowl (page 2-2). Raise the rear wheel off the ground and support the motorcycle securely with a hoist or equivalent.

Start the engine, shift the transmission into gear and check for continuity between the Pink/white and Black/white #2 terminals of the solenoid valve relay. There should be continuity when the speedometer is below 20 km/h (18 mph) and no continuity when the speedometer is 20 km/h (18 mph) or more.

Abnormal

Disconnect the fuel pump transfer relay connector. Measure the voltage between the Black/white #1 ( + ) terminal of the solenoid valve relay and ground ( —) with the ignition switch ON.

AIR VENT CONTROL \ SOLENOID VALVE

• Normal —»*- • Check the induction ducts and hoses, and the solenoid valve operation (page 5-36)

SOLENOID VALVE RELAY

FUEL PUMP TRANSFER RELAY

Pink/white-

SOLENOID VALVE RELAY

Pink/white-

FUEL PUMP TRANSFER RELAY

-No voltage • Open circuit in Black/white # 1 wire

Voltage

Measure the voltage between the Pink/yellow ( + ) terminal of the solenoid valve relay and ground ( —) with the ignition switch ON.

■ No voltage • Faulty solenoid valve relay

Voltage

Connect the transfer relay connector. Start the engine, shift the transmission into gear and measure the voltage between the Pink/yellow ( + ) terminal of the solenoid valve relay and ground ( —). There should be battery voltage when the speedometer is below 20 km/h (18 mph) and no voltage when the speedometer is 20 km/h (18 mph) or more.

Abnormal

(Go to following page)

1 Faulty solenoid valve relay

(From previous page: Abnormal)

Remove the combination meter without disconnecting the connector (page 19-6). Start the engine, shift the transmission into gear and measure the voltage between the Pink/yellow ( + ) and Green ( — ) terminals of the meter. There should be battery voltage when the speedometer is below 20 km/h (18 mph) and no voltage when the speedometer is 20 km/h (18 mph) or more.

Abnormal

1 Faulty combination meter

Normal

1 Open circuit in Pink/yellow wire

COMBINATION METER

(From previous page: No sound)

Disconnect the solenoid valve 2P (Black) connector and measure the battery voltage between the Pink/white ( + ) and Green { —) terminals at the harness side connector with the ignition switch ON.

No voltage

Voltage • Check the solenoid valve operation (page 5-36)

SOLENOID VALVE CONNECTOR

Remove the seat cowl (page 2-2). Measure the voltage between the Black/white #2 ( + ) terminal of the solenoid valve relay and ground ( —) with the ignition switch ON.

SOLENOID VALVE CONNECTOR

-No voltage-

1 Open circuit in Black/white # 2 wire

Voltage

Check for continuity between the Pink/white and Black/white #2 terminals of the solenoid valve relay with the ignition switch ON.

1 Open circuit in Black/white # 2 wire

SOLENOID VALVE RELAY

JnEfV Pink/ye I low Black/white #2 ^ Black/white # 1 Continuity »- • Open circuit in Pink/white or Green wire

No continuity

(Go to following page)

(From previous page: No continuity)

Measure the voltage between the Black/white # 2 ( + ) and Pink/yellow ( —) terminals of the solenoid valve relay with the ignition switch ON.

-No voltage—• Faulty solenoid valve relay

Voltage

Voltage

Disconnect the combination meter connector (page 19-6).

Check for continuity between the Pink/yellow terminal of the meter connector and ground.

No continuity

Faulty combination meter

-No voltage—• Faulty solenoid valve relay

• Continuity—• Short circuit in Pink/yellow wire

COMBINATION METER CONNECTOR

Direct Air Induction (D.A.I.) system malfunction (CALIFORNIA type)

Normal—(Go to following page)

Voltage —• Faulty combination meter

Continuity

Continuity

• Faulty air vent control solenoid valve

Normal—(Go to following page)

Voltage —• Faulty combination meter

2P CONNECTOR No continuity-*- • Open or short circuit in Pink/yellow wire

(From previous page: Normal

Disconnect the EVAP CAV solenoid valve 2P (black) connector.

Measure ihe voltage between the Black ( + ) and Green ( —) terminals at the harness side connector with the ignition switch ON.

Voltage

• Check the induction ducts, hoses, and the air vent control solenoid valve and EVAP CAV solenoid valve operation (page 5-36 and 5-41)

-No voltage-»- • Open circuit in Black or Green wire

EVAP CAV SOLENOID VALVE 2PCONNECTOR

EVAP CAV SOLENOID VALVE 2PCONNECTOR

Fuel pump system malfunction

Abnormal

1 Faulty combination meter

(From previous page: Normal)

(From previous page: Normal)

(From previous page: Continuity)

Measure the battery voltage between the Black/ white ( + ) terminal of the fuel cut-off relay and ground ( —) with the ignition switch ON.

• No voltage-»- • Open circuit in Black/white wire

Voltage

• No voltage-»- • Open circuit in Black/white wire

Voltage

Measure the battery voltage between the Blue/ black ( + ) terminal of the fuel cut-off relay and ground ( —) with the ignition switch ON.

■ No voltage-*- • Open circuit in Blue/black wire

Voltage

1 Faulty fuel cut-off relay

R-12

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