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Symptom and possible causes


Starting difficulty.

1. Clogged starter jet.

2. Clogged starter jet passage.

3. Air leaking from joint between starter body and carburetor.

4. Air leaking from carburetor joint or vacuum hose joint. 5. Improperly working starter (enricher) plunger.

Clean. Clean.

Tighten, adjust or replace gasket.

Tighten or replace defective part. Adjust.

Idling or low-speed trouble.

1. Clogged or loose pilot jet.

2. Clogged or loose pilot air jet.

3. Air leaking from carburetor joint, vacuum pipe joint, or starter.

4. Clogged pilot outlet port.

5. Clogged bypass port.

6. Starter (enricher) plunger not fully closed.

Clean or tighten.

Clean or tighten.

Tighten or replace defective part.




Medium-or high speed trouble.

1. Clogged main jet.

2. Clogged main air jet.

3. Clogged needle jet.

4. Improperly working throttle valve.

5. Clogged fuel filter.

Clean. Clean. Clean. Adjust.

Clean or replace.

Overflow and fuel level fluctuations.

1. Worn or damaged needle valve.

2. Broken needle valve spring.

3. Improperly working float.

4. Foreign matter on the needle valve.

5. Incorrect float chamber fuel level.

Replace. Replace.

Adjust or replace. Clean or replace with needle valve seat. Adjust float height.



Symptom and possible causes


Steering is heavy.

1. Overtightened steering stem nut.

2. Broken bearing/race in steering stem.

3. Distorted steering stem.

4. Low tire pressure.

Adjust. Replace. Replace. Regulate.

Handlebar wobbles.

1. Loss of balance between right and left front forks.

2. Distorted front fork.

3. Distorted front axle.

4. Twisted tire.

Adjust or replace. Repair or replace. Replace. Replace.

Front wheel wobbles.

1. Distorted wheel rim.

2. Worn front wheel bearing.

3. Defective or incorrect tire.

4. Loose front axle nut.

5. Loose front axle pinch bolt.

6. Incorrect fork oil level.








Symptom and possible causes


Front suspension too soft.

1. Weak spring.

2. Insufficient fork oil.


Check level and add.

Front suspension too stiff.

1. Excessively viscous fork oil.

Check level and drain.

Front suspension too noisy.

1. Insufficient fork oil.

2. Loose front suspension fastener.

Check level and add. Tighten.

Rear wheel wobbles.

1. Distorted wheel rim.

2. Worn rear wheel bearing.

3. Defective or incorrect tire.

4. Worn swingarm bearing.

5. Worn rear suspension bush.

6. Loose rear suspension fastener.

Replace. Replace. Replace. Replace. Replace. Tighten.

Rear suspension too soft.

1. Weak rear shock absorber spring.

2. Rear shock absorber leaks oil.

3. Improper suspension setting.

Replace. Replace. Adjust.

Rear suspension too stiff.

1. Improper suspension setting.

2. Bent rear shock absorber shaft.

3. Bent swingarm.

4. Worn swingarm and rear suspension related bearings.

Adjust. Replace. Replace. Replace.

Rear suspension too noisy.

1. Loose rear suspension fastener.

2. Worn rear suspension bush.

3. Worn swingarm bearing.






Symptom and possible causes


Brake power insufficient.

1. Leakage of brake fluid.

2. Worn brake pad.

3. Oil on brake pad surface.

4. Worn brake disc.

5. Air in hydraulic system.

Repair or replace. Replace.

Clean brake disc and brake pads. Replace. Bleed.

Brake squeaks.

1. Carbon adhesion on brake pad surface.

2. Tilted brake pad.

3. Damaged wheel bearing.

4. Worn brake pad.

5. Foreign material in brake fluid.

6. Clogged return port of master cylinder.

7. Loose front or rear axle.

Clean surface with sandpaper. Readjust brake pad position or replace. Replace. Replace.

Change brake fluid. Disassemble and clean master cylinder. Tighten.

Brake lever or pedal stroke excessive.

1. Air in hydraulic system.

2. Insufficient brake fluid.

Check level and add. Bleed any air. Change.

Brake fluid leaks.

1. Loose connection joint.

2. Cracked hose.

3. Worn piston seal.

4. Worn secondary cup.

Tighten. Replace. Replace. Replace.


Symptom and possible causes


2. Insufficient brake lever or brake pedal pivot lubrication.

Clean and lubricate. Lubricate.



Symptom and possible causes


No sparking or poor sparking.

1. Defective ignition coil.

2. Defective spark plug.

3. Defective signal generator.

4. Defective ignitor.

Replace. Replace. Replace. Replace.

Spark plug is wet or quickly becomes fouled with carbon.

1. Excessively rich air/fuel mixture.

2. Excessively high idling speed.

3. Incorrect gasoline.

4. Dirty air cleaner element.

5. Incorrect spark plug (cold type).

Adjust carburetor. Adjust carburetor. Change.

Clean or replace. Change to hot type spark plug.

Spark plug quickly becomes fouled with oil or carbon.

1. Worn piston ring.

2. Worn piston.

3. Worn cylinder.

4. Excessive valve-stem to valve-guide clearance.

5. Worn valve stem oil seal.

Replace. Replace.

Rebore or replace.



Spark plug electrodes overheat or burn.

1. Incorrect spark plug (hot type).

2. Overheated engine.

3. Loose spark plug.

4. Excessively lean air/fuel mixture.

Change to cold type spark plug. Tune-up. Tighten.

Adjust carburetor.

Generator does not charge.

1. Open or short in lead wires, or loose lead connections.

2. Shorted, grounded or open generator coil.

3. Shorted or punctured IC regulator or rectifier.

Repair, replace or connect properly. Replace. Replace.

Generator charges but charging rate is below the specifications.

1. Lead wires tend to get shorted or open-circuited or loosely connected at terminal.

2. Grounded or open-circuited stator coils or generator.

3. Defective IC regulator or rectifier.

4. Defective battery cell plates.

Repair or tighten.

Replace. Replace. Replace battery.

Generator overcharges.

1. Internal short-circuit in the battery.

2. Damaged or defective IC regulator or rectifier.

3. Poorly grounded IC regulator.

Replace battery. Replace.

Clean and tighten ground connection.

Unstable charging.

1. Lead wire insulation frayed due to vibration, resulting in intermittent shorting.

2. Internally shorted generator.

3. Defective IC regulator or rectifier.

Repair or replace.

Replace. Replace.

Starter button does not work.

1. Run down battery.

2. Defective switch contact.

3. Brushes do not seat properly on the commutator in the starter motor.

4. Defective starter relay/starter interlock switch.

Recharge or replace. Replace.

Repair or replace. Replace.

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DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

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