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Motorcycle Troubleshooting
A motorcycle, often called a motorbike, bike, cycle, or trike, is a two- or three-wheeled motor vehicle. Motorcycle design varies greatly to suit a range of different purposes: long-distance travel, commuting, cruising, sport, and off road riding. Motorcycling is riding a motorcycle and being involved in other related social activity such as joining a motorcycle club and attending motorcycle rallies.
While this Motorcycle Troubleshooting Guide is not a complete guide of every possible cause for each problem listed, it will help assist mechanics in troubleshooting some of the most common difficulties they will face.
Engine Doesn't Start, Starting Difficulty:
-Starter motor not rotating:
-Starter lockout or neutral switch trouble
Starter motor rotating but engine doesn't turn over:
-Starter motor clutch trouble
-Engine won't turn over:
No fuel flow:
-Fuel tap vacuum hose clogged
-Fuel tank air vent obstructed
Engine flooded:
-Fuel level in carburetor float bowl too high
-Float valve worn or stuck open
No spark; spark weak:
-Battery voltage low
-Spark plug dirty, broken, or maladjusted
Compression Low:
-Spark plug loose
-Cylinder head not sufficiently tightened down
Poor Running at Low Speed:
-Battery voltage low
-Spark plug dirty, broken, or maladjusted
Fuel/air mixture incorrect:
-Pilot screw maladjusted
-Pilot jet, or air passage clogged
Compression low:
-Spark plug loose
-Cylinder head not sufficiently tightened down
Other:
-IC igniter trouble
-Carburetors not synchronizing
Poor Running or No Power at High Speed:
-Firing incorrect:
-Spark plug dirty, broken, or maladjusted
Fuel/air mixture incorrect:
-Starter plunger stuck open
-Main jet clogged or wrong size
Compression low:
-Spark plug loose
-Cylinder head not.sufficiently tightened down
Knocking:
-Carbon built up in combustion chamber
-Fuel poor quality or incorrect
Miscellaneous:
-Throttle valve won't fully open
-Vacuum piston doesn't slide smoothly
Overheating:
-Firing incorrect:
-Spark plug dirty, broken, or maladjusted
Fuel/air mixture incorrect:
-Main jet clogged or wrong size
-Fuel level in carburetor float bowl too low
Compression high:
-Carbon built up in combustion chamber
-Engine load faulty:
Lubrication inadequate:
-Engine oil level too low
-Engine oil poor quality or incorrect
Coolant incorrect:
-Coolant level too low
-Coolant deteriorated
Cooling system component incorrect:
-Radiator clogged
-Thermostat trouble
Over Cooling:
-Cooling system component incorrect:
-Thermostatic fan switch trouble
Clutch Operation Faulty:
-Clutch slipping
-Friction plate worn or warped
Clutch not disengaging properly:
-Clutch plate warped or too rough
-Clutch spring tension uneven
Gear Shifting Faulty:
-Doesn't go into gear; shift pedal doesn't return:
-Clutch not disengaging
Jumps out of gear:
-Shift fork worn
-Gear groove worn
Overshifts:
-Neutral positioning pin spring weak or broken
-Pawl spring broken
Abnormal Engine Noise:
-Knocking:
-IC igniter trouble
Overheating Piston slap:
-Cylinder/piston clearance excessive
-Cylinder, piston worn
Valve noise:
-Valve clearance incorrect
-Valve spring broken or weak
Other noise:
-Connecting rod small end clearance excessive
-Connecting rod big end clearance excessive
Abnormal Drive Train Noise:
-Clutch noise:
-Weak or damaged damper
Transmission noise:
-Bearings worn
-Transmission gears worn or chipped
Drive chain noise:
-Drive chain adjusted improperly
-Chain worn
Abnormal Frame Noise:
-Front fork noise:
-Oil insufficient or too thin
Rear shock absorber noise:
-Shock absorber damaged
-Disc brake noise:
Other noise:
-Bracket, nut, bolt, etc. not properly mounted or tightened
Oil Pressure Warning Light Goes On:
-Engine oil pump damaged
-Engine oil screen clogged
Exhaust Smokes Excessively:
-White smoke:
-Piston oil ring worn
Black smoke:
-Air cleaner clogged
-Main jet too large or fallen off
Brown smoke:
-Main jet too small
-Fuel level in carburetor float bowl too low
Handling and/or Stability Unsatisfactory:
-Handlebar hard to turn:
-Steering stem locknut too tight
Handlebar shakes or excessively vibrates:
-Tire worn
-Swing arm pivot bearing worn
Handlebar pulls to one side:
-Frame bent
-Wheel misalignment
Shock absorption unsatisfactory: (Too hard)
-Front fork oil excessive
-Front fork oil viscosity too high
Shock absorption unsatisfactory: (Too soft)
-Front fork oil insufficient and/or leaking
-Front fork oil viscosity too low
Brake Doesn't Hold:
-Air in the brake line
-Pad or disc worn
Battery Discharged:
-Battery faulty (e.g., plates sulphated, shorted through sedimentation, electrolyte level too low)
-Battery leads making poor contact
Battery Overcharged:
-Regulator/Rectifier trouble
Source: cyclepedia.com