98
Troubleshooting
Problem: Spark absent or weak
Condition Remedy
1. Ignition coil defective
2. Spark plug defective
3. Magneto defective
4. ECM defective
5. Pick-up coil defective
1. Replace ignition coil
2. Replace plug
3. Replace stator coil
4. Replace ECM
5. Replace stator coil
Problem: Spark plug fouled with carbon
Condition Remedy
1. Gasoline incorrect
2. Air cleaner element dirty
3. Spark plug incorrect (too cold)
4. Valve seals cracked — missing
5. Oil rings worn — broken
1. Change to correct gasoline
2. Clean element
3. Replace plug
4. Replace seals
5. Replace rings
Problem: Spark plug electrodes overheat or burn
Condition Remedy
1. Spark plug incorrect (too hot)
2. Engine overheats
3. Spark plug loose
1. Replace plug
2. Service cooling system
3. Tighten plug
Problem: Battery does not charge
Condition Remedy
1. Lead wires/connections shorted — loose — open
2. Magneto coils shorted — grounded — open
3. Regulator/rectifier defective
1. Repair — replace — tighten lead wires
2. Replace magneto coils
3. Replace regulator/rectifier
Problem: Battery charges, but charging rate is below the specification
Condition Remedy
1. Lead wires shorted — open — loose (at terminals)
2. Stator coil (magneto) grounded — open
3. Regulator/rectifier defective
4. Cell plates (battery) defective
1. Repair — tighten lead wires
2. Replace stator coil
3. Replace regulator/rectifier
4. Replace battery
Problem: Battery overcharges
Condition Remedy
1. Internal battery short circuited
2. Regulator/rectifier resistor damaged — defective
3. Regulator/rectifier poorly grounded
1. Replace battery
2. Replace resistor
3. Clean — tighten ground connection
Problem: Charging unstable
Condition Remedy
1. Lead wire intermittently shorting
2. Magneto internally shorted
3. Regulator/rectifier defective
1. Replace lead wire
2. Replace stator coil
3. Replace regulator/rectifier
Problem: Starter button not effective
Condition Remedy
1. Battery charge low
2. Switch contacts defective
3. Starter relay defective
4. Emergency stop — ignition switch off
5. Wiring connections loose — disconnected
1. Charge — replace battery
2. Replace switch
3. Replace relay
4. Turn on switches
5. Connect — tighten — repair connections
Problem: Battery “sulfation” (acidic white powdery substance or spots on surfaces of cell plates)
Condition Remedy
1. Charging rate too low — too high
2. Battery run-down — damaged
3. Electrolyte contaminated
1. Replace battery
2. Replace battery
3. Replace battery
Problem: Battery discharges too rapidly
Condition Remedy
1. Charging system not charging
2. Cell plates overcharged — damaged
3. Battery short-circuited
4. Electrolyte contaminated
1. Check magneto — regulator/rectifier — circuit connections
2. Replace battery — correct charging system
3. Replace battery
4. Replace battery
Problem: Battery polarity reversed
Condition Remedy
1. Battery incorrectly connected 1. Reverse connections — replace battery — repair damage
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