2002 Yamaha Motorsports VK 540 lll Owners Manual - Page 67

2002 Yamaha Motorsports VK 540 lll Manual

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ESU00277 TROUBLESHOOTING A. Engine turns over but doesn't start 1. Fuel system No fuel supplied to combustion chamber • No fuel in tank ...Supply fuel. • Clogged fuel line ...Clean fuel line. • Clogged carburetor ...Clean carburetor. Fuel supplied to combustion chamber. • Flooded engine (too much choke) ...Crank engine with throttle open or wipe spark plug dry. 2. Electrical system Poor or no spark • Spark plug dirty with carbon/wet ...Remove carbon/wipe spark plug dry, or replace spark plug. • Faulty ignition system ...Consult dealer. • T.O.R.S. system malfunction ...Disconnect the carburetor switch connectors and connect the wire harness connectors together to bypass T.O.R.S.. 3. Compression Insufficient • Loose cylinder head nuts ...Tighten nuts properly. • Damaged gasket ...Replace gasket. • Worn out piston and cylinder ...Consult dealer. B. Engine does not turn over with manual starter 1. Seized engine ...Seizure is caused by poor lubrication, inadequate fuel, or an air leak -- Consult dealer. 2. "Hydrolock" (fuel has filled crankcase when vehicle was transported) ...Remove spark plug(s), turn engine over several times with ignition off to expel excess fuel. Consult dealer. C. Electric starter does not operate or operates slowly 1. Faulty wire connections ...Check connections or consult dealer. 2. Battery discharged ...Check battery fluid and charge battery. 3. Engine trouble ...Check B above. D. Engine power is low 1. Faulty spark plug(s) ...Clean or replace spark plug(s). 2. Jetting incorrect for altitude or temperature ...carburetor. Consult dealer. 3. Improper fuel flow ...See A.1. above. 4. Clutch settings not correct for altitude and/or conditions ...Consult dealer. E. Engine constantly backfires or misfires 1. Faulty spark plug(s) ...Replace spark plug(s). 2. Fuel system clogged ...See A.1. above. 3. T.O.R.S. malfunction ...See T.O.R.S. in A.2. above. 816-023 WARNING • • Before bypassing the T.O.R.S., be sure the throttle returns properly to the fully-closed position. The T.O.R.S. is an important safety device; in the case of a malfunction, take the machine to a Yamaha dealer immediately for repair. 9-1

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9-1
816-023
3. Compression
Insufficient
•
Loose cylinder head nuts ... Tighten nuts
properly.
•
Damaged gasket ... Replace gasket.
•
Worn out piston and cylinder ... Consult
dealer.
B. Engine does not turn over with
manual starter
1. Seized engine ... Seizure is caused by
poor lubrication, inadequate fuel, or an
air leak –– Consult dealer.
2. “Hydrolock” (fuel has filled crankcase
when vehicle was transported) ... Re-
move spark plug(s), turn engine over
several times with ignition off to expel
excess fuel. Consult dealer.
C. Electric starter does not operate or
operates slowly
1. Faulty wire connections ... Check con-
nections or consult dealer.
2. Battery discharged ... Check battery fluid
and charge battery.
3. Engine trouble ... Check B above.
D. Engine power is low
1. Faulty spark plug(s) ... Clean or replace
spark plug(s).
2. Jetting incorrect for altitude or tempera-
ture ... carburetor. Consult dealer.
3. Improper fuel flow ... See A.1. above.
4. Clutch settings not correct for altitude
and/or conditions ... Consult dealer.
E. Engine constantly backfires or mis-
fires
1. Faulty spark plug(s) ... Replace
spark plug(s).
2. Fuel system clogged ... See A.1. above.
3. T.O.R.S. malfunction ... See T.O.R.S. in
A.2. above.
ESU00277
TROUBLESHOOTING
A. Engine turns over but doesn’t
start
1. Fuel system
No fuel supplied to combustion chamber
•
No fuel in tank ... Supply fuel.
•
Clogged fuel line ... Clean fuel line.
•
Clogged carburetor ... Clean carburetor.
Fuel supplied to combustion chamber.
•
Flooded engine (too much choke) ...
Crank engine with throttle open or wipe
spark plug dry.
2. Electrical system
Poor or no spark
•
Spark plug dirty with carbon/wet ... Re-
move carbon/wipe spark plug dry, or re-
place spark plug.
•
Faulty ignition system ... Consult dealer.
•
T.O.R.S. system malfunction ... Discon-
nect the carburetor switch connectors
and connect the wire harness connectors
together to bypass T.O.R.S..
WARNING
•
Before bypassing the T.O.R.S., be
sure the throttle returns properly to
the fully-closed position.
•
The T.O.R.S. is an important safety
device; in the case of a malfunction,
take the machine to a Yamaha dealer
immediately for repair.