1. NO SPARK
A. THE KILL SWITCH IS IN THE WRONG POSITION. ADJUST THE ON/OFF SWITCH
B. CHECK OIL LEVEL
C. PLUG ON BACK OF SMALL ATVS NOT COMPLETELY PLUGGED IN. PUSH PLUG COMPLETELY IN OR DISCONNECT PLUG.
D. CHECK GROUND ON BATTERY
E. CHECK MAGNETO (check magneto section this is rather important)
F. SPARK PLUG NEEDS REPLACED 1. 49cc to 150cc - use NGK C7HSA 2. 150cc to 500cc- use CHAMPION A-6 HC (SPARK PLUGS CAN LOOK FINE AND BE DEFFECTIVE)
G. BAD COIL CHECK TO SEE IF YOU HAVE CURRENT COMING TO COIL-IF YOU DO AND DONT HAVE SPARK THEN HAVE A DEFFECTIVE COIL.
H. CHECK WIRES TO CDI BOX
I.BAD CDI BOX- ALWAYS CHECK WIRES GOING IN AND OUT OF CDI BOX- A BAD CONNECTION CAN CAUSE PROBLEMS-SEE CDI SECTION THE CDI BOX IS THE BRAIN BOX OF YOUR UNIT. IT MAY NEED REPLACED.
2. GAS LEAKING FROM SCOOTER
A. ALWAYS CHECK THE FUEL VALVE EITHER UNDER GAS TANK OR FRAME MOUNTED. THE FUEL VALVE IS A VACUM OPERATED VALVE THAT TURNS GAS ON WHEN ENGINE IS CRANKING. IF WORKING PROPERLY GAS SHOULD NOT COME OUT OF TANK UNLESS MACHINE IS CRANKING OR RUNNING
B. CHECK FOLAT LEVEL ON CARBURATOR
C. SEE THAT FUEL FILTER IS NOT LEAKING
3. MACHINE WONT IDLE
A. CARBURATOR IS PLUGGED FROM EITHER BAD GAS OR FROM THE PROTECTIVE COATING THAT IS SHIPPED IN MACHINE NEW.
B. STP MAKES A PRODUCT CALLED CARB-INJECTION CLEANER THIS IS A GAS ADDITIDE. BLEND THIS IN YOUR GAS AND LET YOUR MACHINE IDOL FOR 1 HOUR. THIS SHOULD REMOVE THE NEW PROTECTIVE COATING OR HELP CLEAN A CARBURATOR FROM BAD GAS. ON NEW MACHINES THIS GAS TREATMENT IS A MUST. AFTER MACHINE HAS RUN FOR 1 HOUR ADJUST IDLE.
C. BAD CDI BOX—A DEFFECTIVE CDI BOX CAN MAKE YOU THINK YOU HAVE CARBURATOR PROBLEMS (SEE CDI BOX SECTION) THE CDI BOX IS THE BRAIN BOX TO YOUR UNIT. ALWAYS CHECK WIRING TO CDI BOX
A. ALWAYS TRICKLE CHARGE BATTERIES FOR TWO HOURS PRIOR TO INSTALLING. ALWAYS TRICKLE CHARGE BATTERY AFTER YOUR UNIT HAS SET FOR ANY PERIOD OF TIME.
B. DO NOT USE JUMPER CABLES OR HIGH VOLTAGE CHARGERS. THIS WILL CAUSE MAJOR PROBLEMS. IF YOUR UNIT IS RUNNING CORRECTLY IT SHOULD START WITHOUT EXCESSIVE CRANKING.
C. IF YOUR BATTERY WILL NOT STAY CHARGED TEST CONNECTION. TEST BATTERY OR CHARGING SYSTEM. (SEE MAG SECTION ALSO SEE VOLTAGE REGULATORY SECTION)
4. MACHINE WILL NOT TURN OVER
A. SQUEEZE BRAKE HANDLE
B. CHECK FUSE
C. CHECK ON/OFF SWITCH
D. CHECK CURRENT TO STARTER CELONOID
E. CHECK BATTERY
F. CHECK CURRENT TO STARTER
G. CHECK WIRING ON SWITCH
H. ALWAYS CHECK WIRING CONNECTIONS
5. AIR PRESSURE
A. ALWAYS CHECK TIRE PRESSURE ON ALL UNITS
B. NEW UNITS ARE SHIPPED WITH LOW AIR PRESSURE
C. LOW PRESSURE WILL MAKE YOUR UNIT RUN SLOW
A. ENGINE OIL—USE ANY BRAND OF 10W-30 OR 10W-40 MOTOR OIL.
B. TRANSMISSION- USE 90 SAE- OR GEAR LUBE
7. EXHAUST SYSTEM
A. KEEP BOLTS TIGHT
B. NEW UNITS SHOULD BE CHECKED OFTEN DURING THE FIRST 100 HOURS
C. YOU CAN PUT LOCK-TIGHT ON THESE EXHAUST BOLTS.
8. ROLLER CHAINS
A. DO NOT RUN ROLLER CHAIN TOO TIGHT ALLOW SOME FREE PLAY
B. KEEP CHAIN LUBRICATED
C. DO NOT ALLOW A CHAIN TO RUN TO LOOSE.
9. NO LIGHTS ON UNIT
A. CHECK BULB
B. CHECK MAGNETO(see magneto section)
C. CHECK CONNECTIONS AND GROUND
D. CHECK VOLTAGE REGULATOR (see voltage regulator section)
E. CHECK WIRING FOR BROKEN OR DISCONNNECTED WIRE CAUSING A SHORT
11. The MAGNETO
The mag has a dual purpose it serves as a alternator providing charging and lights to the unit. There are 5 wires coming out of the engine. From the magneto the charging side of the mag will usually have 1 yellow wire, 1 white wire, 1 green wire (ground), Sometimes 2 yellow and 1 green wire. These wires will feed the voltage regulator and are fed into a plug usually square 4 prong. The spark advance side of the mag. (stator) feeds pulse spark to the engine there will be 2 wires coming out of this side of the mag. Usually black with some other color. These wires feed the CDI box. When a unit has no spark, no lights, or the unit wont charge Always start by checking the magneto. Use a test light with machine cranking you should have current in each wire. (EXCEPT THE GREEN GROUND) If you dont have you have a defective magneto.
12. VOLTAGE REGULATOR
The voltage regulator is a ribbed box. (fins on it) the purpose is to reduce the voltage. Coming from the charging side of mag the yellow and white wires of magneto and transfer voltage to lights and battery. (voltage regulators are mass produced) If you are getting current from charging side of mag but no lights or poor charging the voltage regulator may be bad.
13. CDI BOX
The CDI box is a black smooth plastic box with plug. (it has no ribs on it) It receives current from the 2 black or black and other colored wires from magneto. The purpose of the CDI box is to act as the spark distributor and also the brain box of the unit. The CDI box can be in several sizes or shapes with various plugs on them. CDI boxes are mass produced with a computer chip in them. (They can go bad). Most common cause of defective CDI box is no spark and also poor performance that might make you think you have a bad carburetor.