4.54
Cleanfire Fuel Injection
TROUBLESHOOTING
Engine Will Not Start
• Is the key inserted in key switch and turned to
RUN?
• Is the safety slap switch pulled up?
• Is the throttle lever free play set to specification?
• Is there fuel in the fuel tank?
• Is the fuel tank vent/vac. hose plugged or
malfun
ctioning? Remove fuel tank cap and try to
start engine.
• Are the spark plugs fouled? Replace with new
sp
ark plugs.
• Is there spark at the spark plugs? Test with spark
plug
tester.
• Inspect wire harness connectors. Are connectors
disco
nnected? Are there any broken wires?
• Is the throttle plate gap set to specification?
• Is there fuel pressure? Test using fuel pressure
gau
ge. Determine if fuel filter requires
replacement.
• Inspect the stator using mu
ltimeter and/or Digital
Wrench®. Are the fuel injectors receiving 16 VDC?
Is the fuel pump receiving VDC power when
pulling recoil?
• Are there any diagnostic trouble codes? Use
Dig
ital Wrench® to view trouble codes and
perform guided diagnostics.
• Is the engine mechanically sound? Check cylinder
co
mpression, piston condition, etc.
Engine Starts - Won’t Idle/Stalls
• Is the throttle lever free play set to specification?
• is the fuel tank vent/vac. hose plugged or
malfun
ctioning? Remove fuel tank cap and test.
• Are the spark plugs fouled? Replace with new
sp
ark plugs.
• Inspect wire harness connectors. Are connectors
disco
nnected? Are there any broken wires?
• Is there fuel pressure? Test using fuel pressure
gau
ge. Determine if fuel filter requires
replacement.
• Are there any diagnostic trouble codes? Use
Dig
ital Wrench® to view trouble codes and
perform guided diagnostics.
• Is the throttle plate gap/TPS set to specification?
Poor Performance
• Fuel quality. Use recommended fuel (91 octane
minimum).
• Ethanol/Non-ethanol fuel resistor plug. Is the
cor
rect fuel selector plug connected for the type of
fuel in the tank?
• Are the spark plugs fouled? Correct gap set?
• Is the fuel pressure correct at idle and during
op
eration?
• Fuel filter. Has the fuel filter been serviced as part
of per
iodic maintenance?
• VES system. Have the valves, and bases been
ser
viced/cleaned as part of periodic maintenance?
• VES system. Are the hoses loose, damaged or
p
lugged/frozen?
• Inspect fuel injector power
. Are injectors receiving
16 VDC during operation?
• Is the engine mechanically sound? Perform a
comp
ression check on both cylinders. Are the
results within 10% of each other?
• Inspect piston skirts through exhaust ports. Is
ther
e any scuffing, ring damage, etc.?
• Inspect the exhaust system. Are there any leaks,
missing spr
ings, or damaged exhaust seals?
• Driveline. Inspect the driveline for damage. Set the
trac
k tension to specification. Is the track too tight
or missing lugs? Is the gear ratio correct for
desired riding style?
• Inspect the drive, driven clutches, and drive belt.
Repla
ce worn or damaged parts. Clean clutch
sheaves, and set belt deflection.
• Are there any diagnostic trouble codes (DTCs).
Use
Digital Wrench® to retrieve any codes.
• Reference CFI Troubleshooting Flowchart
• Is detonation occurring and/or
detonation engine
RPM limit occurring? Reference Detonation
Troubleshooting Flowchart/checklist.
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