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16-28 APPENDIX
Troubleshooting
Air cleaner duct loose
Air cleaner O-ring damaged
Compression high:
Carbon build up in combustion chamber
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Brake dragging
Drive train trouble
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Clutch Operation Faulty
Clutch slipping:
Clutch cable maladjusted
Clutch inner cable sticking
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch release function trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch lever free play excessive
Clutch spring force uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing seized
Clutch release function trouble
Clutch hub nut loose
Clutch plate warped or rough
Clutch hub spline damaged
Gear Shifting Faulty
Doesn’t go into gear; shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent, worn, or seized
Shift return spring pin loose
Shift return spring weak or broken
Shift external mechanism arm broken
Shift external mechanism arm spring bro-
ken
Shift pawl broken
Gear seized
Gear set lever operation trouble
Shift drum broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear set lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear set lever spring weak or broken
Shift external mechanism arm spring bro-
ken
Abnormal Engine Noise
Knocking:
IC igniter trouble
Carbon build up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect heat value
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valvespringbrokenorweak
Camshaft bearing portion worn
Valve lifter worn
Other noise:
Connecting rod big end, small end clear-
ance excessive
Piston ring worn, broken, or stuck
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con-
nection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Camshaft chain tensioner trouble
Camshaft chain, sprocket, chain guide worn
Primary gear worn or damaged
Balancer bearing worn
Alternator rotor loose
Bevel gear backlash & tooth contact malad-
justed
Bevel gear bearing worn
Bevel gear worn or damaged
Abnormal Drive Train Noise
Clutch noise:
Clutch housing and friction plate engage-
ment portion worn
Clutch housing gear worn
Outside friction plate groove incorrect in-
stallation
Foreign matter jammed in clutch housing
gear teeth
Transmission noise:
Bearing worn
Transmission gear worn or damaged
Foreign matter jammed in gear teeth
Engine oil insufficient, low viscosity
Drive chain noise:
Drive chain maladjusted
430


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