Suzuki Ozark Service Manual page 259

Complaint
Engine is noisy. Noise seems to come from the crankshaft
Noise seems to come from transmission
Noise seems to come from transfer
Noise seems to come from secondary bevel gear and
rear drive bevel gear
Slipping clutch.
Dragging clutch.
Transmission will not
shift.
Transmission will not
shift back.
Transmission jumps
out of gear.
Transfer will not shift
or shift back.
Symptom and possible causes
1. Worn or burnt bearing.
2. Big-end bearing worn or burnt.
3. Thrust clearance too large.
1. Gears worn or rubbing.
2. Badly worn splines.
3. Primary gears worn or rubbing.
4. Badly worn bearings.
5. Worn bushing.
1. Worn down gears or shafts.
2. Damage to bearings/bushing.
1. Drive and driven bevel gears damaged or worn.
2. Excessive backlash.
3. Improper tooth contact.
4. Damage to bearing.
5. Gears worn or rubbing.
6. Badly worn splines.
7. Secondary bevel gear thrust clearance too large.
8. Rear drive bevel gear thrust clearance too large.
1. Clutch control out of adjustment or loss of play.
2. Weakened clutch springs.
3. Worn clutch shoes.
4. Worn or distorted pressure plate.
5. Distorted clutch plates, driven and drive.
1. Clutch control out of adjustment or too much play.
2. Some clutch springs weakened while others are not.
3. Distorted pressure plate or clutch plates.
4. Worn or damage clutch release mechanism.
1. Broken gearshift cam.
2. Distorted gearshift forks.
3. Worn gearshift shaft.
4. Worn or damage clutch release mechanism.
5. Improperly adjusted reverse cable.
1. Broken reverse shift cam.
2. Shift shafts are rubbing or sticky.
3. Distorted or worn gearshift forks.
4. Broken or damaged gearshift lever return spring.
1. Worn shifting gears on driveshaft or countershaft.
2. Distorted or worn gearshift forks.
3. Weakened cam stopper spring on gearshift cam.
4. Worn gearshift lever stopper pin.
1. Broken or worn sliding dog.
2. Broken or worn gearshift fork.
3. Worn gearshift cam.
4. Weakened cam stopper spring.
5. Worn gearshift fork shaft.
SERVICING INFORMATION 9-3
Remedy
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace
Adjust or replace.
Adjust or replace.
Adjust.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Adjust or replace.
Adjust.
Replace.
Repair
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.