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17-14 APPENDIX
Troubleshooting Guide
Shift return spring weak or broken
Shift shaft lever broken
Pawl guide plate broken
Shift pawl broken
Shift pawl spring tension lose
Gear seized
Gear positioning 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 positioning lever spring weak or bro-
ken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear positioning lever spring weak or bro-
ken
Pawl guide plate worn
Abnormal Engine Noise:
Knocking:
ECU trouble
Carbon built 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
Valve spring broken or weak
Camshaft bearing or cam face 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
Decompressor spring broken
Magneto flywheel loose
Abnormal Drive Train Noise:
Clutch noise:
Clutch housing finger and friction plate tang
worn
Clutch housing gear worn
Metal chips jammed in clutch housing gear
teeth
Transmission noise:
Bearings worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient, low viscosity
Kick ratchet gear not properly disengaging
from kick gear
Kick shaft idle gear worn or chipped
Drive chain noise:
Drive chain maladjusted
Drive chain worn
Rear and/or engine sprocket worn
Drive chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Front fork air pressure high
Rear shock absorber noise:
Shock absorber trouble
Spring weak or broken
Disc brake noise:
Pad surface glazed
Disc warped
Caliper trouble
Pad installed incorrectly
Master cylinder damaged
Other noise:
Bracket, nut, bolt, etc., not properly
mounted or tightened
Abnormal Exhaust Color:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner element clogged
Brown smoke:
Air cleaner duct loose
Air cleaner clogged
Air cleaner poorly sealed or missing

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