Table of Contents
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Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
• Cracked or broken ignition coil
4. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken magneto rotor woodruff key
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to "STARTING FAILURES " on page 9-1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
FAULTY GEAR SHIFTING
Shifting is difficult
Refer to "Clutch drags".
SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Bent shift shaft
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
TROUBLESHOOTING
JUMPS OUT OF GEAR
Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
Shift forks
• Worn shift fork
Shift drum
• Incorrect axial play
• Worn shift drum groove
Transmission
• Worn gear dog
FAULTY CLUTCH
Clutch slips
1. Clutch
• Improperly assembled clutch
• Improperly adjusted clutch cable
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
Clutch drags
1. Clutch
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Broken clutch boss
• Burnt primary driven gear bushing
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
OVERHEATING
Engine
1. Clogged coolant passages
• Cylinder head and piston
• Heavy carbon buildup
2. Engine oil
• Incorrect oil level
9.2
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Troubleshooting
