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17-50 APPENDIX
Troubleshooting Guide
For KLEEN, do not start the engine under
misfire due to spark plug fouling or poor
connection of the stick coil
For KLEEN, do not coast the motorcycle
with the ignition switch off (Turn the igni-
tion switch ON and run the engine)
ECU trouble
Fuel/air mixture incorrect:
Throttle body assy loose
Air cleaner housing loose
Air cleaner poorly sealed, or missing
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
KACR weights close
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Water temperature gauge incorrect:
Water temperature gauge broken
Water temperature sensor broken
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Wrong coolant mixed ratio
Cooling system component incorrect:
Radiator fin damaged
Radiator clogged
Thermostat trouble
Radiator cap trouble
Radiator fan relay trouble
Fan motor broken
Fan blade damaged
Water pump not turning
Water pump impeller damaged
Over Cooling:
Water temperature meter incorrect:
Water temperature meter broken
Water temperature sensor broken
Cooling system component incorrect:
Thermostat trouble
Clutch Operation Faulty:
Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch slave cylinder trouble
Clutch hub or housing unevenly worn
Clutch master cylinder trouble
Clutch not disengaging properly:
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch hub nut loose
Clutch hub spline damaged
Clutch friction plate installed wrong
Clutch fluid leakage
Clutch fluid deteriorated
Clutch master cylinder primary or sec-
ondary cup damaged
Clutch master cylinder scratched inside
Air in the clutch fluid line
Gear Shifting Faulty:
Doesn't go into gear; shift pedal doesn't
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm 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
Shift mechanism arm return spring weak or
broken
Abnormal Engine Noise:
Knocking:
ECU trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn

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