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Troubleshooting Guide
Valve noise:
Engine not sufficiently warmed up after HLA
installation
HLA damaged (worn, seizure, or spring bro-
ken)
HLA aeration due to low oil level
Air in HLA
Metal chips or dust jammed in HLA
Valve spring broken or weak
Camshaft bearing worn
Other noise:
Connecting rod small end clearance exces-
sive
Connecting rod big end clearance exces-
sive
Piston ring/groove clearance excessive
Piston ring worn, broken, or stuck
Piston ring groove worn
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con-
nection
Crankshaft runout excessive
Engine mounting portions loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suction valve damaged
Air switching valve damaged
Alternator rotor loose
Catalytic converter melt down due to muffler
overheating (KLEEN)
Balancer gear worn or chipped
Balancer shaft position maladjusted
Balancer bearing worn
Balancer shaft coupling rubber damper
damaged
Abnormal Drive Train Noise:
Clutch noise:
Clutch damper weak or damaged
Clutch housing/friction plate clearance ex-
cessive
Clutch housing gear worn
Wrong installation of outside friction plate
Transmission noise:
Bearings worn
Transmission gear worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive line noise:
Drive belt adjusted improperly
Drive belt worn
Rear and/or engine pulley worn
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Other noise:
Bracket, nut, bolt, etc.
mounted or tightened
Warning Indicator Light (Oil Pressure
Warning) Doesn't Go OFF:
Engine oil pump damaged
Engine oil screen clogged
Engine oil filter clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearing worn
Crankshaft bearing worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase
damaged
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Blowby gas system trouble
Black smoke:
Air cleaner clogged
Brown smoke:
Air cleaner housing holder loose
Air cleaner poorly sealed or missing
Handling and/or Stability
Unsatisfactory:
Handlebar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inade-
quate
Steering stem bent
Tire air pressure too low
APPENDIX 17-51
not properly

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