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15-8 APPENDIX
Troubleshooting Guide
Engine oil viscosity too high
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Clutch Operation Faulty:
Clutch slipping:
Friction plate wom or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch hub or housing unevenly wom
No clutch lever play
Clutch inner cable trouble
Clutch release mechanism 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 lever play excessive
Clutch release mechanism trouble
Gear Shifting Faulty:
Doesn't go into gear; shift pedal doesn't
return:
Clutch not disengaging
Shift fork bent, worn, or seized
Gear stuck on the shaft
Shift drum positioning pin spring broken
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism ann spring broken
Shift mechanism ann broken
Shift pawl broken
Pawl spring broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove wom
Gear dogs andlor dog holes worn
Shift drum groove wom
Shift drum positioning pin spring weak or
broken
Shift fork guide pin worn
Drive shaft, output shaft,
and/or gear
splines wom
Overshilts:
Shift positioning pin spring weak or broken
Overshift limiter broken
Abnormal Engine Noise:
Knocking:
IC igniter trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessrve
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing wom
Valve lifter worn
Other noise:
Connecting rod small end clearance exces-
sive
Connecting rod big end clearance exces-
sive
Piston ring/groove clearance excessrve
Piston ring worn, broken, or stuck
Piston ring groove wom
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con-
nection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suction valve damaged
Vacuum switch valve damaged
Alternator rotor loose
Primary chain wom
Abnormal Drive Train Noise:
Clutch noise:
Clutch rubber damper weak or damaged
Clutch housinglfriction plate clearance ex-
cessive
Clutch housing gear worn
Transmission noise:
Bearings wom
Transmission gears wom or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive line noise:
Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned

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