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Troubleshooting Guide
Abnormal Frame Noise:
Front fork noise:
insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surtace glazed
Disc warped
Caliper trouble
Other noise:
Bracket, nut, bolt, etc.
not properly
mounted or tightened
Oil Pressure Warning Light Goes On:
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 bearings worn
Oil pressure warning light switch damaged
Oil pressure warning light switch Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase
Exhaust Smokes Excessively:
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
Main jet too large or fallen off
Starter plunger stuck open
Fuel level in carburetor float bowl too high
Brown smoke:
Main jet too small
Fuel level in carburetor float bowl too low
Air cleaner duct loose
Air cleaner O-ring damaged
Air cleaner poorly sealed or missing
Handling and/or Stability
Handlebar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem locknut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inade-
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm pivot bearings worn
Rim warped, or not balanced
Wheel bearing worn
Handlebar clamp bolts loose
Steering stem head nut loose
Front/rear axle runout excessive
Handlebar pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Steering maladjusted
Front fork bent
Right and left front fork oil level uneven
Shock absorption unsatisfactory:
(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Rear shock absorber adjustment too hard
Tire air pressure too high
Front fork bent
(Too soft)
Tire air pressure too low
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Rear shock adjustment too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
Brake Doesn't Hold:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged in master
Master cylinder scratched inside
Battery Trouble:
Battery discharged:
Battery faulty
Battery leads making poor contact
Load excessive (e.g., bulb of excessive
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Regulator/rectifier trouble


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