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Troubleshooting Guide
Compression low:
Cylinder, piston worn
Piston rings bad (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
Cylinder head gasket damaged
Cylinder head not sufficiently tightened down
Cylinder head warped
No Valve clearance
Spark plug loose
Valve not seating properly (Valve bent, worn or
carbon accumulation on the seating surface)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Miscellaneous:
Float level too high too or too low
Main jet clogged
Throttle valve does not fully open
Air cleaner clogged
Water or foreign matter in fuel
Brake dragging
Clutch slipping
Overheating
Engine oil level too high
Engine oil viscosity too high
Crankshaft bearing worn or damaged
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
Igniter trouble
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Fuel level too low
Carburetor holder loose
Air cleaner clogged
Air cleaner poorly sealed, or missing
Air cleaner duct loose
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Brakes dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Clutch Operation Faulty:
Clutch slipping:
No clutch release play
Friction plate worn or warped
Steel plate worn or warped
Clutch spring or weak
Clutch release maladjusted
Clutch release mechanism trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch release play excessive
Clutch plate warped or too rough
Clutch spring tension uneven
Engine oil deteriorated
TROUBLESHOOTING 15-3
Engine oil level too high
Engine oil viscosity too high
Clutch housing frozen on drive shaft
Clutch release mechanism trouble
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
Shift return spring weak or broken
Shift pawl spring broken
Shift return spring pin loose
Gear set level binding on pivot bolt
External shift mechanical arm worn
Shift drum damaged
Jumps out of gear:
Shift fork worn
Gear groove worn
Gear dogs, holes, and/or recesses worn
Shift drum groove worn
Shift drum set lever spring weak or broken
Shift fork guide pin worn
Shift pawl spring weak or broken
Drive shaft, output shaft, and/or gear splines worn
Overshifts:
Shift drum set lever spring weak or broken
Shift pawl spring weak or broken
Abnormal Engine Noise:
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Overheating
Spark plug incorrect
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston holes worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft journals worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken, or stuck
Piston seizure or damaged
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Loose magneto flywheel
Abnormal Drive Train Noise:
Clutch noise:
Clutch housing or hub damaged
Clutch housing/friction plate clearance excessive
Clutch housing gear/primary gear backlash excessive

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