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Table of Contents
172 TROUBLESHOOTING GUIDE
Fuel/air mixture
incorrect
Main
jet
clogged or wrong size
Jet
needle
or
need
le
jet worn
Jet
needle
clip in wrong position
Fuel
level
too
high
or too low
Needle jet bleed
hole
clogged
Air
cleaner
clogged, poorly
sealed,
or
missing
Water
or
foreign matter
in fuel
Carburetor holders loose
Fuel
tank
air
vent
obstructed
Fuel
tap clogged
Fuel
line clogged
Compression low
Spark plug loose
Cylinder head
not
sufficiently tightened
down
No
valve clearance
Cylinder,
piston
worn
Piston rings bad
(worn, weak, broken, or
sticking)
Piston ring/land
clearance
excessive
Cylinder head
gasket damaged
Cylinder
head warped
Valve
sticking
Valve
not
closing
Valve spring broken or
weak
Valve
not seating properly
(valve
bent,
warped,
or
worn)
Knocking
Ignition timing maladjusted
Carbon
built
up
in
combustion
chamber
Fuel poor
quality
or incorrect
Overheating
Spark
plug incorrect
Other
Throttle
valve won't
ful
ly
open
Vacuum
pistons
don't
slide smoothly
Damaged diaphragm
Ignition timing maladjusted
Timing
not advancing
Brakes
dragging
Clutch slipping
Overheating
Engine oil level
too high
Engine oil viscosity too
high
Overheating
Firing
incorrect
Spark
plug
dirty, damaged,
or maladjusted
Ignition
timing
maladjusted
Spark plug
incorrect
Fuel/air mixture incorrect
Main jet clogged
Fuel
level too
low
Carburetor
holders
loose
Air
cleaner
clogged,
poorly
sealed,
or
missing
Compression
high
Carbon
built
upjn combustion
chamber
Engine load faulty
Clutch
slipping
Engine
oi
l
level too high
Engine
oil
viscosity too high
Brakes dragging
Lubrication inadequate
Engine oil level too
low
Engi
ne oil poor
quality
or
incorrect
Clutch Operation Faulty
Clutch
slipping
No clutch
lever
play
Friction plate worn or
warped
Steel plates
worn
or warped
Clutch
springs
weak
Clutch release
maladjusted
Clutch inner cable
catching
Clutch release
mechanism
trouble
Clutch
hub
or housing unevenly
worn
Clutch not disengaging properly
Clutch
lever play
excessive
Clutch
plates warped or
too rough
Clutch spring
tension uneven
Engine oil deteriorated
Engine
oi
l
of too
high a
viscosity
Engine
oil
level too
high
Clutch
housing
frozen
on drive shaft
Clutch
release mechanism trouble
Loose clutch
hub
nut
Gear Shifting Faulty
Doesn't go into gear; shift pedal doesn't return
Clutch not
disengaging
Shift fork(s)
bent
or
seized
Gear{s)
stuck
on the
shaft
Shift
return
spring
weak or
broken
External shift mechanism arm broken
Shift return spring
pin loose
External
shift mechanism arm
spring
broken
Jumps out of gear
Shift fork(s)
worn
Gear
groove (s)
worn
Gear dogs,
dog holes,
and/or dog recesses
worn
Shift drum
groove(s) worn
Shift fork
pin(s) worn
Drive shaft,
output
shaft,
and/or
gear splines
worn
Overshifts
Shift return spring pin
loose
External
shift mechanism
arm spring weak or
broken
Abnormal Engine Noise
Knocking
Ignition timing
maladjusted
Carbon
built up in
combustion chamber
Fuel poor quality or incorrect
Ovcrheati ng
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
Rocker
arms or
rocker shaft worn

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Table of Contents

   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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