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Carburetor holder loose
Air cleaner duct loose
Fuel tap clogged
Fuel line clogged
Comp
ression
low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder nut loose
Cylinder,
piston worn
Piston ring bad (wom, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Reed valve damaged
Engine
rpm w ill
not rise
proper
ly:
Starter plunger stuck open
Fuel level too high or too low
Main Jel clogged
Throttle valve does not fully open
Air cleaner element clogged
Muffler clogged
Water or foreign matter in fuel
Cylinder exhaust pon clogged
Brake dragging
Clutch slipping
Overheating
Transmission oil level too high
Transmission oil viscosity too high
Crankshaft bearing worn or damaged
KIPS
ports
stuck
closed:
KIPS exhaust valves stuck closed (valve seizure,
or carbon accumulation)
KI PS exhaust valves assembled incorrectly
KIPS ports clogged (carbon accumulation)
Exhaust valve advancer spring damaged
Exhaust valve rod seized in cylinder
Main shaft seized in cylinder
Advancer shaft seized in the right engine cover
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
COl unit trouble
Ignition timing maladjusted
Overheating:
Firing
Incorrect
Spark plug dirty,
broken,
or maladjusted
Spark plug incorrect
COl unit trouble
Ignition timing maladjusted
Fuel/air
mixture
Incorrect:
Main jet clogged or wrong size
Fuelleve! too low in carburetor fioat bowl
Carburetor holder loose
Air cleaner element clogged, poorly sealed, or
missing
Air cleaner duct poorly sealed
APPENDIX
15-
3
Compression high:
Carbon built up In combustion chamber
Engine
load
faulty:
Brake dragging
Clutch slipping
Transmission oil level
too
high
Transmission
o
il viscosity too high
Lubrication inadequate:
Transmission oil level too low
Transmission oil poor quality or incorrect
Coolant Incorrect:
Coolant level too low
Coolant deteriorated
Cooling system
component
Incorrect:
Radiator clogged
Radiator cap trouble
Water pump not rotating
Water pump impeller damaged
Clutch Operation
Faulty:
Clulch
slipping:
No clutch lever play
Clutch cable
maladju
sted
Clutch inner cable catChing
Clutch plate worn or warped
Clutch spring broken or
weak
Clutch release mechanism
trou
ble
Clu tch hub or housing unevenly worn
Clutch
not
disengaging
properly:
Clutch
lever
play excessive
Clutch plate
warp
ed or too rough
Clutch spring force uneven
Transmission oil deteriorated
Transmission oil viscosity too high
Transmission oil level
too
high
Clutch housing frozen
on
drive
sh
aft
Clutch release
mechan
ism trouble
Gear
Shifting
Faulty:
Doesn't
g
o into
gear;
shift pedal
doesn'
t
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear set
lever
binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift
dru
m broken
Jumps out
of gear:
Shift fork worn
Gear groove worn
Gear
d
ogs and/or
d
og holes and recesses worn
Shift drum groove worn
Gear set lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear splines worn
Oversh
lfts:
Gear set lever spring weak or broken
Shift
mechan
ism arm spring broken

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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