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15·4 APPENDIX
Abnormal Engine
Noise:
Knocking:
Ignition timing maladjusted
COl unit trouble
Carbon built
up
in combustion chamber
Fuel
poor
quality
or incorrect
Spark plug incorrect
Overheating
Piston
slap:
Cylinder/
piston
clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston
pin,
piston pin holes worn
Other
noise:
Connecting
rod
small end clearance excessive
Connecting rod big
end clearance excessive
Piston ring worn, broken
or stuck
Piston
seized or
damaged
Cylinder
head
gasket leaking
Expansion
chamber leaking at cylinder head
connection
Crankshaft
runou!
excessive
Engine mounts ioose
Crankshaft bearing worn
Primary
gear
worn
or
chipped
Abnormal Drive Train
Noise:
ClullCh nol ••
:
Clutch
housing/friction plate
clearance
excessive
Clutch
housing
gear/primary
gear
backlash
excessive
Friction
plates
installed incorrectly
Metal
chip jammed in clutch housing gear teeth
Transmlulon
noise:
Crankcase
bearing
worn or
damaged
Transmission
gear
worn
or
chipped
Metal
chip
jammed
in
gear teeth
Transmission
oil insufficient or
too thin
Kick
ratchet
not properly disengaging
from kick
gear
Kick
idle
gear
on output shaft worn or chipped
Drive chaIn
noise:
Drive chain adjusted
improperly
Chain
worn
Rear and/or engine
sprocket(s) worn
Chain lubrication
insufficient
Rear
wheel misaligned
Abnormal Frame Noise:
Front tortl. noise:
Oil
insufficient
or too thin
Spring
weak or broken
Rear ahock absorber no
...
:
Shock
absorber damaged
Disc brake noise:
Pad
installed incorrectly
Pad
surface
glazed
Disc
warped
Caliper
trouble
Master
cylinder
damaged
Other noise
Bracket, nut, bolt,
etc.
not
properly mounted or
tightened
Exhaust Smoke:
Excessive
white
smoke:
Crankshaft oil seal damaged
BrownIsh smoke:
Air cleaner
element
clogged
Main let too large or fallen out
Starter
plunger
stuck open
Fuel level too high in carburetor float bowl
Handling and/or
Stability
Unsatisfactory:
Handlebar hard to tum:
Cable or hose routing incorrect
Wiring routing incorrect
Steering stem
nut too
tight
Bearing roller
damaged
Bearing race
dented
or
worn
Steering stem
bearing
lubrication inadequate
Steering stem bent
Tire air pressure
too low
Handlebar
shakes
or excessively
vibrates:
Tire
worn
Spokes loose
Swingarm sleeve or needle bearing damaged
Rim warped, or not balanced
Front. rear axle runout excessive
Wheel bearing (hub bearing) worn
Handlebar
clamp loose
Steering stem
head
nut loose
Handlebar
pulls
to one slda:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shah runout excessive
Steering maladjusted
Steering stem bent
Front
fork leg bent
Right/
left front fork oil level
uneven
Sttock
absorption
unsallsfactory:
(Too
hard
)
Front
fork maladjusted
Front
fork
oil excessive
Front fork oil viscosity too high
Front fork
leg
bent
Tire air pressure too high
Rear shock absorber maladjusted
Rear shock oil viSCOSity too high
(Too soh)
Front fork maladjusted
Front fork
oil insufficient and/or leaking
Front
fork
oil viscosity
too
low
Front
fork,
rear shock absorber spring weak
Tire air pressure too low
Rear shock absorber gas tea king
Rear shock absorber maladjusted
Rear shock oil viscosity too low

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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