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14-4 APPENDIX
Jumps
out
o
f
gear:
Shift fork worn
Gear groove worn
Gear dogs andlor dog holes worn
Shift drum groove worn
Gear positioning
lever
spri ng weak or broken
Shih fork
pin
wOrn
Drive
shaft.
output
shaft,
and/or
gear splines
worn
Overshifts
:
Gear positioning
lever
spring weak or broken
Shift
mec
hanism
arm spring
broken
Abnormal Engine Noise
:
Knocking:
COl unit
trouble
Carbon
bui lt up in
combustion cham ber
Fuel
poor quality or incorrect
Spark
plug
incorrect
Overheating
Pis
ton
slap:
Cylinder/piston
clearance
excessive
Cylinder,
piston
worn
Connecting
rod
bent
Piston
pin,
piston pin holes worn
Othe
r
noise
:
Connecting
rod small
end clea rance
excessive
Connecting
rod big
end
clearance
excessive
Piston
ring worn, broken
or
stu
ck
Piston
seizu
re,
damage
Cylinder head gasket leaking
bhaust pipe
leaking
at cylinder head connection
Crankshaft runout excessive
Engine mounts
loose
Crankshaft bearing worn
Primary gear worn
or
chipped
Abnormal
Drive
Train Noise
:
Clutch
noise
:
Clutch housing/friction plate clearance exccessNe
Clutch housing
gear/primary
gear
backlash
excessive
Metal chip
jammed
in dutch housing gear teeth
Trans
mission 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
gear
not properly
disengaging
fro
m
kick gear
Output shaft
idle
gear worn or chipped
Drive c
hain
noise:
Drive chain
adjusted improperly
Chain worn
Rear
andlor engine sprocket(s) worn
Chain
lubrication
insufficient
Rear
wheel
misaligned
Abnormal Frame
Noise:
Front
fo
rk
noise
;
Oil insufficient or
too thin
Spring
weak
or
broken
Rear
s
hock
abs
orber
noise:
Shock
absorber
damaged
Disc brake
noise
;
Pad
installed
incorrectly
Pad surface glazed
Disc warped
Caliper
trouble
Cylinder damaged
Other
noise
Bracket,
nut,
bolt,
etc.
not
properly
mounted
or
tightened
Exhaust Smoke:
Excessive white smoke
:
Throttle
cable
maladjusted
Brownish
s
moke:
Air
deaner
clogged
Main
jet
too la rge or fallen out
Starter
Plunger
stuck open
Fuel
level too high
Handling
andl
or Stability Unsatisfactory
:
Handle
bar hard to turn
;
Control cable routing
incorrect
Wiring
routing
incorrect
Steering
stem
locknut too tight
Bearing
roller
damaged
Bearing
race
dented
or
worn
Steering ste
m
lubrication
inadequate
Steering
stem bent
Tire
air pressure
too low
Handlebar
s
hakes or
excesslve
ry
vibra tes:
Tire
worn
Swing arm sleeve
or
needle
bearing
damaged
Rim
warped,
or
not
balanced
Fro
nt,
rear
axle
runout
excessive
Wheel bearing worn
Hand
lebar
damp loose
Sleering
stem head
nut
loose
Ha
ndlebar
pulls
to one slda
:
Frame bent
Wheel
misalignment
Swing arm
bent
or
twisted
Swing arm
pivot
shaft
runout
excessive
Steering
maladjusted
Steering stem bent
Front
fork
leg
bent
Right/left front fork
oi
l
level uneven

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