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Kawasaki KZ1300-A1 Quick Reference Manual Page 267

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TROUBLESHOOTING
Clutch not disengaging properly
Clutch lever play excessive
Clutch plates warped or too rough
Clutch spring tension uneven
Engine oil deteriorated
Engine oil 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 drum positioning pin binding
Shift pedal return spring weak or broken
Shift lever broken
External shift mechanism pawl broken
Shift return spring pin loose
Pawl 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 drum positioning pin spring weak or broken
Shift fork pin{s) worn
Drive shaft, driven shaft, and/or gear splines worn
Overshifts
Shift drum positioning pin spring weak or broken
Pawl spring weak or broken
Abnormal Engine Noise
Knocking
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Piston slap
Cylinder/piston cl earance excessive
Cylinder, piston worn
Connecting rod bent
Piston,pin, piston holes worn
Valve noise
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearings worn
Valve lifter worn
Other noise
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring{s) worn, broken, or stuck
Piston seizure damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounting loose
Crankshaft bearings worn
Camshaft chain tensioner trouble
Camshaft chain, timing chain sprockets, guides
worn
Loose alternator rotor
Air suction valve damaged
Vacuum switch valve damaged
Secondary shaft cam damper damaged
Abnormal Drive Train Noise
Clutch noise
Clutch housing/friction plate clearance excessive
Wear or damaged clutch rubber damper{s)
Friction plate installed incorrectly
Transmission noise
Bearings worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Driven shaft cam damper damaged
Secondary shaft cam damper damaged
Drive line noise
Bevel gear bearings worn
Bevel gears worn or chipped
Bevel gears maladjusted
Rear wheel coupling damaged
Insufficient lubricant
Abnormal Frame Noise
Front fork noise
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise
Shock absorber defective
Disc brake noise
Pad B loose
Pad A installed reversely
Pad surface glazed
Disc warped
Other noise
Brackets, nuts, bolts, etc. nor properly mounted or
tightened
Oil Pressure Indicator Light Goes On
Engine oil pump trouble
Engine oil screen clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearings worn
Crankshaft bearings worn
Oil pressure switch trouble
Wiring trouble
Relief valve stuck open
Exhaust Smokes Excessively
White smoke
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Cylinder head gasket damaged
Engine oil level too high
Black smoke
Air cleaner clogged
267

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