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Clutch Operation Faulty; Gear Shifting Faulty; Abnormal Drive Train Noise; Abnormal Frame Noise - Kawasaki KLX110 Service Manual

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Table of Contents
Troubleshooting Guide

Clutch Operation Faulty:

Clutch slipping:
No clutch release play (KLX110C)
No clutch lever play (KLX110D)
Clutch cable maladjusted (KLX110D)
Clutch inner cable sticking (KLX110D)
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch release maladjusted (KLX110C)
Clutch release function trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch release play excessive (KLX110C)
Clutch lever play excessive (KLX110D)
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing seized
Clutch release function trouble
Clutch hub nut loose
Clutch plate warped or rough
Clutch hub spline damaged

Gear Shifting Faulty:

Doesn't go into gear; shift pedal doesn't
Clutch not disengaging
Shift fork bent, worn, or seized
Shift return spring pin loose
Shift return spring weak or broken
Shift shaft lever broken
Pawl guide plate broken
Shift pawl broken
Shift pawl spring tension loose
Gear seized
Gear set lever operation trouble
Shift drum broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes 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
Gear set lever spring weak or broken
Pawl guide plate worn

Abnormal Engine Noise:

Igniter trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing or cam face worn
Valve lifter worn
Other noise:
Connecting rod big end and/or small end
clearance excessive
Piston ring worn, broken or stuck
Piston seizure, damaged
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con-
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Camshaft chain tensioner trouble
Camshaft chain, sprocket, chain guide worn
Primary gear worn or damaged
Alternator rotor loose

Abnormal Drive Train Noise:

Clutch noise:
Clutch housing finger and friction plate tang
Clutch housing gear worn
Metal chips jammed in clutch housing gear
Transmission noise:
Bearings worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient, low viscosity
Kick ratchet gear not properly disengaging
from kick gear
Kick shaft idle gear worn or chipped
Drive chain noise:
Drive chain maladjusted
Drive chain worn
Rear and/or engine sprocket worn
Drive chain lubrication insufficient
Rear wheel misaligned

Abnormal Frame Noise:

Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged


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