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Trouble
Engine is noisy
Noise seems to come from the secondary
drive chain
The clutch slips
The clutch is tight
The gears cannot be inserted.
Ed. 05-2011
TROUBLESHOOTING
Cause
Noise seems to come from piston
1. Too much piston-to-cylinder clearance
2. Worn piston rings or piston grooves
3. Too much carbon build-up in combustion chamber
or on piston crown
Noise seems to come from crankshaft
1. Worn main bearings
2. Connecting rod big end has too much side clear-
ance or end float
3. Crankshaft gear damaged
4. Countershaft not correctly installed
5. Crankshaft and countershaft gears damaged
Noise seems to come from the clutch
1. Worn plates
2. Too much clearance between clutch housing and
friction plates
Noise seems to come from gearbox
1. Worn gears
2. Worn gear grooves
1. Chain stretched (worn) or improperly adjusted
2. Worn transmission sprockets
1. Clutch adjuster screw with insufficient clearance Adjust
2. Weak clutch springs
3. Worn clutch plates
1. Clutch adjuster screw with exceeding clearance
2. Non uniform spring load
3. Bent clutch plates
1. Clutch does not disengage
2. Bent or seized shifter forks
3. Worn gear ratchets
4. Damaged shifter fork shafts
C.3
Remedy
Replace
Replace
Clean
Replace
Replace
Replace
Install correctly
Replace
Replace
Replace
Replace
Replace
Replace or adjust
Replace
Replace
Replace
Adjust
Replace
Replace
Adjust
Replace
Replace
Replace
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