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Observation
Smoke through exhaust
Complaint :Engine Noisy
Engine
Complaint :Premature Wear of Engine Components
Complaint :Gears Hard/Not Engaging
Causes
Wrong grade/recycled lube oil
Damaged valve stem seal
Worn out / scored valve guide / valve stem
Vertically aligned piston ring
Excessive piston ring end gap
Wrong fitment of piston rings
Connecting Rod Bent
Clearance Excess between Piston &
Cylinder Barrel
Glazed cylinder walls
Incorrect octane rating of fuel
Excessive clearance between piston and
cylinder
Loose rocker arm spindle in rocker arm
Hydraulic valve lifters damaged
Excessive small end clearance
A humming/Howling/ backlash noise
when accelerated
Damaged cams
Worn-out/damaged Big end bearings
Cracked or improperly fitted suction/Air filter
Dirty/adulterated fuel
Dirty/adulterated/ Wrong Grade oil
Weak clutch spring.
Clutch lever free play excess
Cam plate pivot pin Oversize
Cam plate ratchet face rubbing against
the face of the pivot pin
Selector fork face rubbing against the cam
plate face
Burr in the cam plate track / outer side of
the cam plate
Ratchet rivet protruding from cam plate
Selector fork & peg edges chipped off
Selector fork shaft bent / scoring marks
in the shaft.
Remedies
Replace it with right grade oil
Replace the seal
Check and Replace
Properly stagger the piston end
gaps rings
Replace the piston rings
Refit the piston rings correctly
Replace the crankshaft
Check and Replace
Check and Replace
Use correct fuel
Check and Replace
Check and Replace
Check and Replace
Check and Replace
Adjust the Cam spindles to
achieve correct cam gears
meshing
Check and Replace
Check and Replace
Check and Correct/Replace
Check and Correct/Replace
Replace oil at regular intervals
Check and Replace
Check and Correct
Change to correct size pin.
Replace pivot pin / camplate.
Change selector fork / Camplate
Remove burr in the cam plate
inner track and outer side
Check and Replace
Check and Replace
Check and Replace
10-5
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