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Problem: Engine noisy (Noise seems to come from transmission)
Condition
1. Gears worn - chipped
2. Splines worn
3. Primary gears worn - chipped
4. Bearings worn
5. Bushing worn
Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Condition
1. Drive - driven bevel gears damaged - worn
2. Backlash excessive
3. Tooth contact improper
4. Bearing damaged
5. Gears worn - chipped
6. Splines worn
Problem: Engine idles poorly
Condition
1. Valve clearance out of adjustment
2. Valve seating poor
3. Valve guides defective
4. Rocker arms - arm shaft worn
5. Magneto defective
6. ECM defective
7. Spark plug fouled - gap too wide
8. Ignition coil defective
9. Idle Step Control (ISC) malfunction
Problem: Engine runs poorly at high speed
Condition
1. High RPM "cut out" against RPM limiter
2. Valve springs weak
3. Valve timing incorrect
4. Cam - rocker arms - tappets worn
5. Spark plug gap too narrow
6. Ignition coil defective
7. Fuel pump defective
8. Air cleaner element obstructed
9. Fuel hose obstructed
Problem: Exhaust smoke dirty or heavy
Condition
1. Oil (in the engine) overfilled - contaminated
2. Piston rings - cylinder worn
3. Valve guides worn
4. Cylinder wall scored - scuffed
5. Valve stems worn
6. Stem seals defective
Problem: Engine lacks power
Condition
1. Valve clearance incorrect
2. Valve springs weak
3. Valve timing incorrect
4. Piston ring(s) - cylinder worn
5. Valve seating poor
6. Spark plug fouled
7. Rocker arms - shafts worn
8. Spark plug gap incorrect
9. Air cleaner element obstructed
10. Oil (in the engine) overfilled - contaminated
11. Intake manifold leaking air
12. Cam chain worn
34
Remedy
1. Replace gears
2. Replace shaft(s)
3. Replace gears
4. Replace bearings
5. Replace bushing
Remedy
1. Replace gears
2. Adjust backlash
3. Adjust contact
4. Replace bearing
5. Replace gears
6. Replace shaft(s)
Remedy
1. Adjust clearance
2. Replace - service seats - valves
3. Replace cylinder head
4. Replace arms - shafts
5. Replace stator coil
6. Replace ECM
7. Adjust gap - replace plug
8. Replace ignition coil
9. Replace ISC
Remedy
1. Shift into higher gear - decrease speed
2. Replace springs
3. Correct timing - check chain, sprockets, and cam chain ten-
sioner
4. Replace cam - arms - tappets
5. Adjust gap
6. Replace ignition coil
7. Replace fuel pump
8. Clean element
9. Clean or replace hose
Remedy
1. Drain excess oil - replace oil
2. Replace - service rings - cylinder
3. Replace cylinder head
4. Replace - service cylinder
5. Replace valves
6. Replace seals
Remedy
1. Adjust clearance
2. Replace springs
3. Re-time valve gear
4. Replace - service rings - cylinder
5. Replace cylinder head/valves
6. Clean - replace plug
7. Replace arms - shafts
8. Adjust gap - replace plug
9. Clean element
10. Drain excess oil - change oil
11. Tighten - replace manifold
12. Replace cam chain
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Table of Contents
Troubleshooting
