C.3
TC 449 2011/2012 I.E.
TE 449 - 511 2011/2012 I.E.
TXC 449 - 511 2011/2012 I.E.
SMR 449 2011 I.E.
SMR 511 2011/2012 I.E.
Workshop Manual Ed. 03-2012
TROUBLESHOOTING
Trouble
Cause
Remedy
Noise seems to come
1. Worn plates
Replace
from the clutch
2. Too much clearance between clutch housing and friction plates
Replace
Noise seems to
1. Worn gears
Replace
come from gearbox
2. Worn gear grooves
Replace
Noise seems to come
1. Chain stretched (worn) or improperly adjusted
Replace or adjust
from secondary drive
2. Worn transmission sprocket and rear chain sprocket
Replace
chain
Clutch slips
1. Weak clutch springs
Replace
2. Worn clutch plates
Replace
3. Loosened clutch idler gear nut
Tighten nut
Clutch is hard to operate
1. Uneven spring load
Replace
2. Bent clutch plates
Replace
Gears do not engage
1. Bent or seized shifter forks
Replace
2. Worn gear ratchets
Replace
3. Damaged shifter fork shafts
Replace
Gear shift pedal
1. Weak or broken selector return spring
Replace
does not return to
2. Worn shifter forks
Replace
original position
Transmission jumps out of gear
1. Worn sliding gear dogs
Replace
2. Worn gear grooves
Replace
3. Worn dog slots in gears
Replace
4. Worn selector shaft splines
Replace
5. Damaged shifter fork shafts
Replace
Engine has low power
1. Dirty air filter
Clean
2. Poor fuel quality
Replace
3. Intake coupling loose
Tighten
4. Spark plug electrode gap too wide
Adjust
5. Insufficient compression
Identify cause
6. Incorrect valve clearances
Adjust
7. Valve seats or guides faulty
Replace
8. Weak or seized valve springs
Replace
Engine overheats
1. Combustion chamber and/or piston crown fouled
with carbon deposits
Clean
2. Insufficient oil in engine or
wrong oil
Top up or change
3. Obstructions blocking air flow on radiator
Clean
4. Cylinder head gasket leaking
Replace
5. Clutch slips
Adjust
6. Cooling fan faulty (TE-TXC
-SMR
)
Replace thermal switch
7. Low coolant level
Top up to correct level
