12. TROUBLESHOOTING
12-3
Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION
1.
Check noise coming from cylinder head area.
Improper valve clearance adjustment. Readjust valve clearance and/or replace defective
part(s).
Faulty chain tensioner. Replace spring and/or mechanism.
Chain guide worn out. Replace chain guide.
Stretched chain and/or worn out sprockets. Replace chain and sprockets.
Sprocket screws got loose. Retighten screws with recommended torque.
Rocker arm(s) is (are) worn out (valve adjustment). Readjust valve clearance and/or
replace rocker arm(s).
Incorrect camshaft timing adjustment. Replace damaged components and readjust
camshaft timing (refer to cylinder and head).
Symptom: OIL CONTANMINATION ON CYLINDER AND/OR HEAD
1.
Check screws for torque.
Loose screws. Retighten screws with recommended torque.
Gaskets are brittle, hard, worn out or otherwise damaged. Replace damaged gaskets,
O-rings or the V-ring on breather.
CRANKSHAFT
Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION
1. Check noise coming from crankshaft area..
Crankshaft plain bearings are damaged,. Replace crankshaft plain bearings.
Connecting rod plain bearings are damaged. Replace connecting rod plain bearings.
Magneto rotor got loose. Replace damaged components and retighten rotor retaining
screw with recommended torque (refer to MAGNETO SYSTEM).
GEARBOX
Symptom: UNUSUAL GEARBOX NOISE AND/OR VIBRATION
1.
Check oil level in gearbox.
Oil leakage from gearbox. Replace damaged gasket(s) and/or oil seal(s), torque screws
and refill with oil up to specified level (refer to TECHNICAL SPECIFICATIONS and
GEARBOX)
2.
Check bearings in the gearbox for free movement.
Bearing(s) do(es) not move freely. Replace bearing(s)
3.
Check for knocking noise.
Tooth of gears are damaged and/or worn. Replace respective gears.
Symptom: GEAR INDICATION FAILS.
1.
Check contact screws on gear housing center.
Check contact screw outside for contamination and wetness. Clean contact screw and
screw for wiring harness.
Contact(s) is (are) corroded and/or contact screw for wiring harness got loose. Clean
contact surface and retighten contact screw(s) with recommended torque.
Wiring harness has broken cables. Replace wiring harness.
Shifting indicator switch(es) pin(s) is (are) worn and/or damaged. Replace shifting
indicator switch(es).
Symptom: GEAR(S) IS (ARE) HARD TO SHIFT
1.
Check shift shaft splines and/or shift forks for wear and/or damages.
Shift shaft is worn out and/or shows damaged splines. Replace shift shaft.
Shift drum track(s) and/or splines is (are) worn out or damaged. Replace shift drum and
damaged part(s).
Shift fork(s) is (are) worn out and/or engagement pins are damaged. Replace shift fork(s).
Shift fork(s) is (are) worn out and/or fork(s) is (are) damaged. Replace shift fork(s).
Shift gear(s) is (are) worn out. Replace shift gear(s).
Shifting indicator switch(es) pin(s) is (are) worn out (no rounding on top of pin). Replace
shifting indicator switch(es).
2.
Check engine idle speed.
Check throttle cable and throttle adjustment.
Check bypass idle valve and connectors.
3.
Check CVT one way clutch on drive pulley.
CVT one way clutch was not lubricated correctly. Lubricate CVT one way clutch (refer to
CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)).
