
12. TROUBLESHOOTING
12-4
CVT one way clutch is worn out or damaged. Replace defective part(s) (refer to
CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)).
Check if friction washer at one way clutch is worn. Replace friction washer (refer to
CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)).
4.
Check transmission lever and connecting rod.
Ball joint and/or ball joint nut is (are ) loose. Retighten or replace the ball joint.
5.
Check spring on shift shaft in gearbox.
Broken spring. Replace the spring (refer to GEARBOX).
6.
Check for any mud intrusions.
CVT parts dirty. Clean all CVT parts.
CVT
Symptom: UNUSUAL ACCELERATION BEHAVIOR
1.
Check drive belt condition.
Belt is too narrow (drive belt engagement is higher in drive pulley).replace belt if width is
less than specified.
2.
Check lever condition on drive pulley sliding sheave and/or roller(s) on governor cup.
Lever(s) on drive pulley sliding sheave is (are) worn and/or damaged. Replace all levers
at the same time (lever kit).
Roller(s) is (are) worn and/or damaged. Replace governor cup assembly.
3.
Check drive/driven pulley sliding sheave for free axial movement.
Sliding sheave is stuck. Replace damaged part(s).
4.
Check condition of drive/driven pulley spring.
Drive pulley spring tension is too smooth and/or damaged. replace spring.
Driven pulley spring tension is too stiff. Replace spring.
5.
Check if cam of driven pulley is worn.
-- Replace if out of specifications.
6.
Check condition of fixed and sliding sheaves (drive and driven pulley).
Check surface of fixed and sliding sheaves (drive and driven pulley) for grooves or other
damages.
7.
Check valve adjustment.
Intake and/or exhaust valves are not adjusted correctly. Adjust valves.
8.
Check engine condition.
Low engine compression.
9.
Check ignition condition.
Faulty spark plug. Install new spark plug(s).
10.
Check differentials operation.
Vehicle on Neutral is hard to move. Repair or replace defective part(s).
Symptom: ENGINE MAXIMUM RPM IS TOO HIGH AND VEHICLE TOP SPEED IS NOT REACHED.
1.
Check drive/driven pulley area for contamination and/or water intrusion.
CVT area is contaminated with water, dirt or oil. Clean CVT system and replace damaged
part(s).
2.
Check drive/driven pulley spring tension.
Drive pulley spring tension is too stiff. Replace spring.
Driven pulley spring tension is too smooth and/or damaged. Replace spring.
Symptom: DRIVE PULLEY NOISE IN IDLE SPEED
1.
Check slider shoes (drive pulley).
Worn slider shoes (increased clearance between governor cup and drive pulley sliding
sheave). Replace all slider shoes at the same time (slider shoes kit).
2.
Check driven pulley sliding mechanism (between driven pulley outer and inner sheave).
Mechanism is stuck and/or damaged. Replace driven pulley assembly.
1.
Check roller(s) and/or levers for wear (located on sliding sheave of drive pulley).
Roller(s) on governor cup is (are) worn out and/or damaged. Replace governor cup
assembly.
Lever(s) on drive pulley sliding sheave is (are) worn out and/or damaged. Replace all
levers at the same time (lever kit).
2.
Check drive pulley screw for torque.
Loose screw. Retighten screw with recommended torque.
3.
Check one-way clutch condition on drive pulley sliding sheave.
Bearing(s) do(es) not move freely. Replace damaged part(s) and lubricate inside of