Service Manual (KLZ1000C) — page 758 of 762
Appendix › Troubleshooting Guide
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18-60 APPENDIX
Troubleshooting Guide
Air switching valve damaged O-ring at the oil passage in the crankcase
Alternator rotor loose damaged
Catalytic converter melt down due to muffler
overheating (KLEEN) Exhaust Smokes Excessively:
Balancer gear worn or chipped White smoke:
Balancer shaft position maladjusted Piston oil ring worn
Balancer bearing worn Cylinder worn
Balancer rubber damper damaged Valve oil seal damaged
Valve guide worn
Abnormal Drive Train Noise: Engine oil level too high
Clutch noise: Black smoke:
Clutch damper weak or damaged Air cleaner clogged
Clutch housing/friction plate clearance ex- Brown smoke:
cessive Air cleaner housing holder loose
Clutch housing gear worn Air cleaner poorly sealed or missing
Wrong installation of outside friction plate
Transmission noise: Handling and/or Stability
Bearings worn Unsatisfactory:
Transmission gear worn or chipped Handlebars hard to turn:
Metal chips jammed in gear teeth Cable routing incorrect
Engine oil insufficient Hose routing incorrect
Drive line noise: Wiring routing incorrect
Drive chain adjusted improperly Steering stem nut too tight
Drive chain worn Steering stem bearing damaged
Rear and/or engine sprocket worn Steering stem bearing lubrication inade-
Chain lubrication insufficient quate
Rear wheel misaligned Steering stem bent
Tire air pressure too low
Abnormal Frame Noise: Handlebars shakes or excessively
Front fork noise: vibrates:
Oil insufficient or too thin Tire worn
Spring weak or broken Swingarm pivot bearing worn
Rear shock absorber noise: Rim warped, or not balanced
Shock absorber damaged Wheel bearing worn
Disc brake noise: Handlebar holder bolt loose
Pad installed incorrectly Steering stem nut loose
Pad surface glazed Front, rear axle runout excessive
Disc warped Engine mounting bolt loose
Caliper trouble Handlebars pulls to one side:
Other noise: Frame bent
Bracket, nut, bolt, etc. not properly Wheel misalignment
mounted or tightened Swingarm bent or twisted
Swingarm pivot shaft runout excessive
Red Oil Pressure Warning Indicator Steering maladjusted
Light (LED) Doesn’t Go OFF: Front fork bent
Engine oil pump damaged Shock absorption unsatisfactory:
Engine oil screen clogged (Too hard)
Engine oil filter clogged Front fork oil excessive
Engine oil level too low Front fork oil viscosity too high
Engine oil viscosity too low Rear shock absorber adjustment too hard
Camshaft bearing worn Tire air pressure too high
Crankshaft bearing worn Front fork bent
Oil pressure switch damaged (Too soft)
Wiring faulty Tire air pressure too low
Relief valve stuck open Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Rear shock adjustment too soft