Service Manual — page 712 of 715
Appendix › Troubleshooting Guide
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17-40 APPENDIX
Troubleshooting Guide
Air cleaner housing holder loose Clutch hub nut loose
Air cleaner poorly sealed, or missing Clutch hub spline damaged
Air cleaner clogged Clutch friction plate installed wrong
Compression high: Clutch lever play excessive
Carbon built up in combustion chamber Clutch release mechanism trouble
Engine load faulty:
Clutch slipping Gear Shifting Faulty:
Engine oil level too high Doesn’t go into gear; shift pedal doesn’t
Engine oil viscosity too high return:
Drive train trouble Clutch not disengaging
Brake dragging Shift fork bent or seized
Lubrication inadequate: Gear stuck on the shaft
Engine oil level too low Gear positioning lever binding
Engine oil poor quality or incorrect Shift return spring weak or broken
Oil cooler incorrect: Shift return spring pin loose
Oil cooler clogged Shift mechanism arm spring broken
Gauge incorrect: Shift mechanism arm broken
Water temperature meter broken Shift pawl broken
Water temperature sensor broken Jumps out of gear:
Coolant incorrect: Shift fork ear worn, bent
Coolant level too low Gear groove worn
Coolant deteriorated Gear dogs and/or dog holes worn
Wrong coolant mixed ratio Shift drum groove worn
Cooling system component incorrect: Gear positioning lever spring weak or bro-
Radiator fin damaged ken
Radiator clogged Shift fork guide pin worn
Thermostat trouble Drive shaft, output shaft, and/or gear
Radiator cap trouble splines worn
Radiator fan relay trouble Overshifts:
Fan motor broken Gear positioning lever spring weak or bro-
Fan blade damaged ken
Water pump not turning Shift mechanism arm spring broken
Water pump impeller damaged
Abnormal Engine Noise:
Over Cooling: Knocking:
Gauge incorrect: ECU trouble
Water temperature meter broken Carbon built up in combustion chamber
Water temperature sensor broken Fuel poor quality or incorrect
Cooling system component incorrect: Spark plug incorrect
Thermostat trouble Overheating
Piston slap:
Clutch Operation Faulty: Cylinder/piston clearance excessive
Clutch slipping: Cylinder, piston worn
Friction plate worn or warped Connecting rod bent
Steel plate worn or warped Piston pin, piston pin hole worn
Clutch spring broken or weak Valve noise:
Clutch hub or housing unevenly worn Valve clearance incorrect
No clutch lever play Valve spring broken or weak
Clutch inner cable trouble Camshaft bearing worn
Clutch release mechanism trouble Valve lifter worn
Clutch not disengaging properly: Other noise:
Clutch plate warped or too rough Connecting rod small end clearance exces-
Clutch spring compression uneven sive
Engine oil deteriorated Connecting rod big end clearance exces-
Engine oil viscosity too high sive
Engine oil level too high Piston ring/groove clearance excessive
Clutch housing frozen on drive shaft Piston ring worn, broken, or stuck