Service Manual — page 713 of 715
Appendix › Troubleshooting Guide
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APPENDIX 17-41
Troubleshooting Guide
Piston ring groove worn Warning Indicator (LED) (Oil
Piston seizure, damage Pressure Warning) Doesn’t Go OFF:
Cylinder head gasket leaking Engine oil pump damaged
Exhaust pipe leaking at cylinder head con- Engine oil screen clogged
nection Engine oil filter clogged
Crankshaft runout excessive Engine oil level too low
Engine mount loose Engine oil viscosity too low
Crankshaft bearing worn Camshaft bearing worn
Primary gear worn or chipped Crankshaft bearing worn
Camshaft chain tensioner trouble Oil pressure switch damaged
Camshaft chain, sprocket, guide worn Wiring faulty
Air suction valve damaged Relief valve stuck open
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
Steering maladjusted
Front fork bent