Over Cooling:

Gauge incorrect:

Water temperature gauge broken Water temperature sensor broken

Cooling system component incorrect:

Radiator fan relay trouble Thermostat trouble

Clutch Operation Faulty:

Clutch slipping:

Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak

Clutch hub or housing unevenly worn No clutch lever play

Clutch inner cable trouble

Clutch release mechanism trouble

Clutch not disengaging properly: Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated

Engine oil viscosity too high Engine oil level too high

Clutch housing frozen on drive shaft Clutch hub nut loose

Clutch hub spline damaged

Clutch friction plate installed wrong Clutch lever play excessive

Clutch release mechanism trouble

Gear Shifting Faulty:

Doesn’t go into gear; shift pedal doesn’t return:

Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft

Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose

Shift mechanism arm spring broken Shift mechanism arm broken

Shift pawl broken

Jumps out of gear:

Shift fork ear worn, bent Gear groove worn

Gear dogs and/or dog holes worn Shift drum groove worn

Gear positioning lever spring weak or bro- ken

Shift fork guide pin worn

Drive shaft, output shaft, and/or gear splines worn

Overshifts:

Gear positioning lever spring weak or bro- ken

Shift mechanism arm spring broken

Abnormal Engine Noise:

Knocking:

IC igniter in ECU trouble

Carbon built up in combustion chamber Fuel poor quality or incorrect

Spark plug incorrect Overheating

Piston slap:

Cylinder/piston clearance excessive Cylinder, piston worn

Connecting rod bent

Piston pin, piston pin hole worn

Valve noise:

Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn

Other noise:

Connecting rod small end clearance exces- sive

Connecting rod big end clearance exces- sive

Piston ring/groove clearance excessive Piston ring worn, broken, or stuck Piston ring groove worn

Piston seizure, damage Cylinder head gasket leaking

Exhaust pipe leaking at cylinder head con- nection

Crankshaft runout excessive

Engine mount loose Crankshaft bearing worn Primary gear worn or chipped

Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn Air suction valve damaged

Air switching valve damaged Alternator rotor loose

Catalytic converter melt down due to muffler overheating (KLEEN)

Abnormal Drive Train Noise:

Clutch noise:

Clutch housing/friction plate clearance ex- cessive

Clutch housing gear worn

Wrong installation of outside friction plate

Transmission noise:

Bearings worn

Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient

Drive line noise:

Drive chain adjusted improperly Drive chain worn

Rear and/or engine sprocket worn Chain lubrication insufficient

Rear wheel misaligned

Abnormal Frame Noise:

Front fork noise:

Oil insufficient or too thin Spring weak or broken

Rear shock absorber noise:

Shock absorber damaged

Disc brake noise:

Pad installed incorrectly Pad surface glazed Disc warped

Caliper trouble

Other noise:

Bracket, nut, bolt, etc. not properly mounted or tightened

Oil Pressure Warning Light Goes On:

Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn

Oil pressure switch damaged Wiring faulty

Relief valve stuck open

O-ring at the oil passage in the crankcase damaged

Exhaust Smokes Excessively:

White smoke: Piston oil ring worn Cylinder worn

Valve oil seal damaged Valve guide worn Engine oil level too high

Black smoke:

Air cleaner clogged

Brown smoke:

Air cleaner duct loose

Air cleaner O-ring damaged

Air cleaner poorly sealed or missing

Handling and/or Stability Unsatisfactory:

Handlebar hard to turn: Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight

Steering stem bearing damaged

Steering stem bearing lubrication inade- quate

Steering stem bent

Tire air pressure too low

Handlebar shakes or excessively vibrates:

Tire worn

Swingarm pivot bearing worn Rim warped, or not balanced Wheel bearing worn Handlebar holder bolt loose Steering stem nut loose

Front, rear axle runout excessive Engine mounting bolt loose

Handlebar pulls to one side:

Frame bent

Wheel misalignment Swingarm bent or twisted

Swingarm pivot shaft runout excessive Steering maladjusted

Front fork bent

Right and left front fork oil level uneven

Shock absorption unsatisfactory:

(Too hard)

Front fork oil excessive

Front fork oil viscosity too high

Rear shock absorber adjustment too hard Tire air pressure too high

Front fork bent (Too soft)

Tire air pressure too low

Front fork oil insufficient and/or leaking Front fork oil viscosity too low

Rear shock adjustment too soft

Front fork, rear shock absorber spring weak Rear shock absorber oil leaking

Brake Doesn’t Hold: Air in the brake line Pad or disc worn

Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated

Primary or secondary cup damaged in master cylinder

Master cylinder scratched inside