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TROUBLESHOOTING GUIDE

1. Cylinder worn e Valve oil seal damaged e Valve guide worn e Engine oil level too high Black smoke e Air cleaner element clogged e Main jet too large or fallen out e Starter plunger stuck open Fuel level in carburetor float bowl too high Brownish e Main jet too small Fuel level in carburetor float bowl too low e Air cleaner duct loose e Air cleaner O ring damaged e Air cleaner poorly sealed or missing Poor handling and or stability Handlebar hard to turn e Control cable incorrectly routed e Wiring incorrect routed e Steering stem locknut too tight e Roller bearing damaged Steering stem inadequately lubricated e Steering stem bent Tire air pressure too low Handlebar shakes or vibrates excessively e Tire worn e Swingarm sleeve or needle bearing damaged e Rim warped or out of balance e Front and or rear axle runout excessive e Wheel bearing worn e Handlebar clamp loose e Steering head nut loose Handlebar pulls to one side e Frame bent Wheel misaligned e Swingarm bent or twisted e Swingarm pivot shaft runout excessive e Steering maladjusted e Steering stem bent e Front fork leg bent e Right left front fork oil level uneven Shock absorption unsatisfactory suspension too hard Front fork oil excessive Front fork oil viscosity too high e Front fork leg bent e Front fork air pressure high e Tire air pressure too high e Rear shock absorber improperly adjusted Shock absor
2. or gap improperly ad justed e Spark plug type incorrect e CDI unit defective Fuel air mixture incorrect e Main jet clogged or wrong size Carburetor fuel level too low Carburetor holder loose e Air cleaner element clogged poorly sealed or not installed e Air intake duct poorly sealed e Hot starter stuck open Compression high e Carbon built up in combustion chamber TROUBLESHOOTING GUIDE 137 Engine overloaded e Brake dragging e Clutch slipping Engine oil level too high e Engine oil viscosity too high e Drive chain trouble Lubrication inadequate e Engine oil level too low e Engine oil quality poor or type incorrect Coolant inadequate e Coolant level too low e Coolant deteriorated Cooling system component defective e Radiator clogged e Radiator cap defective e Water pump not rotating Clutch operation faulty Clutch slipping e No clutch lever play e Clutch cable improperly adjusted e Clutch cable defective e Clutch plate worn or warped e Clutch spring broken or weak Clutch release mechanism defective e Clutch hub or housing unevenly worn 138 TROUBLESHOOTING GUIDE Clutch not disengaging properly Clutch lever play excessive e Clutch plate warped or too rough e Clutch spring tension uneven e Engine oil deteriorated e Engine oil viscosity too high e Engine oil level too high e Clutch housing frozen on drive shaft e Clutch release mechanism defective e Clutch hub nut loose
3. 134 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE O This troubleshooting guide is not exhaustive and does not give every possible cause for each prob lem listed It is meant simply as a quick guide to assist you in troubleshooting for some of the more common difficulties Starting failure or difficulties Engine does not turn over Valve seized e Valve lifter seized Cylinder or piston seized e Crankshaft seized e Connecting rod small end seized e Connecting rod big end seized e Camshaft seized e Transmission gear or bearing seized e Kick shaft return spring broken e Kick ratchet gear not engaging Fuel does not flow e No fuel in tank e Fuel tap turned off e Tank cap air vent obstructed e Fuel tap clogged e Fuel line clogged e Float valve clogged Engine flooded e Fuel level too high e Float valve worn or stuck open e Wrong starting technique when the engine is flooded kick with the throttle fully closed by pulling the hot starter lever in Spark missing or weak e Spark plug dirty broken or gap improperly ad justed e Spark plug cap or high tension wiring defective e Spark plug cap not contacting properly e Spark plug type incorrect e Crankshaft sensor defective e CDI unit defective e Ignition coil defective e Engine stop switch wiring defective e Ignition coil resistor defective disconnected e Flywheel magneto damaged e Neutral switch defective Wiring shorted or interrupted F
4. e Clutch plate warped or rough e Clutch hub spline damaged Gear shifting faulty Transmission does not go into gear shift pedal does not return Clutch not disengaging Shift fork bent or seized e Gear stuck on the shaft Shift lever broken e Pawl guide plate broken e Shift return spring weak or broken Shift return spring pin loose e Shift pawl broken Shift pawl spring tension lose Shift drum broken Transmission jumps out of gear Shift fork worn e Gear groove worn e Gear dogs and or dog grooves worn Shift drum groove worn Gear positioning lever spring weak or broken e Shift fork pin worn Drive shaft output shaft and or gear splines worn Transmission skips gears e Gear positioning lever spring weak or broken e Pawl guide plate worn Engine noise abnormal Knocking e CDI unit defective e Carbon built up in combustion chamber e Fuel quality poor or type incorrect e Spark plug type incorrect e Engine overheating Piston slap e Piston clearance excessive e Cylinder or piston worn e Connecting rod bent e Piston pin or piston pin bores worn Valve noise e Valve clearance incorrect e Valve spring broken or weak e Camshaft bearing or camface worn Valve lifter worn Other noise e Connecting rod small end clearance excessive Connecting rod big end clearance excessive e Piston ring worn broken or stuck e Piston seized or damaged e Cylinder head gasket leaking e Exhaust pipe leakin
5. g at cylinder head e Crankshaft runout excessive Engine mounts loose e Crankshaft bearing worn e Primary gear worn or chipped e Camshaft chain tensioner trouble e Camshaft chain sprocket chain guide worn e Decompression spring broken Flywheel magneto loose Abnormal drive train noise Clutch noise e Clutch housing friction plate clearance excessive Clutch housing gear excessive e Metal chip jammed in clutch housing gear teeth Transmission noise e Crankcase bearing worn or damaged e Transmission gear worn or chipped Metal chip jammed in gear teeth e Engine oil level or viscosity too low e Kick ratchet gear not properly disengaging from kick gear TROUBLESHOOTING GUIDE 139 Output shaft idle gear worn or chipped Drive chain noise e Drive chain slack imprope e Drive chain worn rly adjusted e Rear and or engine sprocket s worn e Drive chain inefficiently lubrified e Rear wheel misaligned Frame noise abnormal Front fork noise e Oil level or viscosity too low e Spring weak or broken e Front fork air pressure high Rear shock absorber nois e Shock absorber damaged Disc brake noise e Pad installed incorrectly e Pad surface glazed e Brake disc warped e Brake caliper defective e Brake cylinder damaged Other noise e Bracket nut bolt etc tightened e improperly mounted or 140 TROUBLESHOOTING GUIDE Exhaust smoke Excessively white e Piston oil ring worn
6. ption unsatisfactory suspension too soft e Front fork oil level insufficient and or front fork leaking oil e Front fork oil viscosity too low e Front fork and or rear shock absorber spring weak e Rear shock absorber leaking gas e Rear shock absorber improperly adjusted Poor braking performance e Air in the brake line e Brake pad or disc worn e Brake fluid leaking e Brake disc warped e Brake pads contaminated e Brake fluid deteriorated e Primary and or secondary master cylinder cup s damaged e Master cylinder scratched e Brake maladjusted lever or pedal play excessive TROUBLESHOOTING GUIDE 141
7. supply to carburetor insufficient e Fuel contaminated with water or foreign matter e Fuel tank air vent obstructed e Carburetor holder loose e Air intake duct loose e Fuel tap clogged Fuel line clogged e Hot starter stuck open e Needle Jet or air passage clogged Compression low e Spark plug loose e Cylinder head insufficiently tightened Cylinder nut loose e Cylinder or piston worn e Piston ring worn weak broken or sticking e Piston ring side clearance excessive e Cylinder head gasket damaged e Cylinder head warped e No valve clearance e Valve spring broken or weak e Valve not seating properly valve bent worn or carbon accumulation on seating surface Cylinder gasket damaged e Decompression trouble Improper acceleration e Starter plunger stuck open e Carburetor fuel level too high or too low e Main jet clogged e Throttle valve does not fully open e Air cleaner element clogged e Muffler clogged e Fuel contaminated with water or foreign matter e Brake dragging Clutch slipping e Engine overheating e Engine oil level too high e Engine oil viscosity too high e Crankshaft bearing worn or damaged e Ignition timing incorrect e Crankshaft sensor defective e Hot starter stuck open Knocking e Carbon built up in combustion chamber e Fuel quality poor or type incorrect e Spark plug type incorrect e CDI unit defective Engine overheating Firing incorrect e Spark plug dirty broken
8. tuck open e Fuel tap clogged Compression low e Spark plug loose e Cylinder head insufficiently tightened Cylinder nut loose e Cylinder or piston worn e Piston ring worn weak broken or sticking e Piston ring side clearance excessive e Cylinder head gasket damaged e Cylinder head warped Cylinder gasket damaged e No valve clearance e Valve spring broken or weak e Valve not seating properly valve bent worn or carbon accumulation on the seating surface Decompression trouble 136 TROUBLESHOOTING GUIDE Other e Engine oil viscosity too high e Brake dragging e Ignition timing incorrect e Engine oil level too high e CDI unit defective Drive chain trouble e Engine over heating Clutch slipping Poor or no high speed performance Firing incorrect e Spark plug dirty damaged or gap improperly ad justed e Spark plug cap or high tension wiring defective Spark plug cap shorted or not contacting properly e Spark plug type incorrect e CDI unit defective e Ignition coil defective e Crankshaft sensor defective Flywheel magneto defective Wiring connector not in good contact Fuel air mixture incorrect e Main jet clogged or wrong size e Jet needle or needle jet worn e Jet needle clip in wrong position e Carburetor fuel level too high or too low e Air jet or air passage clogged e Air cleaner element clogged poorly sealed or not installed e Starter plunger stuck open e Fuel
9. uel air mixture incorrect e Idling adjusting pilot screw improperly adjusted e Slow jet or air passage clogged e Air cleaner element clogged poorly sealed or not installed e Starter jet clogged Compression low e Spark plug loose e Cylinder head insufficiently tightened e Cylinder nut loose Cylinder or piston worn e No valve clearance e Crankshaft oil seal leak e Valve spring broken or weak e Valve not seating properly valve bent worn or carbon accumulation on the seating surface e Piston ring worn weak broken or sticking e Piston ring side clearance excessive e Cylinder head gasket damaged e Cylinder head warped e Cylinder gasket damaged Poor low speed performance Spark weak e Spark plug dirty broken or gap improperly ad justed e Spark plug cap or high tension wiring defective e Spark plug cap shorted or not contacting properly e Spark plug type incorrect e CDI unit defective e Ignition coil defective e Crankshaft sensor defective e Flywheel magneto defective e Wiring connector not in good contact TROUBLESHOOTING GUIDE 135 Fuel air mixture incorrect e Idling adjusting pilot screw improperly adjusted Slow jet Needle jet or air passage clogged e Air cleaner element clogged poorly sealed or not installed e Starter plunger stuck open e Carburetor fuel level too high or too low Fuel tank air vent obstructed e Carburetor holder loose e Air intake duct loose e Hot starter s

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