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17-60 APPENDIX
Troubleshooting Guide
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)
Balancer gear worn or chipped
Balancer shaft position maladjusted
Balancer bearing worn
Balancer rubber damper damaged
Abnormal Drive Train Noise:
Clutch noise:
Clutch damper weak or damaged
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
Warning Indicator (LED) (Oil
Pressure Warning) Doesn’t Go OFF:
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 housing holder loose
Air cleaner poorly sealed or missing
Handling and/or Stability
Unsatisfactory:
Handlebars 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
Handlebars 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
Handlebars pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shaft runout excessive
Steering maladjusted
Front fork bent
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