APPENDIX 17-23
Troubleshooting Guide
Abnormal Engine Noise:
Knocking:
IC igni
ter in ECU trouble
Carbon built up in com bustion chamber
Fuel poor quality or incorrect
Spark pl
ug incorrect
Overheating
Piston slap:
Cylinde
r/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pi
n, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spr
ingbrokenorweak
Camshaft bearing worn
Valve lifter worn
Other noi
se:
Connecting rod small end clearance exces-
sive
Connecti
ng rod big end clearance exces-
sive
Piston ring/groove clearance excessive
Piston ri
ng worn, broken, or stuck
Piston ring groove worn
Piston seizure, damage
Cylinder h
ead gasket leaking
Exhaust pipe leaking at cylinder head con-
nection
Crankshaf
t runout excessive
Engine mount loose
Crankshaft bearing worn
Primary ge
ar worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suctio
n valve damaged
Vacuum switch valve damaged
Alternator rotor loose
Catalytic c
onverter melt down due to muffler
overheating (KLEEN)
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 n oise:
Drive c
hain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lu
brication 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
