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APPENDIX 18-5
Troubleshootin g Guide
Worn LSD clutch friction plate (Front final
gear case)
Thrust plug maladjusted (Rear final gear
case)
Damaged side gears or pinions (Front final
gear case)
Abnormal Frame Noise:
Shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Rear brake noise:
Foreign matter in hub
Brake not properly adjusted
Other noise:
Bracket, nut bolt, etc. not properly mounted
or tightened
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Cylinder head gasket damaged
Engine oil level too high
Black Smoke:
Air cleaner clogged
Main jet too large or fallen off
Starter plunger stuck open
Fuel level too high
Brown smoke:
Main jet too small
Fuel level too low
Air cleaner duct loose
Air cleaner poorly sealed or missing
Handling and/or Stability Unsatisfactory
Handlebar hard to turn:
Tire air pressure too low
Steering stem bearing damaged
Steering stem bearing lubrication inade-
quate
Steering stem bent
Damaged steering knuckle joint
Damage tie-rod end
LSD clutch maladjusted (front final gear
case)
Noise when turning:
Damaged side gear or pinion (front final
gear case)
Worn LSD clutch friction plates (Front final
gear case)
Handlebar shakes or excessively vibrates:
Tire worn
Wheel rim warped
Rear axle runout excessive
Wheel bearing worn
Handlebar clamp loose
Steering stem clamp bolt loose
Handlebar pulls to one side:
Frame bent
Wheel maladjustment
Suspension arm bent or twisted
Steering stem bent
Front or rear tire air pressure unbalanced
Front shock absorber unbalanced
Shock absorption unsatisfactory:
Too hard:
Tire air pressure too high
Shock absorber maladjusted
Too soft:
Shock absorber oil leaking
Shock absorber spring weak
Tire air pressure too low
Shock absorber maladjusted
Brake Doesn’t Hold
Front brake:
Air in the brake line
Brake fluid leakage
Brake fluid deteriorated
Primary or secondary cup trouble
Master cylinder scratched inside
Pad overworn or worn unevenly
Oil, grease on pads and disc
Disc worn or warped
Brake overheated
Rear Brake:
Brake not properly adjusted
Plates worn
Brake parts worn or damaged
Kawasaki Engine Brake Control and
Selectable 2WD/4WD System Malfunction:
Actuators failed
Speed sensor short or open
Forward/Reverse detecting sensor short or
open
Actuator controller failed
Controller 10A fuse blown
Battery disconnected