Filter
Top Products
– 104 –
TRBL
SHTG
FAULTY GEAR SHIFTING/
OVERHEATING
TROUBLESHOOTING
N
OTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for checking,
adjusting and replacing of parts.
FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to “CLUTCH SLIPPING” in CHAPTER 10 (Manual No.: 5TE-F8197-10).
SHIFT LEVER DOES NOT MOVE
Shift shaft
●
Groove jammed with impurities
●
Bent shift shaft
Shift fork
●
Seized shift fork
●
Bent shift fork guide bar
Transmission
●
Seized transmission gear
●
Jammed impurities
●
Incorrectly assembled transmission
Shift guide
●
Broken shift guide
OVERHEATING
OVERHEATING
Ignition system
●
Improper spark plug gap
●
Improper spark plug heat range
●
Faulty CDI unit
Fuel system
●
Improper carburetor main jet
(improper setting)
●
Improper fuel level
●
Clogged air filter element
Compression system
●
Heavy carbon build-up
JUMPS OUT OF GEAR
Shift shaft
●
Improperly adjusted shift lever position
●
Worn shift shaft lever
●
Improperly returned stopper lever
●
Improper thrust play
●
Worn shift shaft groove
Shift fork
●
Worn shift fork
Transmission
●
Worn gear dog
Engine oil
●
Improper oil level
●
Improper oil viscosity
●
Inferior oil quality
Brake
●
Brake drag
Oil cooling system
●
Faulty thermo unit
●
Faulty CDI unit
●
Faulty fan motor relay
●
Faulty fan motor circuit breaker
●
Clogged or damaged oil cooler
●
Inoperative fan motor