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Excessive Vibration
1. Engine tie-bars loose, broken or improperly spaced.
2. Lower mounting bolts loose.
3. Broken frame.
4. Primary chain badly worn or links tight as a result of
insufficient lubrication.
5. Wheels not aligned and/or tires worn.
6. Internal engine problem.
ENGINE LUBRICATION SYSTEM
Oil Does Not Return To Oil Tank
1. Oil tank empty.
2. Return pump gears damaged.
3. Oil feed pump not functioning.
4. Restricted oil lines or fittings.
Engine Uses Too Much Oil or
Smokes Excessively
1. Piston rings badly worn or broken.
2. Valve stem seals worn or damaged.
3. Valve guides worn.
Engine Leaks Oil From Cases, Push Rods,
Hoses, Etc.
1. Loose parts.
2. Imperfect seal at gaskets, push rod cover, washers, etc.
To aid locating leaks, use BLACK LIGHT LEAK
DETECTOR (Part No. HD-35457).
3. Restricted oil return line to tank.
4. Restricted breather passage(s) to air cleaner.
ELECTRICAL SYSTEM
Alternator Does Not Charge
1. Regulator-rectifier module not functioning.
2. Rectifier not grounded.
3. Engine ground wire loose or broken.
4. Loose or broken wires in charging circuit.
5. Stator not functioning.
6. Rotor not functioning.
Alternator Charge Rate Is Below Normal
1. Regulator-rectifier module not functioning.
2. Stator not functioning.
3. Rotor not functioning.
4. Weak battery.
5. Loose connections.
FUEL
Carburetor Floods
1. Excessive “pumping” of throttle control grip.
2. Inlet valve sticking.
3. Inlet valve and/or valve seat worn or damaged.
4. Dirt or other foreign matter between valve and its seat.
5. Float misadjusted or filled with fuel.
TRANSMISSION
Shifts Hard
1. Clutch dragging slightly.
2. Shifter forks (inside transmission) damaged.
3. Corners worn off shifter clutch dogs (inside
transmission).
Jumps Out of Gear
1. Shifter pawl improperly adjusted.
2. Shifter engaging parts (inside transmission) badly worn
and rounded.
3. Shifter forks bent.
4. Damaged gears.
CLUTCH
Slips
1. Clutch controls improperly adjusted.
2. Worn friction plates.
Drags or Does Not Release
1. Clutch controls improperly adjusted.
2. Clutch plates excessively warped.
Chatters
1. Friction or steel plates worn, warped or dragging.
CHASSIS
Irregular/Inadequate Brake Action
1. Master cylinder low on fluid.
2. Brake line contains air bubbles.
3. Master or wheel cylinder piston worn.
4. Brake pads covered with grease or oil.
5. Brake pads badly worn (1/16 in. (1.6 mm) minimum lining
thickness).
6. Brake rotor badly worn or warped.
7. Brake pads dragging or excessive braking (brake fades
due to heat buildup).
8. Insufficient brake pedal or hand lever freeplay (brake
drags).
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