9.TROUBLESHOOTING
9-6
GEARBOX
Symptom: UNUSUAL GEARBOX NOISE AND/OR VIBRATION
1. Check oil level in gearbox.
Oil leakage from gearbox. Replace damaged gasket(s) and/or oil seal(s),
torque screws and refill with oil up to specified level (refer to TECHNICAL
SPECIFICATIONS and GEARBOX)
2. Check bearings in the gearbox for free movement.
Bearing(s) do(es) not move freely. Replace bearing(s)
3. Check for knocking noise.
Tooth of gears are damaged and/or worn. Replace respective gears.
Symptom: GEAR INDICATION FAILS.
1. Check contact screws on gear housing center.
Check contact screw outside for contamination and wetness. Clean
contact screw and screw for wiring harness.
Contact(s) is (are) corroded and/or contact screw for wiring harness got
loose. Clean contact surface and retighten contact screw(s) with
recommended torque.
Wiring harness has broken cables. Replace wiring harness.
Shifting indicator switch(es) pin(s) is (are) worn and/or damaged. Replace
shifting indicator switch(es).
Symptom: GEAR(S) IS (ARE) HARD TO SHIFT
1. Check shift shaft splines and/or shift forks for wear and/or damages.
Shift shaft is worn out and/or shows damaged splines. Replace shift
shaft.
Shift drum track(s) and/or splines is (are) worn out or damaged. Replace
shift drum and damaged part(s).
Shift fork(s) is (are) worn out and/or engagement pins are damaged.
Replace shift fork(s).
Shift fork(s) is (are) worn out and/or fork(s) is (are) damaged. Replace
shift fork(s).
Shift gear(s) is (are) worn out. Replace shift gear(s).
Shifting indicator switch(es) pin(s) is (are) worn out (no rounding on top
of pin). Replace shifting indicator switch(es).
2. Check engine idle speed.
Check throttle cable and throttle adjustment.
Check bypass idle valve and connectors.
3. Check CVT one way clutch on drive pulley.
CVT one way clutch was not lubricated correctly. Lubricate CVT one way
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