9-4 SERVICING INFORMATION
Complaint Symptom and possible causes Remedy
Slipping clutch. 1. Clutch control out of adjustment or loss of play.
2. Weakened clutch springs.
3. Worn clutch shoes.
4. Worn or distorted pressure plate.
5. Distorted clutch plates, driven and drive.
Adjust.
Replace.
Replace.
Replace.
Replace.
Dragging clutch. 1. Clutch control out of adjustment or too much play.
2. Some clutch springs weakened while others are not.
3. Distorted pressure plate or clutch plates.
4. Worn or damage clutch release mechanism.
Adjust.
Replace.
Replace.
Adjust or replace.
Transmission will not
shift.
1. Broken gearshift cam.
2. Distorted gearshift forks.
3. Worn gearshift shaft.
4. Worn or damage clutch release mechanism.
5. Improperly adjusted reverse cable.
Replace.
Replace.
Replace.
Adjust or replace.
Adjust.
Transmission will not
shift back.
1. Broken reverse shift cam.
2. Shift shafts are rubbing or sticky.
3. Distorted or worn gearshift forks.
4. Broken or damaged gearshift lever return spring.
Replace.
Repair
Replace.
Replace.
Transmission jumps
out of gear.
1. Worn shifting gears on driveshaft or countershaft.
2. Distorted or worn gearshift forks.
3. Weakened cam stopper spring on gearshift cam.
4. Worn gearshift lever stopper pin.
Replace.
Replace.
Replace.
Replace.
Transfer will not shift
or shift back.
1. Broken or worn sliding dog.
2. Broken or worn gearshift fork.
3. Worn gearshift cam.
4. Weakened cam stopper spring.
5. Worn gearshift fork shaft.
Replace.
Replace.
Replace.
Replace.
Replace.
Engine idles poorly. 1. Valve clearance out of adjustment.
2. Improper valve seating.
3. Defective valve guide.
4. Worn rocker arm or rocker arm shaft.
5. Excessive spark plug gap.
6. Defective ignition coil.
7. Defective CDI unit.
8. Defective generator.
9. Incorrect float chamber fuel level.
10. Clogged carburetor jet.
11. Defective fuel valve.
12. Improperly set pilot screw.
Adjust.
Replace.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Adjust float height.
Clean.
Replace.
Adjust.
Engine runs poorly in
high-speed range.
1. Weak valve spring.
2. Worn camshafts or rocker arms.
3. Insufficient spark plug gap.
4. Mistimed valves.
5. Defective ignition coil.
6. Low float chamber fuel level.
7. Dirty air cleaner element.
8. Clogged fuel hose, resulting in inadequate fuel supply
to carburetor.
9. Defective fuel valve.
Replace.
Replace.
Regap or replace.
Adjust.
Replace.
Adjust float height.
Clean or replace.
Clean and prime.
Replace.
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