Suzuki Ozark - Page 259

SERVICING INFORMATION 9-3
Complaint Symptom and possible causes Remedy
Engine is noisy. Noise seems to come from the crankshaft
1. Worn or burnt bearing.
2. Big-end bearing worn or burnt.
3. Thrust clearance too large.
Noise seems to come from transmission
1. Gears worn or rubbing.
2. Badly worn splines.
3. Primary gears worn or rubbing.
4. Badly worn bearings.
5. Worn bushing.
Noise seems to come from transfer
1. Worn down gears or shafts.
2. Damage to bearings/bushing.
Noise seems to come from secondary bevel gear and
rear drive bevel gear
1. Drive and driven bevel gears damaged or worn.
2. Excessive backlash.
3. Improper tooth contact.
4. Damage to bearing.
5. Gears worn or rubbing.
6. Badly worn splines.
7. Secondary bevel gear thrust clearance too large.
8. Rear drive bevel gear thrust clearance too large.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace
Adjust or replace.
Adjust or replace.
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.