TROUBLESHOOTING
8-2
● Discharged battery
● Faulty battery
2. Spark plug
● Incorrect spark plug gap
● Incorrect spark plug heat range
● Fouled spark plug
● Worn or damaged electrode
● Insulator damage
● Faulty spark plug cap
3. Ignition coil
● Faulty spark plug lead
● Cracked or broken ignition coil
4. IGNITION SYSTEM
● Faulty ECU.
● Faulty crankshaft position sensor
EAS28520
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to “STARTING FAILURES” on page 8-1.
ENGINE
1. Air filter
● Clogged air filter element
Fuel system
1. Fuel pump
● Faulty fuel pump
2. Throttle bodies
● Defective throttle body
3. ECU
● Faulty ECU.
EAS28530
FAULTY GEAR SHIFTING
Shifting is difficult
Refer to “Clutch drags”.
EAS28540
SHIFT PEDAL DOES NOT MOVE
Shift shaft
● Improperly adjusted shift rod
● Bent shift shaft.
Shift drum and shift forks
● Foreign object in a shift drum groove
● Seized shift fork
● Bent shift fork guide bar
Transmission
● Seized transmission gear
● Foreign object between transmission gears
● Improperly assembled transmission
EAS28550
JUMPS OUT OF GEAR
Shift shaft
● Incorrect shift pedal position
● Improperly returned stopper lever
Shift forks
● Worn shift fork
Shift drum
● Incorrect axial play
● Worn shift drum groove
Transmission
● Worn gear dog
EAS28570
FAULTY CLUTCH
Clutch slips
1. Clutch
● Improperly assembled clutch
● Improperly assembled clutch master cylinder
● Improperly assembled clutch release cylinder
● Incorrect clutch fluid level
● Damaged clutch hose
● Loose or fatigued clutch spring
● Loose union bolt
● Worn friction plate
● Worn clutch plate
● Damaged clutch release cylinder
2. Engine oil
● Incorrect oil level
● Incorrect oil viscosity (low)
● Deteriorated oil
Clutch drags
1. Clutch
● Air in hydraulic clutch system
● Unevenly tensioned clutch springs
● Warped pressure plate
● Bent clutch plate
● Swollen friction plate
● Bent clutch push rod
● Damaged clutch boss
● Burnt primary driven gear
● Damaged clutch release cylinder
2. Engine oil
● Incorrect oil level
● Incorrect oil viscosity (high)
● Deteriorated oil
EAS28590
OVERHEATING
Engine
1. Cylinder head(s) and piston(s)
● Heavy carbon buildup
2. Engine oil
● Incorrect oil level
● Incorrect oil viscosity
● Inferior oil quality
Fuel system
1. Throttle bodies
● Air intake in throttle body joint