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NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for checking,
adjusting and replacing of parts.
FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to "CLUTCH SLIPPING" in CHAPTER 10 (Manual No.: 5TE2-AE1).
SHIFT LEVER DOES NOT MOVE
Shift shaft
Groove jammed with impurities
G
Bent shift shaft
G
Shift fork
Seized shift fork
G
Bent shift fork guide bar
G
Transmission
Seized transmission gear
G
Jammed impurities
G
Incorrectly assembled transmission
G
Shift guide
Broken shift guide
G
OVERHEATING
OVERHEATING
Ignition system
Improper spark plug gap
G
Improper spark plug heat range
G
Faulty CDI unit
G
Fuel system
Improper carburetor main jet
G
(improper setting)
Improper fuel level
G
Clogged air filter element
G
Compression system
Heavy carbon build-up
G
FAULTY GEAR SHIFTING/
TROUBLESHOOTING
JUMPS OUT OF GEAR
Shift shaft
G
G
G
G
G
Shift fork
G
Transmission
G
Engine oil
G
G
G
Brake
G
Oil cooling system
G
G
G
G
G
G
– 104 –
OVERHEATING
Improperly adjusted shift lever position
Worn shift shaft lever
Improperly returned stopper lever
Improper thrust play
Worn shift shaft groove
Worn shift fork
Worn gear dog
Improper oil level
Improper oil viscosity
Inferior oil quality
Brake drag
Faulty thermo unit
Faulty CDI unit
Faulty fan motor relay
Faulty fan motor circuit breaker
Clogged or damaged oil cooler
Inoperative fan motor
TRBL
SHTG
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Table of Contents
Troubleshooting
