Abnormal frame and suspension noise

Front end noise

Low fluid level or improper viscosity oil in forks. This can sound

like spurting and is usually, accompanied by irregular fork action

(Chapter 6). '_ Spring weak or broken. Makes a clicking or scraping sound. Fork

oil, when drained, will have a lot of metal particles in it (Chapter 6).

Steering head bearings loose or damaged. Clicks when braking.

Check and adjust or replace as necessary (Chapters 1 and 6).

Fork yokes loose. Make sure all clamp pinch bolts are tightened to

the specified torque (Chapter 6).

Fork tube bent. Good possibility if machine has been dropped.

Replace tube with a new one (Chapter 6).

Front axle bolt or axle clamp bolts loose. Tighten them to the

specified torque (Chapter 7). ] Loose or worn wheel bearings. Check and replace as needed

(Chapter 7).

Shock absorber noise

Fluid level incorrect. Indicates a leak caused by defective seal. Shock will be covered with oil. Replace shocks as a pair (Chapter 6) or seek advice from a suspension specialist.

□ Defective shock absorber with internal damage. This is in the body
of the shock and can't be remedied. The shocks must be replaced
as a pair (Chapter 6).

Brake noise

□ Squeal caused by dust on brake pads (disc brake) or shoes (drum brake). Usually found in combination with glazed pads. Clean using brake cleaning solvent (Chapter 7).

□ Contamination of brake pads (disc brake) or shoes (drum brake), causing brake to chatter or squeal. Clean or replace pads/shoes (Chapter 7).

~I Pads glazed (disc brake). Caused by excessive heat from prolonged use or from contamination. Do not use sandpaper, emery cloth, carborundum cloth or any other abrasive to roughen the pad surfaces as abrasives will stay in the pad material and damage the disc. A very fine flat file can be used, but pad replacement is suggested as a cure (Chapter 7).

D Disc warped (disc brake). Can cause a chattering, clicking or intermittent squeal. Usually accompanied by a pulsating lever and uneven braking. Replace the disc (Chapter 7).

_] Loose or worn wheel bearings. Check and replace as needed (Chapter 7).

Oil pressure warning light comes on

Engine lubrication system

; Engine oil pump defective, blocked oil strainer gauze or failed relief valve. Carry out oil pressure check (Chapter 1).

D Engine oil level low. Inspect for leak or other problem causing low oil level and add recommended oil {Daily (pre-ride) checks). Engine oil viscosity too low. Very old, thin oil or an improper weight of oil used in the engine. Change to correct oil (Chapter 1).

□ Camshaft or journals worn. Excessive wear causing drop in oil pressure. Replace cam and/or/cylinder head. Abnormal wear

could be caused by oil starvation at high rpm from low oil level or improper weight or type of oil (Chapter 1). L~j Crankshaft and/or bearings worn. Same problems as above. Check and replace crankshaft and/or bearings (Chapter 2).

Electrical system

D Oil pressure switch defective. Check the switch according to the procedure in Chapter 9. Replace it if it is defective.

□ Oil pressure warning light circuit defective. Check for pinched, shorted, disconnected or damaged wiring (Chapter 9).

Fault Finding ref-43 11 Excessive exhaust smoke

White smoke

□ Piston oil ring worn. The ring may be broken or damaged, causing oil from the crankcase to be pulled past the piston into the combustion chamber. Replace the rings with new ones (Chapter 2).

□ Cylinders worn, cracked, or scored. Caused by overheating or oil starvation. The cylinders will have to be rebored and oversize pistons fitted.

□ Valve oil seal damaged or worn. Replace oil seals with new ones (Chapter 2).

Valve guide worn. Perform a complete valve job (Chapter 2).

□ Engine oil level too high, which causes the oil to be forced past the rings. Drain oil to the proper level (Chapter 1).

□ Head gasket broken between oil return and cylinder. Causes oil to be pulled into the combustion chamber. Replace the head gasket and check the head for warpage (Chapter 2).

I Abnormal crankcase pressurisation, which forces oil past the rings. Clogged breather is usually the cause.

Black smoke

~ Air filter clogged. Clean or replace the element (Chapter 1).

~~I Main jet too large or loose. Compare the jet size to the

Specifications (Chapter 4). Zl Choke cable or linkage shaft stuck, causing fuel to be pulled

through choke circuit (Chapter 4).

Fuel level too high. Check and adjust the float height(s) as

necessary (Chapter 4).

□ Float needle valve held off needle seat. Clean the float chambers
and fuel line and replace the needles and seats if necessary
(Chapter 4).

Brown smoke

□ Main jet too small or clogged. Lean condition caused by wrong
size main jet or by a restricted orifice. Clean float chambers and
jets and compare jet size to Specifications (Chapter 4).

i Fuel flow insufficient. Float needle valve stuck closed due to chemical reaction with old fuel. Float height incorrect. Restricted fuel line. Clean line and float chamber and adjust floats if necessary.

□ Carburettor intake manifold clamps loose (Chapter 4).

□ Air filter poorly sealed or not installed (Chapter 1).

Date: 2016-01-14; view: 646