SERVICING INFORMATION 9-3
Complaint Symptom and possible causes Remedy
Engine is noisy. Excessive valve chatter
1. Excessive valve clearance.
2. Weak or broken valve spring.
3. Worn rocker arm and rocker arm shaft.
Noise seems to come from the piston
1. Worn piston.
2. Worn cylinder.
3. Carbon build-up in combustion chamber.
4. Worn piston pin or piston pin bore.
5. Worn piston ring or ring groove.
Noise seems to come from the cam chain
1. Stretched cam chain.
2. Worn cam chain sprocket.
3. Improperly working cam chain tension adjuster.
Noise seems to come from the clutch
1. Worn crankshaft spline.
2. Worn inner race spline.
3. Worn teeth of clutch plates.
4. Distorted clutch plates, driven and drive.
5. Clutch dampers weakened.
Noise seems to come from the crankshaft
1. Rattling bearing.
2. Worn or burnt crank pin bearing.
3. Excessive thrust clearance.
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 the transfer
1. Worn or rubbing gear.
2. Worn transfer input/output shaft.
3. Worn bearing.
4. Worn bushing.
Noise seems to come from front/rear output shaft bevel
gear, front drive (differential) bevel gear and rear drive
bevel gear
1. Worn or damage drive and driven bevel gears.
2. Excessive backlash.
3. Improper tooth contact.
4. Damage bearing.
5. Worn or rubbing gears.
6. Worn output shaft spline.
7. Front drive gear thrust clearance too large.
8. Rear drive gear thrust clearance too large.
Adjust.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Replace.
Replace cam chain and
sprockets.
Replace cam chain and
sprockets.
Repair or replace.
Replace crankshaft.
Replace inner race.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace crankshaft or conrod.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace shaft.
Replace.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace output shaft.
Adjust or replace.
Adjust or replace.
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