Service Manual (KLZ1000C) — page 757 of 762
Appendix › Troubleshooting Guide
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APPENDIX 18-59
Troubleshooting Guide
Lubrication inadequate: Gear positioning lever binding
Engine oil level too low Shift return spring weak or broken
Engine oil poor quality or incorrect Shift return spring pin loose
Water Temperature meter incorrect: Shift mechanism arm spring broken
Water temperature meter broken Shift mechanism arm broken
Water temperature sensor broken Shift pawl broken
Coolant incorrect: Jumps out of gear:
Coolant level too low Shift fork ear worn, bent
Coolant deteriorated Gear groove worn
Wrong coolant mixed ratio Gear dogs and/or dog holes worn
Cooling system component incorrect: Shift drum groove worn
Radiator fin damaged Gear positioning lever spring weak or bro-
Radiator clogged ken
Thermostat trouble Shift fork guide pin worn
Radiator cap trouble Drive shaft, output shaft, and/or gear
Radiator fan relay trouble splines worn
Fan motor broken Overshifts:
Fan blade damaged Gear positioning lever spring weak or bro-
Water pump not turning ken
Water pump impeller damaged Shift mechanism arm spring broken
Over Cooling: Abnormal Engine Noise:
Water Temperature meter incorrect: Knocking:
Water temperature meter broken ECU trouble
Water temperature sensor broken Carbon built up in combustion chamber
Cooling system component incorrect: Fuel poor quality or incorrect
Thermostat trouble Spark plug incorrect
Overheating
Clutch Operation Faulty: Piston slap:
Clutch slipping: Cylinder/piston clearance excessive
Friction plate worn or warped Cylinder, piston worn
Steel plate worn or warped Connecting rod bent
Clutch spring broken or weak Piston pin, piston pin hole worn
Clutch hub or housing unevenly worn Valve noise:
No clutch lever play Valve clearance incorrect
Clutch inner cable trouble Valve spring broken or weak
Clutch release mechanism trouble Camshaft bearing worn
Clutch not disengaging properly: Valve lifter worn
Clutch plate warped or too rough Other noise:
Clutch spring compression uneven Connecting rod small end clearance exces-
Engine oil deteriorated sive
Engine oil viscosity too high Connecting rod big end clearance exces-
Engine oil level too high sive
Clutch housing frozen on drive shaft Piston ring/groove clearance excessive
Clutch hub nut loose Piston ring worn, broken, or stuck
Clutch hub spline damaged Piston ring groove worn
Clutch friction plate installed wrong Piston seizure, damage
Clutch lever play excessive Cylinder head gasket leaking
Clutch release mechanism trouble Exhaust pipe leaking at cylinder head con-
nection
Gear Shifting Faulty: Crankshaft runout excessive
Doesn’t go into gear; shift pedal doesn’t Engine mount loose
return: Crankshaft bearing worn
Clutch not disengaging Primary gear worn or chipped
Shift fork bent or seized Camshaft chain tensioner trouble
Gear stuck on the shaft Camshaft chain, sprocket, guide worn
Air suction valve damaged