2011 Kawasaki KLX110 Owners Manual - Page 99

98 TROUBLESHOOTING GUIDE release mechanism defective • Clutch Clutch hub or housing unevenly worn • groove worn • Gear Gear dogs and/or dog grooves worn • Shift drum groove worn • Gear positioning lever • Shift fork pin worn spring broken or weak • Drive shaft, output shaft, and/or gear splines worn • j Clutch not disengaging properly: Clutch release play excessive (KLX110C Model) Clutch lever play excessive (KLX110D Model) Clutch spring tension uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch release mechanism defective Clutch hub nut loose Clutch plate warped or rough Clutch hub spline damaged Gear shifting faulty Transmission does not go into gear; shift pedal does not return: Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift mechanism arm spring broken Shift mechanism arm broken Shift return spring broken or weak Shift return spring pin loose Shift pawl broken Shift drum broken Transmission jumps out of gear: Shift fork worn • • Transmission skips gears: Gear positioning lever spring broken or weak Shift mechanism arm spring broken or weak Engine noise abnormal - Knocking: Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating Igniter defective Piston slap: Piston clearance excessive Cylinder or piston worn Connecting rod bent Piston pin or piston pin holes worn Valve noise: • clearance incorrect • Valve Valve spring broken or weak • Camshaft bearing or cam face worn •