Service manual

11-6
Smoke through
exhaust
Engine
Observation Causes Remedies
Wrong grade/recycled lube oil Replace it with right grade oil
Damaged valve stem seal Replace the seal
Worn out / scored valve guide / valve stem Check and Replace
Vertically aligned piston ring Properly stagger the piston end
gaps rings
Excessive piston ring end gap Replace the piston rings
Wrong fitment of piston rings Refit the piston rings correctly
Connecting Rod Bent Replace the crankshaft
Clearance Excess between Piston & Check and Replace
Cylinder Barrel
Glazed cylinder walls Check and Replace
Complaint :Engine Noisy
Incorrect octane rating of fuel Use correct fuel
Excessive clearance between piston and Check and Replace
cylinder
Loose rocker arm spindle in rocker arm Check and Replace
Hydraulic valve lifters damaged Check and Replace
Excessive small end clearance Check and Replace
A humming/Howling/ backlash noise Adjust the Cam spindles to
when accelerated achieve correct cam gears
meshing
Damaged cams Check and Replace
Worn-out/damaged Big end bearings Check and Replace
Complaint :Premature Wear of Engine Components
Cracked or improperly fitted suction/Air filter Check and Correct/Replace
Dirty/adulterated fuel Check and Correct/Replace
Dirty/adulterated/ Wrong Grade oil Replace oil at regular intervals
Complaint :Gears Hard/Not Engaging
Weak clutch spring. Check and Replace
Clutch lever free play excess Check and Correct
Cam plate pivot pin Oversize Change to correct size pin.
Cam plate ratchet face rubbing against Replace pivot pin / camplate.
the face of the pivot pin
Selector fork face rubbing against the cam Change selector fork / Camplate
plate face
Burr in the cam plate track / outer side of Remove burr in the cam plate
the cam plate inner track and outer side
Ratchet rivet protruding from cam plate Check and Replace
Selector fork & peg edges chipped off Check and Replace
Selector fork shaft bent / scoring marks Check and Replace
in the shaft.
Trouble Shooting