Overcooling

TROUBLESHOOTING

 • Bent clutch push rod                          • Incorrect spark plug heat range
 • Damaged clutch boss                          2. Ignition system
 • Burnt primary driven gear bushing             • Faulty ECU
 • Damaged clutch release cylinder
                                                EAS28610
 • Match marks not aligned
                                                OVERCOOLING
2. Engine oil
 • Incorrect oil level                          Cooling system
 • Incorrect oil viscosity (high)               1. Thermostat
 • Deteriorated oil                              • Thermostat stays open
EAS28600
                                                EAS28620
OVERHEATING                                     POOR BRAKING PERFORMANCE
                                                • Worn brake pad
Engine
                                                • Worn brake disc
1. Clogged coolant passages
                                                • Air in hydraulic brake system
 • Cylinder head and piston(s)
                                                • Leaking brake fluid
 • Heavy carbon buildup
                                                • Faulty brake caliper kit
2. Engine oil
                                                • Faulty brake caliper seal
 • Incorrect oil level
                                                • Loose union bolt
 • Incorrect oil viscosity
                                                • Damaged brake hose
 • Inferior oil quality
                                                • Oil or grease on the brake disc
                                                • Oil or grease on the brake pad
Cooling system
                                                • Incorrect brake fluid level
1. Coolant
 • Low coolant level                            EAS28660

2. Radiator                                     FAULTY FRONT FORK LEGS
 • Damaged or leaking radiator
 • Faulty radiator cap                          Leaking oil
 • Bent or damaged radiator fin                 • Bent, damaged or rusty inner tube
3. Water pump                                   • Cracked or damaged outer tube
 • Damaged or faulty water pump                 • Improperly installed oil seal
4. Thermostat                                   • Damaged oil seal lip
 • Thermostat stays closed                      • Incorrect oil level (high)
5. Oil cooler                                   • Loose damper rod assembly bolt
 • Clogged or damaged oil cooler                • Damaged damper rod assembly bolt copper
6. Hose(s) and pipe(s)                            washer
 • Damaged hose                                 • Cracked or damaged cap bolt O-ring
 • Improperly connected hose
 • Damaged pipe                                 Malfunction
 • Improperly connected pipe                    • Bent or damaged inner tube
                                                • Bent or damaged outer tube
Fuel system                                     • Damaged fork spring
1. Throttle body(-ies)                          • Worn or damaged outer tube bushing
 • Damaged or loose throttle body joint         • Bent or damaged damper rod
2. Air filter                                   • Incorrect oil viscosity
 • Clogged air filter element                   • Incorrect oil level
                                                EAS28680
Chassis
                                                UNSTABLE HANDLING
1. Brake(s)
 • Dragging brake                               Handlebars
                                                • Bent or improperly installed right handlebar
Electrical system
                                                • Bent or improperly installed left handlebar
1. Spark plug(s)
                                                1. Steering head components
 • Incorrect spark plug gap
                                                  • Improperly installed upper bracket

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