Troubleshooting

Clutch

 

S NoPROBLEMPROBABLE CAUSESREMEDIES
1Noise while pressing the clutch pedalLack of lubrication in Clutch Release BearingLubricate
Clutch Release Bearing damageReplace
2Noise while releasing clutch pedalLack of lubrication in Pilot BearingLubricate
Pilot Bearing damageReplace
Clutch disk hub loose on Input shaftReplace the worn out parts
3Clutch slippageClutch Pedal free playAdjust & correct (25 to 35 mm)
Broken or Weak pressure springReplace springs
Release lever height incorrectAdjust & Correct (SC. 40 to 44mm)(DC 28 to 36mm)
Grease or oil on facingsReplace the facing, check source of
Glazed clutch facingReplace facing
Glazed flywheel or Pressure plate faceCorrect by machining or replace
Wraped Clutch facingReplace the clutch facing
Wraped Flywheel or Pressure plate faceCorrect by machining or replace
4Clutch not disengage while pressing clutchClutch Pedal free play moreAdjust & correct
Release lever height setting improperAdjust & correct
5Wear of clutch facingDriver Clutch pedal ridingKeep foot off clutch pedal
Excessive and incorrect use of clutchReduce use
Cracks in flywheel or pressure plate faceCorrect by machining or replace
Weak or broken pressure springReplace spring
Clutch pedal free play lessAdjust & correct
6Clutch pedal hardLack of lubrication in pedal linkageLubricate
Clutch pedal jam on clutch shaftGrease the shaft
Release lever height setting improperAdjust & correct
7Clutch Pedal PulsationEngine and Transmission not improperRealign
Flywheel face run out moreCorrect run out or replace
Release lever not evenly adjustedAdjust & correct
Pressure plate assembly misalignedRealign
Warped pressure plate or clutch facingReplace
Clutch plate nut free onDe and check clean
Workest clutch facing

 

Brakes

 

S.No.PROBLEMPROBABLE CAUSESREMEDIES
1.NO BRAKING ACTIONPedal linkage broken or disconnectedReplace or Repair
2.POOR BRAKING ACTIONBrake setting improperAdjust & correct
Glazed brake linersReplace
Glazed brake discCorrect by machining or replace
3.BRAKE STUCKINGLinkage retracting spring looseReplace springs
Brake disc plate spring tension lessReplace springs
Binding in linkageLubricate & free
4.NOISE WHILE BRAKINGLoose rivets of brake liningCorrect or replace
Worn out brake liningReplace
Rough or worn out brake disc plateCorrect by machining or replace
Foreign matter imbedded in liningClean the liners
Loose part in the system.Tighten the loose

 

Brake & Clutch Pedal

 

S. No.PROBLEMPROBABLE CAUSESREMEDIES
1Noise while pressing the clutch pedalLack of lubrication in Clutch Release BearingLubricate
Clutch Release Bearing damageReplace
2Noise while releasing clutch pedalLack of Lubrication in Pilot BearingLubricate
Pilot Bearing damageReplace
Clutch disc hub loose on input shaft

 

Replace the worn out parts
3Clutch pedal hard Lack of lubrication in pedal linkage Lubricate Clutch pedal jam on clutch shaft Grease the shaft. Release Lever height setting improper Adjust & correct4 Clutch pedal pulsation Engine and Transmission not aligned. Realign Flywheel face run out more Correct run out or replace Release lever not evenly adjusted. Adjust & correct Pressure plate assembly misaligned Realign Warped pressure plate or clutch facing Replace.

 

GEARBOX

 

S.No.PROBLEMPROBABLE CAUSESREMEDIES
1NOISE
HummingWear on gear teeth flankReplace the gear.
(a pecutior noise)Damage on gear teeth flankReplace the gear.
Metallic grindingOil lever low.Top up oil lever.
Whine (Bullet passing sound)Backlash lessCorrect the back lash either by replacing gears on housing.
Gear machining improperReplace the gear.
HissingWorn out bearingReplace the gearing.
(Leaking noise tent-tire to air lack)Bearing ball/race pittedReplace the gearing.
Ratting (Ruppict series of short loud noise)Backlash moreCorrect the back lash either by
replacing gears or housing.
Bearing seat loosenReplace the gearing or replace the housing.
Bearing play moreReplace the gearing.
Excessive end playCorrect the end play by tightening the Hex retaining nut or replacing spacers/gears.
Knocking (Noise of sharp blue)Dent on the Gear ToothRemove the dent by polishing.
Gear tooth damageReplace the gear.
Foreign matters presentClean the Gear train and strain the Oil.
Insufficient oil.Top up the oil.
Detent Lock assy.Replace detent-retaining spring.
Tight Bent in Shifter rodReplace the shifter rod.
Gear tooth batteredReplace the gear.
2HARD SHIFTINGSliding Gears tight on shaftFree the Gears shaft by polishing or by replacing gear/shaft.
Pilot Bearing JamReplace the gearing
Excessive Clutch Free PalyAdjust & correct Free Play.
Inter-lock pin tightLoosen the pin by polishing.
Clutch is not disengaging.Adjust & Correct
Incomplete Gear EngagingEngage Gear fully.
Weak Detent Retaining springReplace the spring.
3GEAR SLIPPING OUTShifter rod retaining groove worn outReplace shifter rod.
Gear teeth rounded offReplace the gear.
Worn out / Bent Shifter ForkReplace the Shifter Fork.
Detent balls/ spring stuckFree & Lubricate.
4GEAR STICKINGScoring on Fork.Replace fork
Clutch not disengaging.Adjust & correct.

 

DIFFERENTIAL

 

S.NO.TROUBLEPROBABLE CAUSEREMEDIES
1HUMMING1. Incorrect adjustment of Crown Wheel & Tail Pinion.1. Re-adjust as per the procedure.
2. Tooth contact pattern not correct.2. Correct the tooth contact pattern by doing the adjustment as per the procedure.
2NOISE WHILE ACCELERATINGTooth contact shifted towards thick end.Adjust Tooth Contact pattern as per the procedure.
3NOISE WHILE DE-ACCELERATINGTooth contact shifted towards thin end.Adjust Tooth Contact pattern as per the procedure
1. Bevel Pinion tight on Bevel Gear.1. Correct the gap.
NOISE WHILE2. Damaged teeth of Bevel2. Replace the damaged gear.
4TURNING3. Excessive backlash between Bevel Pinion3. Correct the backlash.
and Bevel Gear4. Replace the bearing.
4. Defective axle bearing