TROUBLESHOOTING
CLUTCH
| S. No. | PROBLEMS | PROBABLE CAUSES | REMEDIES |
| 1 | Noise while pressing the clutch pedal | Lack of lubrication in Clutch Release Bearing | Lubricate |
| Clutch Release Bearing damage | Replace | ||
| 2 | Noise while releasing clutch pedal | Lack of lubrication in Pilot Bearing | Lubricate |
| Pilot Bearing damage | Replace | ||
| Clutch disk hub loose on Input shaft | Replace the worn out parts | ||
| 3 | Clutch slippage | Clutch Pedal free play | Adjust & correct (25 to 35 mm) |
| Broken or Weak pressure spring | Replace springs | ||
| Release lever height incorrect | Adjust & Correct (SC. 40 to 44mm)(DC 28 to 36 mm) | ||
| Grease or oil on facings | Replace the facing, check source of | ||
| Glazed clutch facing | Replace facing | ||
| Glazed flywheel or Pressure plate face | Correct by machining or replace | ||
| Warped Clutch facing | Replace the clutch facing | ||
| Warped Flywheel or Pressure plate face | Correct by machining or replace | ||
| 4 | Clutch not disengaging while pressing clutch | Clutch Pedal free play more | Adjust & correct |
| Release lever height setting improper | Adjust & correct | ||
| 5 | Wear of clutch facing | Driver Clutch pedal riding | Keep foot off clutch pedal |
| Excessive and incorrect use of clutch | Reduce use | ||
| Cracks in flywheel or pressure plate face | Correct by machining or replace | ||
| Weak or broken pressure spring | Replace spring | ||
| Clutch pedal free play less | Adjust & correct | ||
| 6 | Clutch pedal hard | Lack of lubrication in pedal linkage | Lubricate |
| Clutch Pedal- jam on clutch shaft | Grease the shaft | ||
| Release lever height setting improper | Adjust & correct | ||
| 7 | Clutch Pedal Pulsation | Engine and Transmission improper | 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 | ||
| Clutch plate nut free on | De and check clean | ||
| Work clutch facing |
BRAKES
| S.No. | PROBLEMS | PROBABLE CAUSES | REMEDIES |
| 1. | NO BRAKING ACTION | Pedal linkage broken or disconnected | Replace or Repair |
| 2. | POOR BRAKING ACTION | Brake setting improper | Adjust & correct |
| Glazed brake liners | Replace | ||
| Glazed brake disc | Correct by machining or replace | ||
| 3. | BRAKE STUCK | Linkage retracting spring loose | Replace springs |
| Brake disc plate spring tension less | Replace springs | ||
| Binding in linkage | Lubricate & free | ||
| 4. | NOISE WHILE BRAKING | Loose rivets of brake lining | Correct or replace |
| Worn out brake lining | Replace | ||
| Rough or worn out brake disc plate | Correct by machining or replace | ||
| Foreign matter embedded in lining | Clean the liners | ||
| Loose part in the system. | Tighten the loose |
BRAKE & CLUTCH PEDAL
| S. No. | PROBLEMS | PROBABLE CAUSES | REMEDIES |
| 1 | Noise while pressing the clutch pedal | Lack of lubrication in Clutch Release Bearing | Lubricate |
| Clutch Release Bearing damage | Replace | ||
| 2 | Noise while releasing clutch pedal | Lack of Lubrication in Pilot Bearing | Lubricate |
| Pilot Bearing damage | Replace | ||
| Clutch disc hub loose on input shaft | Tighten |
GEARBOX
| S.No. | PROBLEMS | PROBABLE CAUSES | REMEDIES |
| 1 | NOISE | ||
| Humming | Wear on gear teeth flank | Replace the gear | |
| (A peculiar noise) | Damage on gear teeth flank | Replace the gear | |
| Metallic grinding | Oil lever low | Top up oil lever | |
| Whine (Bullet passing sound) | Backlash less | Correct the back lash either by replacing gears on housing | |
| Gear machining improper | Replace the gear | ||
| Hissing | Worn out bearing | Replace the gearing | |
| (Leaking noise tent-tire to air lack) | Bearing ball/ race pitted | Replace the gearing | |
| Rattling (Making series of short loud noise) | Backlash more | Correct the back lash either by | |
| Replacing gears or housing | |||
| Bearing seat loosen | Replace the bearing or replace the housing | ||
| Bearing play more | Replace the bearing | ||
| Excessive end play | Correct the end play by tightening the Hex retaining nut or replacing spacers/gears | ||
| Knocking (Noise of sharp blue) | Dent on the Gear Tooth | Remove the dent by polishing | |
| Gear tooth damage | Replace the gear | ||
| Foreign matters present | Clean the Gear train and strain the Oil | ||
| Insufficient oil | Top up the oil | ||
| Detent Lock assy. | Replace detent-retaining spring | ||
| Tight Bent in Shifter rod | Replace the shifter rod | ||
| Gear tooth battered | Replace the gear | ||
| 2 | HARD SHIFTING | Sliding Gears tight on shaft | Free the Gears shaft by polishing or by replacing gear/shaft |
| Pilot Bearing Jam | Replace the gearing | ||
| Excessive Clutch Free Paly | Adjust & correct Free Play | ||
| Inter-lock pin tight | Loosen the pin by polishing | ||
| Clutch is not disengaging | Adjust & Correct | ||
| Incomplete Gear Engaging | Engage Gear fully | ||
| Weak Detent Retaining spring | Replace the spring | ||
| 3 | GEAR SLIPPING OUT | Shifter rod retaining groove worn out | Replace shifter rod |
| Gear teeth rounded off | Replace the gear | ||
| Worn out / Bent Shifter Fork | Replace the Shifter Fork | ||
| Detent balls/ spring stuck | Free & Lubricate | ||
| 4 | GEAR STICKING | Scoring on Fork | Replace fork |
| Clutch not disengaging. | Adjust & correct |
DIFFERENTIAL
| S.NO. | TROUBLES | PROBABLE CAUSES | REMEDIES |
| 1 | HUMMING | 1. 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. | ||
| 2 | NOISE WHILE ACCELERATING | Tooth contact shifted towards thick end | Adjust Tooth Contact pattern as per the procedure. |
| 3 | NOISE WHILE DE-ACCELERATING | Tooth 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 WHILE | 2. Damaged teeth of Bevel | 2. Replace the damaged gear | |
| 4 | TURNING | 3. Excessive backlash between Bevel Pinion and Bevel Gear | 3. Correct the backlash |
| 4. Defective axle bearing | 4. Replace the bearing |