S No

PROBLEM

PROBABLE CAUSES

REMEDIES

1

Noise while pressingthe clutch pedal

Lack of lubrication in Clutch Release Bearing

Lubricate

Clutch Release Bearing damage

Replace

2

Noise while releasingclutch 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.40to44mm)(DC28to36mm)

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

Wraped Clutch facing

Replace the clutch facing

Wraped Flywheel or Pressure plate face

Correct by machining or replace

4

Clutch not disengagewhile 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 not 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

Workest clutch facing

S.No.

PROBLEM

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 STUCKING

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 imbedded in lining

Clean the liners

Loose part in the system.

Tighten the loose

S. No.

PROBLEM

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

S.No.

PROBLEM

PROBABLE CAUSES

REMEDIES

1

NOISE

Humming

Wear on gear teeth flank

Replace the gear.

(a pecutior 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.

Ratting (Ruppict series of short loud noise)

Backlash more

Correct the back lash either by

replacing gears or housing.

Bearing seat loosen

Replace the gearing or replace the housing.

Bearing play more

Replace the gearing.

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. Tight

Replace detent-retaining spring.

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.

S.NO.

TROUBLE

PROBABLE CAUSE

REMEDIES

1

HUMMING

1 .Incorrect adjustment of Crown Wheel &

1 .Re-adjust as per the procedure.

Tail Pinion. 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

3.Correct the backlash.

and Bevel Gear

4.Replace the bearing.

4.Defective axle bearing