2005-2009 Kawasaki Brute Force 650/KVF 650 4x4 Service Manual, Page 470Get this manual
18-4 APPENDIX Troubleshooting Guide
Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling: Cooling system component incorrect: Radiator fan switch trouble Thermostat trouble Converter Operation Faulty: Belt slipping: Belt dirty, wornor wetted Drive or driven pulley sheave dirty or worn Drive pulley spring broken or weak
Abnormal Engine Noise: Knocking: Igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston Slap: Cylinderpiston clearance excessive Cylinder, piston worn Connecting rod bent Piston pinpiston holes worn Valve noise: Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Other noise: Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring wornbroken, or stuck Piston seizure, damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain, sprocket, guides worn Loose alternator rotor Abnormal Drive Train Noise: Converter noise: Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mount loose Driven pulley shoe worn Drive pulley weight or roller side washer worn Drive pulley weight or roller worn Wear guides worn Transmission noise: Bearing worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient or too thin Front or rear final gear case noise: Insufficient lubricant Incorrect oil (Front final gear case) Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted