9. CLUTCH/GEAR SHIFT MECHANISM
TROUBLESHOOTING
Clutch slips during acceleration Clutch won’t operate; motorcycle moves
• No free play
moves slowly
• Worn friction disk • Excessive free play
• Weak spring • Bent clutch plate
Clutch won’t operate Too much pressure on clutch lever
• Excessive free play • Kinked, twisted or damaged clutch cable
• Bent clutch plate • Damaged clutch lifter
Improper shifting Clutch does not operate smoothly
• Excessive clutch lever free play • Improper clutch outer groove machining
• Bent gear shift spindle
• Worn or deformed gear shift plate Gear tripping
• Damaged transmission drum grooves • Faulty gear shift cam stopper
• Faulty gear shift cam stopper • Bent gear shift spindle
• Worn gear teeth
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