Clutch and Gearbox Troubleshooting
Clutch - Slips
• adjustment
• not enough play in the clutch cable
• friction plates worn or oil soaked
• friction plates warped
• weak or damaged pressure plate springs
• springs not evenly tensioned
• pressure plate not aligned
• synthetic oil .. recommended is dino juice
Clutch - Drags
• adjustment
• oil too heavy or dirty
• pressure plates warped
• gummed pressure plates
• springs not evenly tensioned
• worm gear cracked
• ball bearing missing
• cable binding
• washers missing from clutch assembly
Clutch - Noisy
• worn hub bearing
• basket tongues and/or hub splines worn
• primary gear springs broken
• clutch or main -shaft splines worn
• worn or damaged primary gear
Gearbox - grinds when shifting, shifting is difficult
• clutch adjustment
• oil too heavy
• bent, damaged or worn shift- forks, pins, drum, lever, arm, spring
• counter or main -shaft bent or bearings are worn
• worn or damaged gear dogs and receivers
• shift drum stopper spring broken
Gearbox - noisy
• oil low, dirty, too thin
• worn gears - backlash
• transmission shaft bearings worn
Shift Lever Doesn’t Return
• shift shaft bent
• return spring broken or weak
Won't Shift
• clutch drag
• shift forks bent
• shift return spring broken
• shift shaft bent or circlip lost
Jumps Out Of Gear
• shift drum stopper spring broken
• shift lever adjustment
• gear dogs and receivers worn
• shift forks worn or bent
• shift drum worn
• bent or damaged shift shaft or shift shaft arm
• counter or main -shaft splines worn
• gear teeth worn or broken