Service manual

FAULTY GEAR SHIFTING
HARD SHIFTING
PROBABLE CAUSE
• Clutch • Improperly adjusted clutch cable
• Improperly adjusted push lever position
• Improper engagement of push lever and
push rod
• Warped clutch plate
• Swollen friction plate
• Broken clutch plate
• Transmission oil • High oil level
• Improper quality (High viscosity)
• Deterioration
CHANGE PEDAL DOES NOT MOVE
PROBABLE CAUSE
• Shift shaft • Bent shift shaft
• Shift cam and shift fork • Groove jammed with impurities
• Seized shift fork
• Bent shift forks guide bar
• Transmission • Seized transmission gear
• Jammed impurities
• Incorrectly assembled transmission
JUMP OUT GEAR
PROBABLE CAUSE
• Shift shaft • Improperly adjusted shift lever position
• Improperly returned stopper lever
•Shift fork • Worn shift fork
• Shift cam • Improper thrust play
• Worn shift cam groove
• Transmission • Worn gear dog
CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING
PROBABLE CAUSE
• Clutch • Improperly adjusted clutch cable
• Loose clutch spring
• Fatigued clutch sping
• Worn friction plate
• Worn clutch plate
• Transmission • Low oil level
• Improper quality (Low viscosity)
• Deterioration
9-5
TRBL
SHTG
TROUBLESHOOTING