Faulty Gear Shifting; Hard Shifting; Shift Lever Does Not Move; Jumps Out Of Gear - Yamaha 2004 YXR660 Service Manual

EBS00542

FAULTY GEAR SHIFTING

HARD SHIFTING

Refer to "CLUTCH SLIPPING".

SHIFT LEVER DOES NOT MOVE

Shift drum, shift forks
• Groove jammed with impurities
• Seized shift fork
• Bent shift fork guide bar

JUMPS OUT OF GEAR

Shift forks
• Worn shift fork
EBS00543

FAULTY CLUTCH PERFORMANCE

ENGINE OPERATES BUT VEHICLE WILL NOT MOVE

V-belt
• Bent, damaged or worn V-belt
• V-belt slips
Primary pulley cam and primary pulley
slider
• Damaged or worn primary pulley cam
• Damaged or worn primary pulley slider

CLUTCH SLIPPING

Clutch spring
• Damaged, loose or worn clutch shoe spring
Clutch shoe
• Damaged or worn clutch shoe

POOR STARTING PERFORMANCE

V-belt
• V-belt slips
• Oil or grease on the V-belt
Primary sliding sheave
• Faulty operation
• Worn pin groove
• Worn pin
FAULTY GEAR SHIFTING/
FAULTY CLUTCH PERFORMANCE
10 - 4
Transmission
• Seized transmission gear
• Jammed impurities
• Incorrectly assembled transmission
Shift guide
• Broken shift guide
Shift drum
• Improper thrust play
• Worn shift drum groove
Transmission
• Worn gear dog
Transmission
• Damaged transmission gears
Primary sliding sheave
• Seized primary sliding sheave
Clutch shoe
• Bent, damaged or worn clutch shoe
TRBL
SHTG