Faulty Gear Shifting; Hard Shifting; Shift Lever Does Not Move; Jumps Out Of Gear - Yamaha 5KM2-AE1 Service Manual

FAULTY GEAR SHIFTING

HARD SHIFTING

Refer to "CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING".

SHIFT LEVER DOES NOT MOVE

Shift shaft
Bent shift shaft
G
Shift cam, shift fork
Groove jammed with impurities
G
Seized shift fork
G
Bent shift fork guide bar
G

JUMPS OUT OF GEAR

Shift shaft
Improperly adjusted shift lever position
G
Worn shift shaft lever
G
Improperly returned stopper lever
G
Shift fork
Worn shift fork
G

FAULTY CLUTCH PERFORMANCE

ENGINE OPERATES BUT MACHINE WILL NOT MOVE

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

CLUTCH SLIPPING

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

POOR STARTING PERFORMANCE

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