Faulty Gear Shifting; Hard Shifting; Shift Pedal Does Not Move; Jumps-Out-Of Gear - Yamaha BT1100 2002 Service Manual

EB903000

FAULTY GEAR SHIFTING

HARD SHIFTING

Refer to "CLUTCH DRAGGING".

SHIFT PEDAL DOES NOT MOVE

Shift shaft
• Improperly adjusted shift pedal link
• Bent shift shaft
Shift cam, shift fork
• Groove jammed with impurities
• Seized shift fork
• Bent shift fork guide bar

JUMPS-OUT-OF GEAR

Shift shaft
• Improperly adjusted shift lever position
• Improperly returned stopper lever
Shift fork
• Worn shift fork
EB904000

CLUTCH SLIPPING/DRAGGING

CLUTCH SLIPPING

Clutch
• Improperly adjusted clutch cable
• Loose clutch spring
• Fatigued clutch spring
• Worn friction plate/clutch plate
• Incorrectly assembled clutch

CLUTCH DRAGGING

Clutch
• Warped pressure plate
• Unevenly tensioned clutch springs
• Bent push rod
• Broken clutch boss
• Burnt primary driven gear bushing
• Bent clutch plate
• Swollen friction plate
• Match marks not aligned
FAULTY GEAR SHIFTING/
CLUTCH SLIPPING/DRAGGING
Transmission
• Seized transmission gear
• Jammed impurities
• Incorrectly assembled transmission
Shift cam
• Improper thrust play
• Worn shift cam groove
Transmission
• Worn gear dog
Engine oil
• Improper oil level
• Improper viscosity (low)
• Deterioration
Engine oil
• Improper oil level
• Improper viscosity (high)
• Deterioration
8-3
TRBL
?
SHTG