Main Clutch Faults, Their Causes and Remedies

GENERAL INFORMATION.

Clutch does not disengage (with the clutch pedal fully depressed, the gearshift lever does not move freely to or from the engaged gear position (reverse gear)

reverse gear)

POSSIBLE CAUSES / REMEDY.

Malfunction of clutch drive operation. Eliminate faults.

Short clutch pedal travel. Adjust cable drive.

Play in drive connections. Eliminate faults or replace worn parts.

Clutch driven disc broken. Replace clutch driven disc.

Incorrect installation of release shaft with fork. Remove shaft and reinstall. Lightly apply wheel bearing grease to the ends of the fork levers and diaphragm spring fingers.

Seizure in the spline connection between clutch driven disc hub and input shaft. Repair or replace clutch driven disc.

Warping or bending of clutch driven disc. Replace clutch driven disc.

Clutch slipping.

POSSIBLE CAUSES / REMEDY.

Malfunction of clutch drive operation. Eliminate faults.

Oil contamination of clutch driven disc friction linings. Eliminate oil leaks and replace clutch driven disc.

Wear or separation of friction linings from clutch driven disc. Replace clutch driven disc.

Warping of pressure plate or flywheel. Replace pressure plate or flywheel.

Weakened pressure spring. Replace diaphragm spring.

Clutch driven disc not bedded in. Bed in the disc linings by smoothly starting the vehicle from rest 30 – 40 times. Do not overheat clutch components.

Clutch driven disc overheating. Cool the clutch.

Clutch seizure.

POSSIBLE CAUSES / REMEDY.

Oil contamination of disc friction surfaces. Burning or varnish deposits on friction linings. Eliminate oil leaks and replace clutch driven disc.

Wear of input shaft splines. Replace input shaft.

Warping of pressure plate or flywheel. Replace pressure plate or flywheel.

Friction surfaces contaminated with resinous substances. Clean surface contamination. Replace burnt parts.

Rattling or knocking when shifting gears.

POSSIBLE CAUSES / REMEDY.

Weakened release springs. Replace pressure plate.

Play in fork mounting. Remove and reinstall.

Oil contamination of clutch driven disc damper friction linings. Eliminate oil leaks and replace clutch driven disc.

Clutch driven disc damper springs broken. Replace clutch driven disc.

Release bearing noise with clutch fully engaged.

POSSIBLE CAUSES / REMEDY.

Malfunction of clutch drive operation. Eliminate faults.

Release bearing seizure. Clean off contamination, lubricate, and check for burrs, nicks and other defects.

Incorrect installation of release shaft with lever. Remove shaft with lever and reinstall.

Weakened pedal return spring. Replace pedal return spring.

Release bearing noise with clutch fully engaged.

POSSIBLE CAUSES / REMEDY.

Malfunction of clutch drive operation. Eliminate faults.

Release bearing seizure. Clean off contamination, lubricate, and check for burrs, nicks and other defects.

Incorrect installation of release shaft with lever. Remove shaft with lever and reinstall.

Weakened pedal return spring. Replace pedal return spring.

Increased noise.

POSSIBLE CAUSES / REMEDY.

Release bearing wear. Replace release bearing.

Incorrect installation of release shaft with lever. Remove shaft with lever and reinstall. Lightly apply wheel bearing grease to the ends of the fork levers contacting the release bearing.

Clutch pedal does not return to initial position after release.

POSSIBLE CAUSES / REMEDY.

Seizure of drive or release bearing. Lubricate and eliminate seizure of drive and release bearing.

Weakened pressure plate leaf springs. Replace pressure plate.

High clutch pedal effort.

POSSIBLE CAUSES / REMEDY.

Clutch linkage seizure. Lubricate and eliminate linkage seizure.

Clutch driven disc wear. Replace clutch driven disc.

Cable wear. Replace clutch cable.