Page 250 - 2019 SHOP MANUAL CRF1000/A/D

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CLUTCH/GEARSHIFT LINKAGE (CRF1000/A)
SERVICE INFORMATION
CLUTCH/GEARSHIFT LINKAGE (CRF1000/A)
GENERAL
• This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame.
• Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcycle
creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.
• When using the lock nut wrench, use a deflecting beam type torque wrench 50 mm (2.0 in) long. The lock nut wrench increases
the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The
specification given below is the actual torque applied to the lock nut, not the reading on the torque wrench when used with the
lock nut wrench. The procedure later in the text gives both actual and indicated torque readings.

TROUBLESHOOTING

Clutch lever is too hard to pull in
• Damaged, kinked or dirty clutch cable
• Improperly routed clutch cable
• Damaged clutch lifter mechanism
• Faulty clutch lifter bearing
• Clutch lifter piece installed improperly
Clutch slips when accelerating
• Clutch lifter sticking
• Worn clutch discs
• Weak clutch springs
• No clutch lever freeplay
• Engine oil mixed with molybdenum or graphite additive
Clutch will not disengage or motorcycle creeps with clutch disengaged
• Excessive clutch lever freeplay (page 3-22)
• Clutch plate warped
• Engine oil level too high, improper engine oil viscosity or additive used
• Loose clutch center lock nut
• Damaged clutch lifter mechanism
• Clutch lifter rod installed improperly
• Worn clutch outer slot and clutch center grooves
• Improper clutch operation
Hard to shift
• Incorrect clutch cable adjustment
• Improper clutch operation
• Improper engine oil viscosity
• Damaged or bent shift forks (page 14-15)
• Bent shift fork shaft (page 14-15)
• Bent shift fork claw (page 14-15)
• Loose shift drum center bolt
• Damaged shift drum center
• Damaged shift drum guide grooves (page 14-15)
• Damaged or bent gearshift spindle
• Damaged clutch cam
Transmission jumps out of gear
• Worn shift drum stopper arm
• Weak or broken shift drum stopper arm return spring
• Loose shift drum center bolt
• Damaged shift drum center
• Bent shift fork shaft (page 14-15)
• Damaged or bent shift forks (page 14-15)
• Worn gear engagement dogs or slots
– Mainshaft (page 14-16)
– Countershaft (page 14-15)
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
• Damaged or bent gearshift spindle

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