Shift Pedal Does Not Move

TROUBLESHOOTING

Fuel system                                             • Bent shift shaft
1. Throttle body(-ies)
 • Damaged or loose throttle body joint                 Shift drum and shift forks
 • Improperly synchronized throttle bodies              • Foreign object in a shift drum groove
 • Improperly adjusted engine idling speed              • Seized shift fork
   (throttle stop screw)                                • Bent shift fork guide bar
 • Improper throttle cable free play
 • Flooded throttle body                                Transmission
 • Faulty air induction system                          • Seized transmission gear
                                                        • Foreign object between transmission gears
Electrical system                                       • Improperly assembled transmission
1. Battery
                                                        EAS28550
 • Discharged battery                                   JUMPS OUT OF GEAR
 • Faulty battery
2. Spark plug(s)                                        Shift shaft
 • Incorrect spark plug gap                             • Incorrect shift pedal position
 • Incorrect spark plug heat range                      • Improperly returned stopper lever
 • Fouled spark plug
 • Worn or damaged electrode                            Shift forks
 • Worn or damaged insulator                            • Worn shift fork
 • Faulty spark plug cap
3. Ignition coil(s)                                     Shift drum
 • Broken or shorted primary or secondary coils         • Incorrect axial play
 • Faulty spark plug lead                               • Worn shift drum groove
 • Cracked or broken ignition coil
4. Ignition system                                      Transmission
 • Faulty ECU                                           • Worn gear dog
 • Faulty crankshaft position sensor
 • Faulty cylinder identification sensor                EAS28570

                                                        FAULTY CLUTCH
 • Broken generator rotor woodruff key
EAS28510                                                Clutch slips
POOR MEDIUM-AND-HIGH-SPEED                              1. Clutch
PERFORMANCE                                              • Improperly assembled clutch
Refer to “STARTING FAILURES” on page 9-1.                • Improperly assembled clutch master cylinder
                                                         • Improperly assembled clutch release cylinder
Engine                                                   • Incorrect clutch fluid level
1. Air filter                                            • Damaged clutch hose
 • Clogged air filter element                            • Loose or fatigued clutch spring plate
                                                         • Loose union bolt
Fuel system                                              • Worn friction plate
1. Fuel pump                                             • Worn clutch plate
 • Faulty fuel pump                                      • Damaged clutch release cylinder
                                                        2. Engine oil
EAS28530

FAULTY GEAR SHIFTING                                     • Incorrect oil level
                                                         • Incorrect oil viscosity (low)
Shifting is difficult                                    • Deteriorated oil
Refer to “Clutch drags”.
                                                        Clutch drags
EAS28540                                                1. Clutch
SHIFT PEDAL DOES NOT MOVE                                • Air in hydraulic clutch system
                                                         • Warped pressure plate
Shift shaft                                              • Bent clutch plate
• Improperly adjusted shift rod                          • Swollen friction plate

                                                  9-2