Why Do Shift Forks Have Center Left And Right

Clutch Lever Too Hard To Pull In

* Damaged, kinked or dirty clutch cable

■ Oamaged clutch lifter mechanism

■ Faulty clutch lifter bearing

■ Clutch lifter rod installed inproperly

Clutch Will Not Disengage Or Vehicle Creeps With Clutch Disengaged

■ Too much clutch lever free play

• Warped clutch plate

■ Loose clutch lock nut

■ Oil level too high, improper oil viscosity or oil additive used

- Damaged cluch lifter mechanism

- Clutch lifter rod Installed improperly

Clutch Slips

• Clutch lifter slipping

■ Worn clutch discs

■ Weak clutch springs

■ No clutch lever free play

* Additive in engine oil

Clutch Operation Feels Rough

■ Rough outer drum slots

Hard To Shift

■ Misadjustcd clutch cable

- Improper oil viscosity

• Bern gearshift spindle

■ Bent shift forks

■ Bent shift fork shaft

- Bent fork claw

■ Damaged shift drum cam grooves

Jumps Out Of Gear

• Damaged stopper arm

• Stopper arm spring fatigue

• Damaged shifter cam

■ Damaged or bent shift fork

• Bent shift fork shaft

• Worn gear engagement dogs or slots

Right Crankcase Cover Removal/Installation

Requisite Service

• Side fairing removal/installation (page 2-3) . Engine oil draining <dram m ^^ 3_3

procedure: section 2 of the Common Service Manual)

• Side fairing removal/installation (page 2-3) . Engine oil draining <dram m ^^ 3_3

procedure: section 2 of the Common Service Manual)

Procedure

Q'ty

Remarks

Clutch cable holder

1

Installation is in the reverse order of removal.

14)

Right crankcase cover bolt Right crankcase cover Gasket

1

Loosen the bolts in a crisscross pattern in several steps.

(5) 16) (7)

Oil filler cap/Dip stick

O-ring

Dowel pin

1

<81 (9)

Clutch lifter piece Clutch lifter arm

1 1

(10)

Washer

1

(11) (121

Return spring Oil seal

1 1

Clutch/Gearshift Linkage

Clutch Removal

Xtz750 Clutch Spring Plate

Requisite Service

• Right crankcnase cover removal (page 9-2)

Procedure

Q'ty

Remarks

11!

Clutch lifter plate bolt

4

(2)

Clutch lifter plate

1

(3)

Clutch lifter rod

1

(4)

Stopper ring

1

(5)

Radial ball bearing (16001)

1

16)

Clutch spring

1

(7)

Clutch center lock nut

1

Refer to page 9-6 for removal.

(8)

Cone washer

1

(9)

Clutch center

1

(10)

Judder spring

1

(11)

Spring seat

1

(12)

Clutch disc (larger I D.)

1

(13)

Clutch disc (smaller I.D.)

(14)

Clutch plate

(15)

Clutch pressure plate

1

(16)

Thrust washer

1

(17)

Clutch outer guide

Î3"

-Refer to page 9-6 for removal

(18)

Clutch outer

(19)

Needle bearing

1

Refer to page 9-7 for replacement.

Clutch Center Lock Nut Removal

Unstake the clutch center lock nut.

Set the clutch center holder to the pressure plate and loosely install the nuts.

Clutch center holder

07JMB MN50300 or 07HGB-001000A (U.S.A. only)

(1) CLUTCH CENTER HOLDER

(1) CLUTCH CENTER HOLDER

07jmb Mn50300
(2) NUTS

Remove the tool and tighten the nuts, then reattach the clutch center holder onto the bosses of the pressure plate. Use at least two clutch lifter plate bolts to secure the tool onto the pressure plate.

Remove the clutch center lock unt.

Lock nut wrench, 17X27mm Extension bar

07716-0020300 or

07716-0020500 -

equivalent commercially available in U.S.A.

(1) LOCK NUT WRENCH

(1) LOCK NUT WRENCH

(2) EXTENSION BAR

Clutch Outer Removal

Insert the 5mm pin into the holes in the primary driven gears to align the gear teeth.

Pull the clutch outer guide out by pinching the ribs on the clutch outer guide.

GUIDE

GUIDE

Align the projections of the crankcase with between the teeth of the primary driven gears and remove the clutch outer from the mainshaft.

(1) PROJECTIONS

rs©—J

Clutch Outer Needle Bearing Replacement

Press the needle bearing out of the clutch outer.

Driver 07749-0010000

Attachment, 32x35mm 07746-0010100 Pilot, 30mm 07746-0040700

(1) DRIVER

(1) DRIVER

Press a new needle bearing into the clutch outer so that the edges of the needle bearing and clutch outer are flush

I S TOOu I

Driver 07749-0010000

Attachment, 32*35mm 07746 0010100

Pilot, 30mm 07746-0040700

(1) DRIVER [2] ATTACHMENT

(1) DRIVER [2] ATTACHMENT

Gearshift Linkage Removal/Installation

ALIGN

ALIGN

NOTE

• Make sure the gearshift linkage can be operated properly after assembly-

Requisite Service

- Clutch removal (page 9-4) * Clutch installation (page 9-12)

Procedure

Q'ty

Remarks

Removal Order

Installation is in the reverse order of removal.

(1)

Gearshift pedal pinch bolt

1

(2)

Gearshift pedal link

1

When installing, align the punch marks on the gearshift pedal link and the gearshift spindle

(3)

Gearshift spindle assembly

1

When installing, align the gear shift spindle return spring pin between the return spring ends.

W

Thrust washer

1

(5)

Snap ring

1

Install the snap ring with the chamfered side facing the return spring-

(6)

Return spring

1

(7)

Stopper arm bolt

1

(8)

Stopper arm

1

(9)

Washer

1

(10)

Stopper arm spring

1

(11) Shifter cam center bolt

1

When loosening, be careful not to break the bolt because a

locking agent is applied to the bolt threads.

(12)

Shifter cam

1

When installing, align the hole in the cam with the dowel pin.

(13)

Down pin

1

Shift Drum/Shift Forks Removal/Installation

Requisite Service

• Gearshift linkage removal/installation [page 9-8)

Oil pan removal (page 4-3)

Procedure

Q'ty

Remarks

Installation is in the rev&rse order of removal-NOTE

* Install the set plates with the 01 IT' mark facing out, - Install the set plate near the shift fork shaft so it holds the shaft in place as shown.

Refer to page 9 71 for installation-

Shift Fork Installation

Each shift fork has an identification mark; "R" is for the right shift fork, "L" is for the left shift fork and "C" isforthe center shift fork.

Apply molybdemun disulfide oil (a 50/50 mixture of engine oil and molybdenum disulfide grease] to the M3/4-, C5 and C6 gear shift fork grooves.

Install the shift forks aligning the shift drum pins with the shift drum grooves with the identification marks facing the right side of the engine

Apply clean engine oil to the shift fork shaft and install t> through the shift forks.

12) CENTER SHIFT FORK

(3) RIGHT SHIFT FORK

Xvs Shift Drum

(1) LEFT SHIFT FORK

12) CENTER SHIFT FORK

(3) RIGHT SHIFT FORK

0 0

Responses

  • Ippolito
    Why do shift forks have center left and right?
    2 years ago

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