Repair / Problems / Gearbox and gear change / Loud clunk when selecting first gear

Gearbox and gear change

Loud clunk when selecting first gear

OK to rideAlso called: bang into first, first gear clunk, lurch when selecting first

Power path through the gearbox in each gear
Power path through the gearbox in each gear
Shims on the end of a gear shaft
Shims on the end of a gear shaft
Clutch pack lifted out of the engine: drag causes the clunk
Clutch pack lifted out of the engine: drag causes the clunk
Two gears with engagement dogs
Two gears with engagement dogs
Slight wear and pitting on gear dogs
Slight wear and pitting on gear dogs

When you select first at a standstill with the engine running, the bike gives a clunk and a small jolt. Some clunk is normal on most motorcycles, especially when cold: the clutch plates still turn the gearbox a little, and the gear engages against that movement. A very loud bang, a lurch forward, or a stall means the clutch is not releasing well, the idle is high, or there is slack somewhere in the drive.

Is it safe to ride?

Yes, usually. If the bike lurches forward when you select first, hold the front brake while you do it until it is fixed.

Quick checks first

  • Is it only loud for the first few minutes on a cold morning?
  • Pull the clutch lever, wait two or three seconds, then select first. Is it quieter?
  • Does the bike creep with the clutch pulled?
  • Is the idle faster than usual?

Diagnose it step by step

1Does the clunk get much quieter once the engine is warm, or when you wait a moment after pulling the lever?

  • Yes: this is mostly normal. Cold oil holds the plates together. Use the grade in your manual and wait a moment before selecting first.
  • No: go to step 2.

2Does the bike creep or try to stall when you select first with the lever pulled?

3Is the idle speed higher than specified? (K-Light 125: 1500 ± 100 rpm.)

4Is the oil old, low or the wrong grade?

5Is there a lot of slack in the drive: a loose chain, worn cush rubbers, or loose engine mounts?

6Still a loud clunk with everything above correct?

Causes, most likely first

Cause How to confirm Fix
Cold oil (normal) Quieter when warm Wait a moment; correct oil grade
Clutch drag Creeps with lever pulled Adjust clutch lever free play
High idle Revs above specification Idle speed is too high
Slack in the drive Loose chain, cush play, loose mounts Check the cush drive rubbers
Warped clutch plates Persists after the above Inspect and replace clutch plates and springs

Reference values (K-Light 125)

Item Value Source
Clutch lever free play 10 to 15 mm K-Light 125 manual, PDF p. 69
Idle speed 1500 ± 100 rpm K-Light 125 manual, PDF p. 49

Related problems

Sources
  • K-Light 125 manual, PDF pages 30, 31, 49, 69
  • MAVCC Motorcycle Mechanic, PDF page 577

Values marked K-Light 125 are for that reference bike. Use your own bike's manual for its values. Text CC BY-SA 4.0, Transitions Lab.