Repair / Gearbox and gear change
Gearbox and gear change
Problems, repairs and parts for the gearbox and gear change.
Problems
- Loud clunk when selecting first gearOK to ride
- Finds false neutrals between gearsRide with care
- Gear lever is loose, bent or slipping on its shaftRide with care
- Gear lever does not spring backRide with care
- Whining noise in one or more gearsRide with care
- Gears are hard to selectRide with care
- Jumps out of gear under loadRide with care
- Neutral light does not work or stays on in gearOK to ride
- Stuck in one gearDo not ride
Repairs
- Adjust clutch lever free playRider job · 10 to 15 min
- Check the gear lever and shift linkageHome workshop · 15 to 30 min
- Service footpegs and foot pedalsHome workshop · 20 to 45 min
- Check the engine oil levelRider job · 5 to 10 min (estimate, includes warm-up and settling)
- Change the engine oil and clean the strainerHome workshop · 40 to 60 min
- Inspect and replace clutch plates and springsWorkshop job · 1.5 to 3 h (assessment and plate change, engine in frame)
- Assess internal gearbox faultsWorkshop job · 1 h external checks; internal inspection is usually a full day with engine removal
- Refit or replace the gear leverHome workshop · 15 to 30 min
- Trace an oil leakHome workshop · 30 to 60 min plus a short ride
- Road test to diagnose a faultRider job · 15 to 30 min
- Inspect drained oil for cluesHome workshop · 10 to 15 min (estimate, during an oil change)
- Check and adjust chain slackRider job · 20 to 30 min
- Clean and lubricate the chainRider job · 15 to 30 min
- Check wheel bearingsHome workshop · 15 to 30 min
- Test the neutral switchHome workshop · 20 to 45 min
- Check power to the instrumentsHome workshop · 20 to 40 min
- Replace a bulbRider job · 10 to 30 min
- Clean and seal electrical connectorsHome workshop · 15 to 45 min
- Find a wiring faultHome workshop · 30 to 90 min
- Test the side stand, clutch and neutral switchesHome workshop · 20 to 40 min
- Bleed a hydraulic clutchHome workshop · 30 to 45 min
- Check the cush drive rubbersHome workshop · 30 to 60 min
- Check engine mounting boltsHome workshop · 20 to 40 min
- Replace the clutch cableHome workshop · 30 to 60 min
