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9. CLUTCH/GEAR SHIFT MECHANISM STRYKER 125/150
SERVICE INFORMATION
GENERAL INSTRUCTIONS
· The clutch and gear shift mechanism can be serviced in the frame.
· Install the clutch plates in the same chamfer direction.
· Install the thrust washer with the chamfer facing up and the flat facing down.
SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Clutch spring free length 35.5 34.2
Clutch friction disk thickness 2.82.9 2.5
Clutch plate bending 00.1 0.2
Clutch outer I.D. 111111.5 112.5
O.D. 29.7029.85 29.66
Clutch outer guide
I.D. 30.030.021 30.40
TORQUE VALUES
Clutch center lock bolt 0.81.2kg-m
SPECIAL TOOLS
Universal holder
Pliers (open)
TROUBLESHOOTING
Clutch slips during acceleration Clutch won't operate; motorcycle moves
· No free play moves slowly
· Worn friction disk · Excessive free play
· Weak spring · Bent clutch plate
Clutch won't operate Too much pressure on clutch lever
· Excessive free play · Kinked, twisted or damaged clutch cable
· Bent clutch plate · Damaged clutch lifter
Improper shifting Clutch does not operate smoothly
· Excessive clutch lever free play · Improper clutch outer groove machining
· Bent gear shift spindle
· Worn or deformed gear shift plate Gear tripping
· Damaged transmission drum grooves · Faulty gear shift cam stopper
· Faulty gear shift cam stopper · Bent gear shift spindle
· Worn gear teeth
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