When I shift gears, even from nuteral to first the gears make a hard clunk when they come together. Is this a clutch disk problem??
It could be a clutch problem, if you're disengaging the clutch and holding it for several seconds prior to attempting to shift gears. The gear clusters are heavy enough that, even in an engine oil bath, they'll spin for several seconds after the clutch has been disengaged. Within 10-15 seconds, however, they should be nearly stationary, if the clutch is functioning properly. It can also be aggravated by low viscosity oil in the crankcase; check to make sure that the viscosity of the oil is at least 40W (10W-40, 20W40); sometimes, toward the end of the oil's service life, it can suffer a significant loss in viscosity. If keeping the clutch disengaged longer doesn't minimize the grinding, flush the clutch hydraulic line; if that doesn't work, the clutch assembly will have to be removed and examined for bent or buckled diaphragm spring, pressure plate or clutch disks.
To flush the clutch hydraulic line, remove the left (shift lever side) rear cylinder cover (3 cap screws, 8mm Allen). Beneath the cover at the bottom, you'll see a neoprene "trapdoor"; that covers the drain fitting for the hydraulic clutch assembly. Loosen the fitting, slide a flexible tube over the fitting to route the old fluid to a pan or jar (you really DON'T want the old hydraulic fluid floating around under the cover), and pump the clutch lever, periodically refilling the reservoir on the handlebars, until the fluid coming out the drain is clear and free of bubbles. Remove the flexible tubing, tighten the drain fitting, and recheck clutch operation and gear noise when shifting.
If flushing the clutch hydraulic line does not quiet shifts, I would have to recommend purchase of any one of a number of good maintenance manuals to facilitate removing and inspecting the clutch "pack", the illustrations make a very difficult-to-read procedure quite straightforward.
Aug 17, 2010 |
2004 Yamaha Royal Star Venture