Motorcycle Clutch & Gear Shifting Problems: 12 Common Issues (solved)

One of the charms of motorcycle riding is the smooth-shifting manual clutch and gear system.

Therefore, it’s incredibly frustrating when your clutch or gear shifting action is inhibited by a problem making it hard to change gears on your motorcycle.

This article dives into the 12 most common reasons why a motorcycle develops clutch or gear-shifting problems and how to solve them.

Improper Slack in the Clutch Cable

If the clutch cable is too tight or loose, it can prevent the clutch plates from thoroughly engaging or disengaging, resulting in hard or sloppy shifts.

Clutch cable slack develops due to normal wear and tear of the clutch cable, changes in temperature and humidity, or improper installation or adjustment of the cable.

For smooth clutch plate operation, your clutch cable needs to have the spec amount of free play, but not too much.

To solve this problem, you need to adjust the clutch cable by using the adjusters at both the lever and gearbox ends of the cable.

  • The adjuster near the lever is for fine-tuning, while the adjuster near the engine is for more significant changes.
  • Loosen or tighten the adjusters until you get the recommended free play at the lever, usually 2-3 mm.
  • Lubricate the cable regularly and replace it if it is damaged or worn out.

Low Engine Oil Levels

If the engine oil is low, it can cause overheating, wear and tear, and carbon deposits on the clutch plates, making them stick or slip and affecting the gear shifting.

This problem can develop due to average oil consumption, leakage, or infrequent oil changes.

The engine oil lubricates and cools the clutch plates and helps remove dirt and debris from your gearbox.

If the oil level is low, the clutch plates can overheat, wear out, or get contaminated, resulting in poor clutch performance.

To solve this problem, you need to check the engine oil level regularly and top it off if necessary.

  • Use the oil dipstick or an inspection window, depending on your motorcycle model.
  • Change the oil and filter according to the manufacturer’s recommendations.
  • Use the correct type and grade of oil.
  • Inspect your motorcycle for any signs of oil leakage and repair it as needed.

Poor Oil Quality

If the oil quality is poor, it contaminates the clutch plates and reduces their friction, causing them to slip and preventing smooth gear changes.

When the oil is contaminated by dirt, debris, water, fuel, or other substances, it reduces its lubricating and cooling properties. Poor oil quality can also happen when the oil is old or degraded or if you’re using an improper type or grade for your bike.

To solve this problem, change the oil and filter regularly according to the manufacturer’s recommendations.

  • Always use the type and grade of oil that meets the specifications of your motorcycle engine and clutch outlined in your owner’s manual.
  • Improve the longevity of your oil quality by easing on and off the clutch, avoiding excessive revving, and keeping your motorcycle clean and well-maintained.

Warped Clutch Plates

If the clutch plates are warped due to excessive heat or wear, they can cause uneven pressure and friction on the flywheel, making it hard to shift gears.

This problem develops when the clutch plates are exposed to excessive heat or wear due to improper clutch operation, low- or poor-quality oil, frequent stopping, or using the clutch as a brake alternative.

The heat friction or wear causes the plates to bend or warp, creating gaps or uneven contact between them and the flywheel.

  • To solve this problem, replace the warped clutch plates with new ones that match the specifications of your motorcycle.
  • Inspect and replace any other damaged or worn parts in the clutch system, such as the springs, basket, hub, or cable.
  • Prevent this problem by using the correct type and grade of oil, changing it regularly, adjusting the clutch cable correctly, and riding responsibly.

Chain Loosens While Riding

If the chain is too loose, it can cause excessive slack and vibration in the drivetrain, affecting the transmission and gear shifting.

When the chain stretches due to typical wear and tear or when the chain is not adequately lubricated, cleaned, or maintained, the chain will slack out of adjustment.

It can also happen when the chain is damaged by rust, warps, bends, cracks, or breaks.

  • Adjust the chain tension by using the adjusters on the rear axle.
  • Loosen the axle nut and turn the adjusters equally on both sides until you get the recommended amount of slack, usually 1.2-1.5 inches.
  • Tighten the axle nut and check the alignment of the chain and sprockets.
  • Lubricate and clean the chain regularly and inspect it for any signs of damage.
  • If the chain is too long or worn out, you may need to remove a link or replace the entire chain.

Worn-Out Chain Sprockets

If the chain sprockets are worn-out due to age or misuse, they can cause misalignment and skipping of the chain, resulting in jerky or noisy gear changes.

If the chain sprockets are worn-out due to age or misuse, such as using the wrong chain size, running the chain too loose or tight, or neglecting to clean and lube the chain regularly, it wears your sprockets and rollers.

  • Replace the chain sprockets with new ones that match the specifications of your motorcycle.
  • Replace the chain if it is also worn out or damaged.
  • Prevent worn sprockets by using the correct chain size, adjusting the chain tension properly, and cleaning and lubing the chain regularly.

Seized or Jammed Transmission

If the transmission is seized due to a lack of lubrication, corrosion, or debris, it can prevent the gears from moving freely and smoothly, making it impossible to shift gears.

Transmissions seize in extreme situations of inadequate lubrication, corrosion, or debris, when the engine oil is low or contaminated, or when the transmission gears are damaged by impact, wear, or abuse.

The seized transmission hinders the gears from moving freely and smoothly, making it hard to shift gears.

  • Inspect and repair the transmission components, such as the gears, shafts, forks, and dogs (dog clutch).
  • Disassemble the engine and transmission to access and replace the damaged parts.
  • Check and change the engine oil regularly and use the correct type and grade of oil for your motorcycle.
  • Prevent this problem by riding responsibly and avoiding excessive revving, clutch slipping, or gear grinding.

Faulty Gear Shift Lever

If the gear shift lever is faulty due to damage, wear, or misalignment, it can prevent proper engagement or disengagement of the gears, resulting in hard or sloppy shifts.

The gear shift lever is thrown out of alignment due to damage, wear, or misalignment.

In some cases, the lever is bent or broken by impact, corrosion, or abuse or when the lever is not correctly adjusted or lubricated.

The faulty lever can prevent proper engagement or disengagement of the gears, resulting in rough or sloppy shifting.

  • Check and repair the gear shift lever and its components, such as the linkage, spring, and bolt.
  • Straighten, tighten, lubricate, or replace your shifter parts as needed.
  • Adjust the lever height and position according to your preference and comfort.
  • Prevent this problem by riding responsibly and avoiding excessive force or impact on the lever.

Damaged or Faulty Gearbox

If the gearbox is damaged due to impact, wear, or abuse, it can cause bent or broken gears, shafts, forks, or dogs, resulting in grinding or jamming of the gears.

Your motorcycle’s gearbox can be damaged due to impact, wear, or abuse. When the transmission gears are subjected to excessive force, shock, or friction or when the gearbox is not properly lubricated, cleaned, or maintained.

  • Inspect and repair the gearbox components and replace any damaged or worn parts.
  • Disassemble the engine and gearbox to access and replace the parts.
  • Check and change the engine oil regularly and use the correct type and grade of oil for your motorcycle.
  • Ride responsibly and avoid excessive revving, clutch slipping, or gear grinding.

Maladjusted Shift Pedal Linkage

The shift pedal linkage could become maladjusted due to improper installation, adjustment, or maintenance. In this case, it can prevent proper movement of the shift pedal and lever, resulting in incomplete or missed shifts.

Another reason for this is that the shift pedal’s height or position is unsuitable for the rider’s preference or foot size, or when the linkage is not adequately lubricated, tightened, or aligned.

  • Inspect and adjust the shift pedal linkage and its components, such as the bolt, spring, and rod.
  • Loosen or tighten the bolt, lubricate the spring, or bend the rod as needed.
  • Adjust the shift pedal’s height and position according to your preference and comfort.
  • Avoid excessive force or impact on the pedal.

Please also read my article for beginners about motorcycles making hard gear shifts.

Poorly Timed Clutch Input

If the clutch input is poorly timed due to rider error or habit, it can cause premature or delayed engagement or disengagement of the clutch plates, resulting in irregular or missed shifts.

Poor clutch input is most commonly the result of rider error or habit—when the rider releases the clutch lever too fast, too slow, or when the rider uses the clutch as a brake alternative.

  • Practice and improve your clutch control and shifting technique.
  • Release the clutch lever smoothly and gradually, matching the engine RPMs and road speed to the appropriate gear.
  • Avoid using the clutch as a brake alternative and use the front and rear brakes instead.
  • Avoid excessive revving, clutch slipping, or gear grinding.

Faulty Clutch Cable

If the clutch cable is faulty due to damage, wear, or corrosion, it can prevent proper force transmission from the clutch lever to the clutch plates, resulting in rough, insufficient, or disproportionate clutch action.

Additionally, when the cable is frayed, broken, or rusted by impact, moisture, or abuse, or when the cable is not properly lubricated, cleaned, or maintained, it can cause a fault in the clutch cable.

To solve this problem, inspect and replace the clutch cable if it is damaged or worn out.

  • Lubricate and clean the cable regularly to prevent corrosion and friction.
  • Adjust the cable tension properly by using the adjusters at both ends of the cable.
  • Maintain the recommended amount of free play at the lever for your year model–usually 2-3 mm (check your service manual).
  • Ride responsibly and avoid excessive force or impact on the lever.

Sources:

Trouble Changing Gears On Your Motorcycle?

How to Fix a Faulty Motorcycle Clutch (Explained for Beginners) 

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