When the motorcycle starts in gear, it does not loosen the clutch handle to move forward; When shifting gears, although the clutch is tightly held, the transmission has a gear impact sound, which makes it difficult to shift gears; When braking, the engine is easy to stall.
(2) the cause of the failure and troubleshooting methods
See table 4- 10 for the failure causes and troubleshooting methods of incomplete clutch separation.
Table 4- 10 Failure Causes and Troubleshooting of Incomplete Clutch Separation
(3) Fault diagnosis process
The diagnosis process of manual clutch incomplete separation is shown in Figure 4-28, and the diagnosis process of automatic centrifugal clutch incomplete separation is shown in Figure 4-29.
(4) Key points of fault diagnosis
① The free stroke of the clutch handle is too large. Excessive free travel of the clutch lever means grasping the clutch lever, but the distance that the clutch push rod pushes the pressure plate is too small, resulting in the clutch still in a semi-engaged state, and the engine power is only partially transmitted to the transmission.
Troubleshooting: adjust the clutch free clearance to10 ~ 20 mm.
② The adjustment screw of the clutch push rod is not properly adjusted. Improper adjustment of the adjusting screw of the clutch push rod makes the gap between it and the push rod too large, resulting in incomplete clutch separation.
Troubleshooting: Adjust the adjusting screw of the clutch push rod. Remove the cover of the clutch push rod adjusting screw and find the push rod adjusting screw. Loosen the lock nut with a wrench, turn the push rod adjusting screw 1 ~ 2 turns counterclockwise with a screwdriver, and then turn the push rod adjusting screw clockwise.
Figure 4-28 Diagnosis Process of Manual Clutch Incomplete Separation
Figure 4-29 Diagnosis process of incomplete separation of automatic centrifugal clutch
Nail, when there is slight resistance, don't screw it hard. Screw out 1/4 turns counterclockwise from this position, and tighten the lock nut, being careful not to rotate with the adjusting screw of the push rod, as shown in Figure 4-30.
③ The parts of clutch control mechanism are excessively worn. The parts of the clutch operating mechanism (Figure 4-3 1) are excessively worn, such as the clutch operating handle, steel wire rope, operating lever, rocker shaft, roller and connecting rod cam, etc., so that the mating clearance between parts is too large, which increases the free stroke of the clutch and leads to incomplete clutch separation.
Troubleshooting: Replace worn parts.
Figure 4-30 Method of adjusting the adjusting screw of the clutch push rod
Figure 4-3 1 clutch control mechanism
④ The clutch spring force is uneven. The uneven spring force of the clutch makes the friction plate of the clutch bear uneven force, and when the clutch is held, the phenomenon of incomplete separation will occur.
Troubleshooting: Replace the entire clutch spring.
⑤ The tooth grooves of the driving hub and the driven hub of the clutch are ground into sawtooth shapes. The tooth grooves of the driving hub and the driven hub of the clutch are ground into zigzag, so that the friction plate cannot move freely in the tooth grooves. When grasping the clutch grip, although the push rod can push away the pressure plate, the friction plate is stuck in the sawtooth groove of the tooth groove of the driving hub, and the friction plate keeps in contact with the driven disk, resulting in incomplete clutch separation.
Troubleshooting: repair the clutch driving and driven hub. File the side of the tooth space with a file, and file as little as possible. At the same time, the upper and lower dimensions of the tooth slot are consistent, and the width of each notch is consistent. When the file is repaired, smooth it with an oilstone.