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My 2006 zx6r wants to kill me

2K views 10 replies 7 participants last post by  dngr2manifld 
#1 ·
He everyone, I just bought an 06 636 and took it out for the first long ride yesterday and encountered a few problems I have never had on any other bike.

The first problem- the friction zone on the clutch lever seemed to change by itself from the last 90% of the lever to the first 10%. When it did this it became extremely jumpy easing the clutch out. After my ride I let it cool for a few minutes and jumped back on, the clutch lever was back to engaging in the last 90% and starts were smooth again.

Second issue- the throttle is sticky and doesn't want to go back to original position. Can I just wd40 it? Also at idle I am at just under 2k rpm unless I really push hard up on the throttle, then it drops to just under 1.5k rpm. Wondering if the previous owner set this up or if that's normal with the 636's.

Third and worst issue. During 3rd and 4th gear it seemed that the bike would randomly jump like I blipped the clutch or something. The odd thing is after this would happen I would end up in a lower gear unless I'm going crazy that's what is happening :Oo: Happened 6 times during my 2 hour drive. 4 of them happened right as I was hitting the throttle hard and twice while I was at a constant cruising speed. :O :O :O

I know this is a ton especially for a new user of the forum. Other than these issues I love the bike and it took corners like a champ at 130! When I got it up past 10k rpms it was really smooth so it seems everything happens when I'm not in the sweet spot of the power band. I searched the forum and couldn't find anything pertaining to my third issue other than worn out chain and sprockets, which I will be replacing soon but that doesn't explain the auto downshift. Any help would be much appreciated!
 
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#2 ·
Careful with the speed man. U dont wanna kill yourself.

The clutch: Inspect the cable and make sure its not slowly tearing apart. Its strange that it was bad and then it fixed itself. But it might need adjustments if it does it again.

The sticky throttle: I have the same bike and mine does the same thing...altho its not that bad. Ive noticed the rubber grip tends to rub on the edges and keeps it from goin fully closed. Spray some WD40 on the edges and see if it helps. It does for me but eventually dries up again.

The transmission: Sounds like your transmission is busted. The 05 and 06 models have a weak transmission and are known to wear out the transmission forks and gear dogs. Might have to replace those pieces but its not an easy job. Or u can get a used engine and just seap out the whole thing.
 
#3 · (Edited)
It sounds like you just have a roached clutch.

As for the throttle cable, they do need occasional maintenance so if this is an older bike that has been neglected you will likely see some benefit to lubing that up. You can use some WD40 on the throttle cable but where you will likely get the best results is by cleaning and lubing your throttle linkage.
 
#4 ·
Oh my bad it's an 2006 zx6r. I put it in the title but not the body. I was really hoping it wasn't the transmission forks and gear dogs. That was all I could find that even sounded like the problems I had on it. Getting a new engine on this would suck. Thanks for all the help. I get to checking the simple stuff now. Is there an easy way to check if the transmission is bad?
 
#5 ·
It's not TRYING to kill you.. You need only remember this one piece of advice. You love your bike....she doesn't love you! SO while she might not be trying to kill you... she will not hesitate for a second if she's disrespected!

and yeahhhh. 1600 1700 rpm sounds about what my bike idles at.
 
#6 ·
He everyone, I just bought an 06 636 and took it out for the first long ride yesterday and encountered a few problems I have never had on any other bike.

The first problem- the friction zone on the clutch lever seemed to change by itself from the last 90% of the lever to the first 10%. When it did this it became extremely jumpy easing the clutch out. After my ride I let it cool for a few minutes and jumped back on, the clutch lever was back to engaging in the last 90% and starts were smooth again.
Pull the clutch cover off and look at the rod that pulls the plates apart... connects to the lever that connects the cable up to the clutch perch. If that pull rod has a notch in it you've found the problem. Replace. I had the same issue recently on a clutch I replaced. New pull rod and she's like new.

Second issue- the throttle is sticky and doesn't want to go back to original position. Can I just wd40 it? Also at idle I am at just under 2k rpm unless I really push hard up on the throttle, then it drops to just under 1.5k rpm. Wondering if the previous owner set this up or if that's normal with the 636's.
Take the grip and throttle tube off and inspect it... clean it... make sure everything is dry and not greasy. WD-40 might help for a little bit but it'll attract dirt and end up worse. Clean it all up... make sure that the rubber parts of the grip isn't touching anything that would cause it to bind.

Then make sure your cables are clean and lubed. Replacement would be good. But even new cables won't help if the throttle tube and grip are catching on something.

Third and worst issue. During 3rd and 4th gear it seemed that the bike would randomly jump like I blipped the clutch or something. The odd thing is after this would happen I would end up in a lower gear unless I'm going crazy that's what is happening :Oo: Happened 6 times during my 2 hour drive. 4 of them happened right as I was hitting the throttle hard and twice while I was at a constant cruising speed. :O :O :O
Unfortunately... sounds like a shift fork issue to me. You shouldn't be jumping out of gear at all.

I know this is a ton especially for a new user of the forum. Other than these issues I love the bike and it took corners like a champ at 130! When I got it up past 10k rpms it was really smooth so it seems everything happens when I'm not in the sweet spot of the power band. I searched the forum and couldn't find anything pertaining to my third issue other than worn out chain and sprockets, which I will be replacing soon but that doesn't explain the auto downshift. Any help would be much appreciated!
Don't do 130mph. Please... we've been over this so many times. Just be careful man. If you're gonna do that... make sure it's not around ANYONE that could get hurt or worse if you go down. :coocoo Just be sensible man.
 
#7 ·
Why is it everyone who posts that they just picked up their first bike and are jumping on riding like a mad man. Bikes want to kill you, time and experience teaches you how to tame them, but they still may snap and try to hurt you. Imagine it alot like lion taming, just when you think you are comfortable it strikes.
 
#8 ·
It's my first 636 not first bike. I know what I'm doing I just got off a cbr954 that makes this bike feel slow. I've been riding for 8 years and I know my limits and plenty of safe places to ride. That being said ya'll are right, with the tranny issues I should take it easy slipping out of a gear at that speed is bad news. Thanks for all the help so far, I'm learning more about transmissions than I ever wanted. Looks like I'm going to take a look at everything, just hope the dogs aren't worn or I might just part the bike out and take a loss. I should stick to new bikes from now on, my 954 ended up being a project from the get go as well, fortunately is was only oil and gas leaks.
 
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