[NinjaStylz]

Last year, before I parked my '08 ZX-6R for the winter, I was having an issue with shifting from 1st to 2nd and on occasion shifting from 3rd to 4th. It wasn't all the time, but it was often enough to raise concern.

I've been riding for about 8 years and bought this bike new in '08. I change the oil at the start of every season and use full synthetic oil.

Basically what's happening is I go to shift and it hangs up in neutral. There's no unusual noises and nothing feels stiff, or like its slipping or grinding nor does it feel like it's hard shifting. I'd think I was just getting lazy with my shifts, but after it started happening, I made a point of concentrating on my shifts - just in case.

Is there anything in the shift linkage that might need to be adjusted or tightened? My bike is approaching 25000kms but I'm not aware of any routine servicing that needs to be done at that time.

 

[jerryg951]

I was having the same issue on mine. It was my shifter the bar that the shift linkage hooks up to that turns the star gear. One of the bad had snapped off.

 

[RJ2112]

First thing to check is how well lubricated all the pivot points in the shift linkage are. Usually they start to get sticky on the upshift, because you have to rely on gravity to pull the shifter back down to 'center' to allow the shifter dogs to rachet to the next gear set.

When some girt and grime build up on the bearings at the shift lever pivot, or at the point where the shaft passes through the gasket into the transmission, or at either end of the rod between... it starts to hang up.

Peel back the rubber boots on the shift rod, and soak the ball joints in white lithium grease, then do the same at the transmission input shaft gasket, as well as at the foot shifter bearing.

 

[NinjaStylz]

Thanks for the suggestions. My bike comes home from storage this weekend, so I'll be checking it over then

 

[riverszzr]

First and most common place to look........

the shifter pivot off the footpeg bracket, I see these things rusty and all grimed up often and it will restrict movement and if bad enough hold the shift pedal from returning

Sadly it is held in with a bolt from the back of the footpeg bracket on most models and it is red loctited in, so heat and good tools would be your friend!

 

[zx6ixxer]

First and most common place to look........

the shifter pivot off the footpeg bracket, I see these things rusty and all grimed up often and it will restrict movement and if bad enough hold the shift pedal from returning

Sadly it is held in with a bolt from the back of the footpeg bracket on most models and it is red loctited in, so heat and good tools would be your friend!

^ +1
I remember when this happened on my 03' 3 years ago I posted a "HELP" thread...lol

I thought my tranny was shot because it got so bad that I could not shift up or down....I panicked.

Turned out crud/rust built up on the pivot point of the shifter/bracket and I pulled it apart, sanded a bit, greased it, and it was smooooth as butter after..."click...click..click"

 

[NinjaStylz]

Great advice guys! Thanks again. If it's as simple as cleaning up the pivot point on the shifter, I'll be good.

 

[honestSquid]

Well this is odd. I just bought a 14' 636 and I am having the same issues. Sometimes the shift is smooth and easy, other times it goes in gear but feels "jagged" or rather not smooth. I only have 126 miles on it, and I have not been hard on the bike. I am starting to get a little worried because my 300 never had this issue. I notice there is play in the clutch lever but not more than normal. Any guesses?

 

[NinjaStylz]

Hey Squid. I can't say I have any guesses, but if it's a new bike, if be taking it back to the dealership. It'll be under warranty, so before you do some permanent damage, have their mechanics look at it.

 

[NinjaStylz]

My bike hasn't had this issue yet this season. I got it out of storage last weekend and have put about 250km on it since and its been fine. I'll look everything over when I service it this weekend, but maybe I've gotten lucky.

 

[honestSquid]

Yeah I went by and spoke to someone at the desk. They basically told me to bring it back when it wasnt going to rain...so now I sit and wait. Here in Texas it never rains when it should and always rains when it shouldnt OH well rain is a blessing either way i guess.

 

[rkt14]

Well this is odd. I just bought a 14' 636 and I am having the same issues. Sometimes the shift is smooth and easy, other times it goes in gear but feels "jagged" or rather not smooth. I only have 126 miles on it, and I have not been hard on the bike. I am starting to get a little worried because my 300 never had this issue. I notice there is play in the clutch lever but not more than normal. Any guesses?

You'll notice that when you start to push the bike more and more .. you're shifts will become a lot smoother .. if you're switching gears at lower rpms the shits won't be so smooth .

Something I noticed on my 2013 636 . it's nothing to worry about .. if you are really worried then do what your dealer said and just bring it back To them .

 

[soc_monki]

also check adjustment of your clutch cable. i started having some rough shifting on my bike and the adjustment at the lever was good. checked at the clutch end and it was a good bit out of adjustment. tightened it up and i was good after that.