Kawasaki zx636r clutch / gearbox issue?

G

guardrailjim

New member
Adjust the clutch cable.
You've already noticed a problem with the clutch - rebuild it (change the clutch plates).
Adjust the drive chain and check the condition of the rear sprocket damper.
The next step would be to inspect the transmission - they can get damaged even on low mileage bikes from overly aggressive riders (SLAMMING the shift lever thinking he's on a race course).
Are you sure that wasn't you "knocking" down through the gears?
Are you one of those guys that thinks it's not harmful to a transmission when shifting without using the clutch?
The problems you describe are from shifting without using the clutch.
 
Ahh, here is;
In the past two weeks up-shifting is very CLUNKY and down-shifting is no different. Engaging 1st gear is usual clunk. But gears seem to be stiff or worn almost. Also a small gear WHINE when Revs are low cruising through town at 60or so K's an hr, in 4th or 3rd gear.

Bike is an 02 zx636r with less than 7thousand K's on it
Had it's 5thousand service.
Previous owner hardly rode machine hence low K's.
.
Shortly after i purchased it, knocked it down a to 3rd gear, gave it some stick and at this point the clutch seemed to be slipping or have some run-on, not hugely almost like someone riding the clutch. if u know what i mean. That 1 off slipping has not happened again.

And now I have this scarey loud clunk in every gear. everything works fine just very loud.
I have had lots of kwaka's and this noise is different.

Ideas, thoughts please down want to rip it apart if i don't have to.
some xtra's 4 u

yes i agree Kwakas have a reputation for very noisy GBox's. Though this time the noise is somewhat above normal/acceptable, and the low rev WHINING is only adding to my worries.
when i informed my mech about noise his suggestion was break in. 5000K service.

gear shifting is done with the clutch and blurping of throttle when downshifting.
I may have a few times up-shifted without the clutch but this was in the first days of owning it.
I wont get into a debate about how to ride a bike, soft or hard. I don't believe a bike especially a 636 is supposed to be ridden in top gear and never revved/ridden.

Clutch is nicely adjusted with about 3mm of play. basically because it's a low k bike everything is still very tight. no need to adjust anything.

Clutch works so why rebuild?
Chain is sweetly adjusted.
The other additive is when rolling rear wheel around on bike stand in 1st gear chain has some chatter or skipping at GBox end. Bike running.
 
If the only problem is noise, I would not worry about it till it gets worse. Provided that everything is working properly. It could be with the low mileage that the tranny is finally getting broken in, or it may be a more serious problem.

As a long time Kawasaki owner myself, I have to say that they are some of the clunkiest transmissions around. But since I am not hearing/feeling what you are I am not in a position to judge IF this is a problem or not.
 
I'd take it to a dealer. Could be a serious problem on its way. If it were my bike, I would adjust the clutch to spec and do an oil change. If the bike came with a magnetic drain plug, I would check for steel filings on it. If not, I would install a mag. plug now, and check it later.
 
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