05 zx636 jumping outta 1st gear?

[GlennB]

sounds like a re-call on this bike should be done. Not to sure if I will buy a 05 model now and I wonder if they fixed the problem in the 06 model??

Mate, it is not that big of an issue, seriously they are a good bike, and damn they are awesome fun..... a couple of ppl experiencing a gearbox issue, is hardly reason to recall the lot, there is no need to sensationalise the issue.... overall they are a damn good bike....

The only reason I said it should be recalled is that Ive read that 4+ people have had the same/similar issue, and thats only on our forum and not everybody rides a 05zx6 on this forum, so that makes the odds high. Im not saying re-call the whole bloody lot but it could be a problem on bikes made between 2-3 certain months of the year, and there seems to be a problem.

[mitch179]

my 03 is clunky between 1st and second but thats pretty normal .. and dont have problems shifting down gears either! the rest of the box is smooth as.

i use motul 5100 if that matters at all. and change oil every 2500k's

[Barrabob]

pulled the clutch out yesterday it was still brand new and i dont know what these guys that kill clutches in 9000kms are doing to them, I couldnt get the clutch basket out though so had to abort and will take it to a man with a rattle gun.

I changed the oil to comp 4 semi synthetic from silkolene pro it has quietened the whole thing down but it still clunks like a kawaski and finds neautral between first and second whenever i dont want it too.

The continuing saga.

[hidepenny]

but now i'm not sure what to do with this thing, it's not like i can't ride the thing, it's just annoying, and also i can only down gear when i release the clutch to the fliction point and somehow it engages the gear box and i am able to down gear, however sometiems i have to do this all the way from 6th to 1st at the lights, it's annoying!!

i'll book in the BK next time to check it out, hopefuully it's not something major, but yeah

Barrabob , pls let me know ur findings

[Saki]

is this gear box prob only occuring for a few people or wat ?

[RichB]

I don't think its uncommon for later model 636s to have an issue with the gearbox, don't let the dealers tell you they've never heard of it before, I bet they get told about it plenty by their customers and through factory updates. Check out all the members in the states with the same problem on this other zx6r forum, amazing coincidence.

http://www.kawiforums.com/forum/forum.asp?FORUM_ID=13

I've got an 05 model, and it's a bit rough between 1st and 2nd occasionally but it hasn't gotten too bad yet. My biggest prob has been occasionally not finding neutral, and sometimes once in neutral not being able to get out unless I pull the clutch in again to resort the box and then I'm away. I wonder how hard it is to install the factory pro widget?

[Jockey]

Sorry about the late reply have been away overseas...yeh well i took into another stealership today to get another opinion on it and well they too said,there doesnt seem to be anything wrong ,and blamed me for my rideing style,i race bikes aswell and this is the 1st time ive eva had a drama with a bikes gearbox!!! its starting to drive me insane...do i flogg it off or do i pull it down and replace the dogs and the detent springs,kawa hass to start admitting to there problems and stop turning a blind eye...

Im told that the gearbox in the 07 is nearly the same?

i mentioned that i was going to try full synt oil and there reply was ohh but kawa aust doesnt recoment id,anyways despite what they told me i did and i ran motol full syn oil and has made the gearbox run alot better the problem is still there but not as bad... in my conclusion i resken that the case hardening on the spindel and the main dogs is wareing and the detent springs(which hold the bike in gear) hav lost tention...the bike does hav 30 000km on her... but hey what about the 2 year kawa factory warranty?

ps the dearlership also told me that in the fine print that kawa aust doesnt cover doggs under warrenty,,,i was quoter nearly 2g to fix her


what do i do?

[mitch179]

man kick up an almighty stink. take it to fair trading.. the warranty is there to cover it if things fuck up.. how would your riding style kill first gear .. i could understand 2nd .. but not first

dont take this crap lying down dude go mental over it .. i would.

[Plaz]

sounds like a re-call on this bike should be done. Not to sure if I will buy a 05 model now and I wonder if they fixed the problem in the 06 model??

Mate, it is not that big of an issue, seriously they are a good bike, and damn they are awesome fun..... a couple of ppl experiencing a gearbox issue, is hardly reason to recall the lot, there is no need to sensationalise the issue.... overall they are a damn good bike....

The only reason I said it should be recalled is that Ive read that 4+ people have had the same/similar issue, and thats only on our forum and not everybody rides a 05zx6 on this forum, so that makes the odds high. Im not saying re-call the whole bloody lot but it could be a problem on bikes made between 2-3 certain months of the year, and there seems to be a problem.

Well I have an 05 mate, one of the first on the site from memory (I think Swabio just beat me) and I haven't had a single issue. I have 25000km up on mine in just over a year, 2 trips to Vic (thats right, I am am a masochist) and some resonably hard riding. I think the worst I have ever had to deal with is the engine hunting at idle a bit and in the end we've put that down to the aftermarket pipe that I chose to fit.

[Deserteagle]

Hey guys I'm just about to buy a second hand 2004 Blue ZX636... this was not good to hear.

I've just come off my provisional licence too so I don't think I'll have the ability to thrash it to find this flaw. It'll be the first time on anything other then a ZX2R...

Any recommendations?

[Barrabob]

The word on the factory pro widget is its a good thing but it wont fix a clunky gearbox.

It just gives the gearbox a harder kick on your behalf which is still a good thing.

I paid to have mine fitted in the end because it needed a air wrench to remove the clutch basket but if this isnt a problem to you just go for it its worth it.

[Minorci]

I have a 06 636, my gearbox is noisy as the kwaka's are, its popped out of gear going from 1st - 2nd .. 2nd - 1st a couple of times.

Although i put this down to not being firm enough with the gear shifts. I highly recommend you first adjust your gear lever to suit your foot position to provide you with more positive shifts.

Also clutchless shifting from 1st - 2nd is a no no in my opinion so use the clutch

Oil has made a huge difference in how smooth the bike shifts. Currently the best oil i have used to date is Castrol R4 Superbike. Bike was a dream to ride.

I'm currently trying some Motul 300V Factory line - Seems to be great as well.

[Kawastu]

17000 kms on mine, running 300V, BMC A/F, PC3 and Micron pipe and no probs at all here. Clutch wheelies and all.

The only problem I had was not kicking the lever up hard enough and it slipped out. I think its happened twice ever. Other than that its all fine here.

[GlennB]

Sorry about the late reply have been away overseas...yeh well i took into another stealership today to get another opinion on it and well they too said,there doesnt seem to be anything wrong ,and blamed me for my rideing style,i race bikes aswell and this is the 1st time ive eva had a drama with a bikes gearbox!!! its starting to drive me insane...do i flogg it off or do i pull it down and replace the dogs and the detent springs,kawa hass to start admitting to there problems and stop turning a blind eye...

Im told that the gearbox in the 07 is nearly the same?

i mentioned that i was going to try full synt oil and there reply was ohh but kawa aust doesnt recoment id,anyways despite what they told me i did and i ran motol full syn oil and has made the gearbox run alot better the problem is still there but not as bad... in my conclusion i resken that the case hardening on the spindel and the main dogs is wareing and the detent springs(which hold the bike in gear) hav lost tention...the bike does hav 30 000km on her... but hey what about the 2 year kawa factory warranty?

ps the dearlership also told me that in the fine print that kawa aust doesnt cover doggs under warrenty,,,i was quoter nearly 2g to fix her


what do i do?

Kick up a stink mate , thats what I would do. Even get a independent report done on the bike from a non kwaka delership to say there is a problem with the bike. These bikes are made hard to ride hard and I would not cop this shit " that its your riding style."
Also make a complant to the complants department at the kwaka head office about this dealership, that usually get the finger out of their arse.
hope things work out
Glenn

[Barrabob]

Strangly enough i have done 10000 kms since my last post and my gearbox has improved out of sight, i used to be a fastidious oilchanger and a pull apart of my clutch found no mechanical wearto speak of so i figured i was overdoing things and needed a little wear in my clutch.

I went from silkolene pro 10-40 to comp four 15-50 for a couple of changes and also fitted the factory pro widget and its gone from missed changes daily and plenty of harsh clunking between first and second to just changes gear as it should.

Maybe there is such a thing as too clean inside......hope all the ballbearings in the widget stay in the widget....just another thought.