My last fuel up before winterizing, my shifter hung up on me also at about 50 degree farienhiet. I fired it up to ride it in March and still had problems. I took it apart and cleaned everything as mentioned. I then took a die grinder with small disc shaped mounted point (grinding stone) that would fit into shifter shaft hole (about 1/2"/13mm dia,) and carefully ground a small "grease ring" in the center of shaft fit area in the cover. I used marine grade wheel bearing grease as the lubricate of choice. Then I changed the oil and used Shell Rotella 5-40 W synthectic oil which has the highest flash point of most off the shelf synthetic oils and resonably priced at $17.00 a gallon/3.7 L. So far no problems since this maintence/ modification. I been riding in 50 to 57 degree mornings in the past 10 days. But I do believe engine oil breakdown was the most contributing factor to this problem.














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After close to 25K miles (I'm the original owner) I pulled the counter-shaft cover off yesterday, not due to hard shifting, but 'cuz I wanted to check the sprocket (my original chain needs to be replaced) for wear. Thank to JonF's pictorial, it was very easy to see ahead of time how everything fits together.

My cover came off with no drama, although I had my rubber mallet standing by. I scraped as much muck out of the inside of the cover as possible, then blasted it with contact cleaner, followed by compressed air. There must've been a pound of gunk in there, not including the rubber bushing (the forward mount point for the plastic side cover) that I lost a few thousand miles ago while doing some under-tank tasks. I also discovered that the bolt securing the electrical switch (I assume the neutral safety switch) just forward of the counter-shaft was loose, so be sure to check yours while you've got the cover off.

After cleaning the shifter shaft, I found that the portion of the surface of the shaft that goes thru the hole in the cover was rough, so I attacked it with 1000 grit sandpaper, then wet 1000, then Crocus cloth, then wet Crocus. If I had more time, I would've hit it was my Dremel tool and polishing wheels. But even with only about 10 minutes work, the surface of the shaft is nice and smooth. I also carefully used Crocus cloth on the inside surface of the hole thru which the shaft goes. On assembly, I smeared a little high-temp grease on the shaft and in the hole in the cover. Went for a 150-miler this morning thru the PA countryside; the shifting action is noticeably easier and smoother. Maybe I hadn't noticed how it had changed over time, or perhaps its even smoother than when new with the now semi-polished shaft.

OMG! I don't think I have ever gained such a change for such a small effort. I just completed this maintenance and I am shocked at how easy it shifts now.

I was off the bike for about a 10days and when I got back on it was suddenly hard to shift into neutral. I was afraid the clutch cable was going on me. I decided to try this first and I can't believe the difference. Although, I am still having trouble shifting into neutral. This time it's because it shifts so easy that it just slips past neutral into the next gear. Guess I gotta learn to ease up on the shifter.

Thanks for such a simple fix. The hardest part was getting the cover off the shifter shaft. This is gonna be a yearly project from now on.

Originally Posted by wineguy

Good post, Jon. I clean that area once a year just for the heck of it.
On my ZR, the only time I have trouble shifting is when it is time for an oil change. Seriously, as I approach 3K miles the tranny lets me know "it's time for an oil change" because it doesn't go into 5th as easily and assuredly as it does with fresh oil.
Just wondering if anyone else has this "early warning" feature built in to their ZR.
Jim

why would the oils age have anything to do with the shifting?

Can/t explain it myself .... But when I find it hard to shift into neutral ,,,, its time to change my oil ... About 3-4000 mile intervals ..... Shifts like hot knife thriugh butter than .... Berto ,,,, have a clinical answer ....???

Originally Posted by cobjerry

Can/t explain it myself .... But when I find it hard to shift into neutral ,,,, its time to change my oil ... About 3-4000 mile intervals ..... Shifts like hot knife through butter than .... Berto ,,,, have a clinical answer ....???

You share oil with the Engine, every impurity (dirt/fuel) and breakdown in oil is "shared". It wouldn't seem it should make that much difference, but many of us have noticed the difference.

Clinically speaking, "if it works, do it!"

I just did the JonF Shifter clean, because for some reason when Im gunning it, when I shift from first to second, it sometimes shifts back to nuetral even though I firmly put it in second. Its a a very dangerous jerk when it happens, and throws my passengers head into mine.

The cleaning helped a bit, but didnt cure it. Any ideas?

Originally Posted by nightviper19

I just did the JonF Shifter clean, because for some reason when Im gunning it, when I shift from first to second, it sometimes shifts back to nuetral even though I firmly put it in second. Its a a very dangerous jerk when it happens, and throws my passengers head into mine.

The cleaning helped a bit, but didnt cure it. Any ideas?

make sure the shifter is adjusted for you. if you're leaning forward while accelerating aggressively you may not be shifting all the way up. Also if you dont wear sturdy boots your shoe (or flipflop) can flex and not shift fully. Also, are you due for an oil change?

Originally Posted by JonF

make sure the shifter is adjusted for you. if you're leaning forward while accelerating aggressively you may not be shifting all the way up. Also if you dont wear sturdy boots your shoe (or flipflop) can flex and not shift fully. Also, are you due for an oil change?

Wise words. Now that I think about it, I do hug the tank and change my riding position for hard acceleration, so Im probably not pushing it up all the way. Im not a tool, I dont wear flipflops on a bike...

I just changed my oil, say about 60 miles ago. PM sent.

This is my first time on the forum. I have a 2001 with 45000 miles on it. It is my primary transportation here in Hawaii. I have noticed a lot of transmission/clutch noise on shifting. For this reason, I have disassembled the covers and clutch assembly numerous times (at least once a year) looking for trouble. Funny thing, the noise usually went away every time I took it apart, regardless of finding no problems. Never understood it...guess it must have been the clean and lube during the reassembly. However, at this mileage, I was having more difficulty shifting. I replaced the entire clutch assembly approx 6 years ago cuz my ex-husband rode wayyyy to hard. Bought brand new clutch cable recently and still had trouble. Finally caved and adjusted attachment point one notch from recommended on the shaft out of the case. Drives like a dream now. Just wondering if anyone else noticed this?
Any other problems I should look for at this milestone?

I bought this 2000 zr7 and the guy had the carbs off and didnt finish.... can you possible take some pictures of how the hoses run under the take? I got like 3 connections on the carb, 2 on the tank plus the petcock connections....

markmess2000@yahoo.com

Try these

End

I have just checked mine after seeing these pictures & believe they changed the design cause my gear shift shaft is outside the chain housing. not sure when kawa redesigned this, I own a 2006 model.

Really nice & clear though welldone

Just did the Shifter Clean and definitly helps with shifting. and i found out its time for a new front sprocket.