Sticky/hard shifting repair with pics.

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Sticky/hard shifting repair with pics.

This is a discussion on Sticky/hard shifting repair with pics. within the ZR-7 Maintenance forums, part of the Kawasaki ZR-7 category; The ZR's shifter gets stiff and sometimes sticks up or down due to road grime, old chain lube accumulation, and lack of lubricant on the ...

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  1. #1
    Johnny Blue Lightnin'
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    Sticky/hard shifting repair with pics.

    The ZR's shifter gets stiff and sometimes sticks up or down due to road grime, old chain lube accumulation, and lack of lubricant on the shift shaft where it goes through the countershaft sprocket cover.
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    Jon

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  2. #2
    Johnny Blue Lightnin'
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    You need to to remove the countershaft sprocket cover, clean and lube the shift shaft and the hole in the cover. I use waterproof marine grease because I already have it. Any type of grease will do.

    The first step is to scribe the shift shaft so you properly re-aign the linkage upon assembly. Then remove the shift linkage from the shaft.
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    Last edited by JonF; 11-09-05 at 03:29 PM.
    Jon

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  3. #3
    Johnny Blue Lightnin'
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    I also remove the shift lever pivot bolt and lube it too. Make a note of the direction of the linkages so you dont get confused on reassembly.
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    Jon

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  5. #4
    Johnny Blue Lightnin'
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    4 bolts hold on the countershaft sprocket cover. One is somewhat hidden behind the shift shaft. The bolts are all the same size. you may need to tap the cover with a hammer handle or block of wood. It has 2 dowel pins to align it and it often gets stuck on the shift shaft. Spraying rust penetrant on the shift shaft may help it come off easier. After you get it off make sure you have 2 alignment pins and all of the rubber bumpers on the back of the cover.
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    Last edited by JonF; 11-09-05 at 03:20 PM.
    Jon

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  6. #5
    Johnny Blue Lightnin'
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    This shaft has been lubed before and is not sticking. You can see how stuff accumulates on the shaft and in the hole.
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    Jon

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  7. #6
    Johnny Blue Lightnin'
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    Here you can see the chain lube buildup inside the cover. The red dust or rust is from my worn out chain.
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    Jon

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  8. #7
    Johnny Blue Lightnin'
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    The first pic is the countershaft sprocket and the shift shaft. The second pic is the shift shaft cleaned and ready to be lubed. I also cleaned the inside of the cover and the shift shaft hole in the cover but I forgot to take a pic of it. Lube the shaft and the hole in the cover, lube, and reassemble. The bolts for the countershaft sprocket cover are torqued to 104 in/lb.
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  9. #8
    Supreme Being AndreL's Avatar
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    Bravo John! These photographs take care of what I believe is the most common complaint about the ZR-7. Well done.
    André
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    what do you have growing in there? not riding enuff and your bike starts to grow weeds, hehe !! thanks for the info. i haven't opened mine up yet and i'm close to 50k now...i suppose at the next chain change i'll open it up i haven't got any "stickyness" in my shifting or perhaps i've just gotten used to it but i can still find every gear no problems first try...
    "Group rides are simple, we all go together, we all come home together"

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  11. #10
    Johnny Blue Lightnin'
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    I forgot to take a few pics along the way but I think most people will get the idea.
    Jon

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  12. #11
    wineguy
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    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

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    Gold Member/Community Dad Berto's Avatar
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    Quote 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
    A few folks have noticed this. I haven't noticed it since running on Amsoil Synthetic. Even at 4.5k miles til an oil change.

    Could be the tranny's sharp edges are a little rounded off with some mileage .
    Berto
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  14. #13
    Johnny Blue Lightnin'
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    I've never had any shifting issues related to the ZR. Just an occasional new boot or lazy left foot.
    Jon

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  15. #14
    J2X
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    While I'm riding I *usually* don't have any trouble shifting, but I always have trouble popping it up into neutral when I'm stopped at a light. Takes a LOT of pressure to get it to cooperate. is this the shifting trouble that this procedure was written to address?

  16. #15
    Johnny Blue Lightnin'
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    Quote Originally Posted by J2X
    While I'm riding I *usually* don't have any trouble shifting, but I always have trouble popping it up into neutral when I'm stopped at a light. Takes a LOT of pressure to get it to cooperate. is this the shifting trouble that this procedure was written to address?
    This may help you with that. Also check your clutch cable adjustment and make sure your oil is not past due for changing.
    Jon

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