Question about 2006 kawasaki ZZR 250

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Having trouble with the clutch/gears

I have a problem with my ZZR250 which has slowly been getting worse over the last few days. Before I first start the bike to warm it up, it has trouble getting into neutral. I have to "pump" the clutch lever a few times to find neutral before starting. While riding I also have to pump the lever sometimes to shift up or down gears.
This happens randomly and it is like trying to force the bike into gear even with the clutch lever in. The only thing to get rid of the forcing effect is to pump the clutch a few times.

Initially i though that it might be a clutch cable problem but i am not sure how to adjust or tighten it. The engine was low on oil a few days prior to this happening, but never had trouble with the gears before topping the oil up and am not sure if the gearbox and engine share oil. Not sure how to check gearbox fluid levels if they are seperate.

Seems to happen more at night when it is colder... possibly something sticking?? Any help appreciated :)

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Hi and welcome to FixYa,

To my knowledge, the engine and the gear/transmission share the same oil in the crankcase. Clutch cable adjustment on most bikes could be done 2 ways:

  • after the clutch lever itself. There would be an adjustable end of the cable. It is locked in place by a coin like nut with grooved edge. This locked must be loosed before the cable end could be adjusted.
  • similarly at the bottom end of the cable that attaches to the clutch arm, the cable end would also have a thread end. There would be 2 lock nuts that must be loosened up.
You can experiment clutch play/slack to your personal preference. Soon as you are satisfied (number of tries clutching/engaging gears), then the locks could be tightened in place.

Good luck and thank you for using FixYa.

Posted on Mar 07, 2009

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