Question about kawasaki ZZR 600 Motorcycles

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Kawasaki ZZR 600 clutch noise

Hi i got a problem with gearbox?clutch noise?while im rideing and start breaking harder i can hear horrible clunking noise from the engine,or if i put it on a center stand,start engine,select first gear,let the cluch i can hear very metalic clunking when pressing rapidly rear brake:/ what is it?even gear change seems to be to loud,i did hear they are very noisey,but this one is a bit to much i think:(,i had the same problem with en500 with belt transmission,kawasaki zzr600 2001year,thanks a lot

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  • kawasaki Master
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Hi, Tompolv6 I would love to help you with your engine or chassis noise but I just loaned my brand new pair of listening ears to your local dealer's chief technician so he could take your bike for a test ride and give you his professional opinion and estimate about your noise and repair cost. If you are a little short on "DRACHMA" and a Dealership is not on your list of fun places to visit then perhaps the list below will help soothe your worried mind so you can make an informed decision.
1. Bearings---SCREECH
2. Belts---CHIRP
3. Brake Rotors---BUZZ
4. Chains---RATTLE
5. Clutches---CHATTER
6. Cylinders---PING
7. Fairing Panels---WHISTLE
8. Fronk Forks---Plunk
9. Gears---WHINE
10. Head Gasket---HISS
11. Hydraulic Lifters---TAP
12. Pistons---SLAP
13. Rear Shocks---SQUEAK
14. Shifting Trans---CLUNK
15. Solid Lifters---TICK
16. Starters---CLICK
17. Connecting Rods Go---KNOCK-KNOCK---who's there, it's me "*****"
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
03 zzr600 Loud clunking noise at idle
zzr600 clutch noise
Kawasaki ZZR 600 Complete Service Repair Manual Download Manuals Technical $10
OEM Parts for Kawasaki
2006 Kawasaki ZZR600 Owner Manual

Posted on May 25, 2017

4 Suggested Answers

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  • 2 Answers

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Posted on Jan 02, 2017

  • 2 Answers

SOURCE: 04 Sportster 883 gearbox Clunk.

pull the clutch lever in and out several times before droppin it into 1st its sort of get n use to it mental dirt bikes have the same set up

Posted on Sep 06, 2009

wd4ity
  • 4565 Answers

SOURCE: My Harley 883 Sportster suddenly became stuck in 5th gear.

More than likely the shifter pawl has broken. Breaking in 5th gear is kind of unusual however, they usually break between first and second.

You'll have to remove the outer primary cover to look at the shifter pawl. It's partially covered by the clutch assembly.

Posted on Mar 07, 2010

Testimonial: "Thankyou for your help, I have been looking at an exploded drawing of the Sportster gearbox, so I can see what you mean."

  • 4088 Answers

SOURCE: 2008 Z750 bad grinding noise in first gear

It is possible that the first gear shift fork in the transmission is bent causing the 'dog-clutch' between two gears to just barely mesh. With engine off, push the shift into first and clutch lever released. Rock the bike back and forth to see if the gearing seems to be jumping in and out. There may be a problem with the shift lever shaft mechanism not allowing a complete shift into first gear. Hope this helps!

Posted on Apr 11, 2010

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Hi, Anonymous I would love to help you with your engine or chassis noise but I just loaned my brand new pair of listening ears to your local dealer's chief technician so he could take your bike for a test ride and give you his professional opinion and estimate about your noise and repair cost. If you are a little short on "DRACHMA" and a Dealership is not on your list of fun places to visit then perhaps the list below will help soothe your worried mind so you can make an informed decision.
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Hi, Jayikonic nice novella I would love to help you with your engine or chassis noise but I just loaned my brand new pair of listening ears to your local dealer's chief technician so he could take your bike for a test ride and give you his professional opinion and estimate about your noise and repair cost. If you are a little short on "DRACHMA" and a Dealership is not on your list of fun places to visit then perhaps the list below will help soothe your worried mind so you can make an informed decision.
1. Bearings---SCREECH
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4. Chains---RATTLE
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9. Head Gasket---HISS
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For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
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I am hearing a clunk when breaking with in town driving..not all the time. Took to repair shop, put on new struts in front. Still hearing the clunk occasionally.


It sounds like a cv joint noise how dose the steering wheel feel dos it shake side to side when brakeing truthfuly im not that formilar with your car but its a front end problem. New struts would help but not completly elimitate it. Im not sure if the engine is inverted on your vehicle is it front wheel drive if so its likely cv joints

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1 Answer

My car is a 94 325i manual. it goes into gears much better when it's off but when it's on it will not shift into gears and if i force it i hear a horrible grinding noise.


you have 2 choices either the clutch is not disengageing properly or the gearbox is shot.put the car in first,put the clutch pedal down, then start the car and if its trying to pull away before you take you foot of the clutch you have you answer....if its the clutch cable you can adjust it..

Aug 26, 2010 | 1994 BMW 3 Series

1 Answer

2009 street glide when I let the clutch in first gear I hear A clunk noise


If your engine is running with the clutch out and you pull in the clutch and put the transmission in first gear, you'll hear a clunk, this is normal. The reason is that although your transmission is a constant mesh transmission it is not a synchronized transmission. I don't know of any motorcycle that has synchronizers in the transmission. When the engine is idling in neutral with the clutch out, the gears and shafts in the transmission are spinning. When you pull the clutch in, wait a second or two for the spinning transmission components to slow down or stop spinning before you kick the transmission into low gear. The hotter the transmission is, the thinner the lubricant in it and the longer you need to wait.

A clunk is normal but if the bike trys to pull forward and you have to hold the front brake to keep the bike from moving or you cannot find neutral with the engine running, you need to adjust the clutch. To adjust the clutch, find the rubber bellows in the middle of the clutch cable. Slide the bellows up and break the locknut loose. Shorten the cable as much as possible. Remove the derby cover from the left side of the primary cover. In the center of the clutch assembly, you'll see a clutch release rod adjustment. Break the locknut loose and adjust the center bolt inwards until a resistance is felt. Do not force the bolt, just until a resistance is felt. Back off on the bolt 1/2 to 1 full turn and lock the nut. Replace the derby cover and adjust the cable so that you've vote about an 1/8 inch of freeplay at the clutch lever. Lock the lock nut and replace the bellows. Good Luck, Steve

Apr 28, 2010 | 2008 Harley Davidson FLHX Street Glide

1 Answer

My Harley 883 Sportster suddenly became stuck in 5th gear.


More than likely the shifter pawl has broken. Breaking in 5th gear is kind of unusual however, they usually break between first and second.

You'll have to remove the outer primary cover to look at the shifter pawl. It's partially covered by the clutch assembly.

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Auto light comes on when going up a hill or put foot down


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What you do is once the engine is warm, with the engine running you remove the centre plug and is the gearboxs level is low nothing much will come out. Some will come out as the tube gets full from normal running. If it is high the excess will come out and will stop at the ring.

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In effect you have just carried out an transmission service.

I didn't even bother checking the oil level as 3.5 litres is the amount you need to put in and the gearbox has been running perfect ever since. The new oil worked a treat. Snappy changes and the clunking change with the light on stupidity went away.

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1 Answer

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The clunk as you describe could be one of three problems, the steering lower column, the steering gearbox or the constan velocity joints.
The lower steering coloumn viewable from the engine bay below the brake unit has a rubber coupler which breaks and can cause the column to lock up, the steering gearbox which the column mounts to can also fail inside, fiunally the c.v. joints break and will cause intermittant binding of the steering, you need to goto a car park and drive the vehicle full lock left and right and have someone listen for the clunk, if it is coming from the wheel area then its the cv joints.
I would start there, hope this helps
JPTCAT

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