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I have a 6 month old Kawasaki W800 I bought new. Sometimes when I ride gear changes seem stiff and clunky. Other times they seem smooth and normal.

Would anyone know what could be causing this? Doesnt seem to matter if the engine is warm or not.

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How did break in procedure go? Did you do first (early) oil change? Remember, many motorcycles have wet-sump clutch and gearbox sharing the case with the engine, so they use that very oil. Also, switching to synthetic, may help. My shifts got much better after swapping out stock mineral oil to Rotella T6. By the way, W800 is a gorgeous motorcycle. – theUg Dec 11 '13 at 1:12
@theUg yeah break in was fine - I followed the manual and kept revs under 4K for the first 1500klm. I did an oil and filter change a few weeks back to synthetic but the issues is the same. – MeltingDog Dec 11 '13 at 1:32
Have you checked your Owner's manual? I know that my 2009 Kawasaki Vulcan 900, was recommending different maximum speed for gear changes, depending on how many miles you have, you might still be in break in period. – Vladimir Oselsky Jan 13 '14 at 16:18
I am experiencing the same issue. My local Kawasaki service says everything is OK, however it is completely not pleasant to ride this motorcycle because of this harsh gearbox. Did you fix your problem? – jacek May 5 at 8:15
@jacek No. After replacing and fiddling around with the clutch cable tension with no changes I've sort of just accepted it :/ – MeltingDog May 6 at 1:46

2 Answers 2

As the motor cycle is 6 months from new I would recommend putting it into the suppliers repair shop under warranty. If you were to attempt any sort of dismantling to effect a repair you will more or less invalidate any warranties for the motor cycle.

The symptoms point to either a clutch or gearbox fault.

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It's a Kawasaki, I've ridden two before and they both had fairly clunky gearboxes (especially between gears 1 and 2), it's quirky!

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