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Originally Posted by zx600d
Im also experiencing this problem on my ZZR600 and it's got 38000 km on it. Gear shift is tough and makes a clunk noise when I shift. Also, when im standing still and put it into first the bike jumps forward. Is this a clutch or gearbox problem?
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There is an excellent explanation for this in the current issue of Cycle World. It's in the "Service" section by Paul Dean. I couldn't find a link to post, but I will sum it up:
A reader asked about an '04 zx6r. His question was about a loud clunk shifting into 1st gear, and he said that his bike even lurched forward a bit when he made this shift.
Mr. Dean answered that the transmission mainshaft still spins even though clutch is engaged. When you engage first gear, and the mainshaft and countershaft gears mesh, the mainshaft is brought to a sudden halt(!).
He aslo advises this can be reduced by ensuring your idle speed is correct and by not "blipping" the throttle before you shift into gear.