Hard shifting

Hey people. I used to have 82 police and now I found 93 with only 5k miles. Problem it’s been sitting for while and has few issues like usually. Biggest one is very hard shifting to 2nd from neutral then hard all the way up and back all the way down to neutral. 1st gear is good. Linkage is stiff (I thought that was the issue)  so I tried to loosen it but left treaded side still stiff ( I will order new one). So I removed linkage and used pliers to shift directly and it’s extremely hard to go to second. Any help is appreciated 

Clutch plates could be fused together. With clutch lever pulled in, clutch disengage, trans in 1st, can you push the bike? Not sure on you model but most Kz bike will only shift from neutral on up if the bike is rolling. 

Please explain “linkage”. 

Thank you. I see. I just put bike in first (not running) pulled the clutch and tried to push it. It would not budge. That means clutch plates fused? What’s the solution to this problem? 

Does it feel like the clutch lever is doing anything?   
I would do a basic clutch adjustment as per the owner's manual or factory service manual.   
On some models you're supposed to turn the clutch release adjusting screw Counterclockwise first until hard to turn,  then clockwise 1/4 or 1/2 turn.  It's kind of counter-intuitive.  The 93 1000-P12 has the same adj. screw as my motorcycle which is ccw first.

I like Martins question. Do you feel any resistance in the clutch lever. If it’s working correctly it should feel floppy/loose the first 1/4” or so of pull then you should feel it get harder to pull. It should have a smooth pull all the way till the handle stops at the grip. You should find a factory service manual and do a clutch cable, release adjustment. Its the easiest first adjustment towards finding the problem.

If it feels like the clutch lever is functioning, you can sit on the bike not running, pull in the clutch and try to rock the bike back and forward to see if it will break the plates free. What happens sometimes when a bike sits is the fiber plates will bond to the steel plates. If it won’t free up then a clutch disassembled and inspection is necessary. 

Also, make sure the clutch inner cable is running freely in the outer sheath.
It's not uncommon for cables to seize up after sitting unused for prolonged periods, they can become dry, corroded and stick together then when you try to use it , it will fray.
Also check the cable where it runs near the exhaust to make sure it has not been badly heat affected/melted.
Good luck.

wrote:

Does it feel like the clutch lever is doing anything?   
I would do a basic clutch adjustment as per the owner's manual or factory service manual.   
On some models you're supposed to turn the clutch release adjusting screw Counterclockwise first until hard to turn,  then clockwise 1/4 or 1/2 turn.  It's kind of counter-intuitive.  The 93 1000-P12 has the same adj. screw as my motorcycle which is ccw first.
Yes clutch is working plus I when I start the bike I shift easily into first from neutral . 
 

Awesome. So I put it in first (not running) and rock it back and forth. Got you. 
yes I think clutch is working properly or it would not shift into first when started. Would it? 

My bikes, Kz900, 1000’s will down shift from neutral to first and back without touching the clutch lever. 

By dimanya:  Awesome. So I put it in first (not running) and rock it back and forth. Got you. 
yes I think clutch is working properly or it would not shift into first when started. Would it? 

My way is to check & adjust the simple stuff first as per the Kawasaki service manual.  Do the adjustment, double check your work, then go on to the next thing.  My neighbor bought the same motorcycle as mine.  Took a trip, then encountered clutch/shifting problems & limped home.  He took the clutch apart & bought a new cable & I forget what else he did.  Turns out the clutch just needed a basic adjustment.  Check the easy stuff first >> doing so usually doesn't take much time or effort & often times should be done anyway as normal maintenance.

Excellent advice Martin CSR!  Same holds true for most areas.  I learned a long time ago to check grounds first when encountering electrical problems and the next step is battery condition.  Too many people want to jump in with both feet and go for the difficult stuff first.

Rick H.

It may very well be that he has bigger problems. but you never know sometimes. hee.  It's a police bike, so it may have had a rough life.