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Trouble down shifting FWIW, I had the same problem last spring. At one point it was so bad I thought I had bent something in the shift mechanism by down shifting too hard. Problem went away when I adjusted the clutch cable per the manual to take out some extra slack..and I changed my oil, for the first time, from mobile 1 red cap, to Shell Rotella T, and discovered that it had been overfilled. Not sure which of the three solved the problem, but I suspect it was the clutch cable adjustment. It's been shifting great ever since. RB
Overfilling the oil will result in hard shifting. Check the level and don't fill to the Kawi spec, which is too high. I use the sight glass and fill to the top, leaving a little bubble at the top. Also, the clutch lever and cable should be checked to make sure you're fully disengaging the clutch.

I experienced similar problem with 2004. I asked a mechanic at a Kawa dealer about this and he said our transmissions are not designed for consecutive down shifting (i.e. shifting from 5th to 2nd/1st and bypassing 4th & 3rd). It had something to do with gear speeds not matching up all the time. Maybe he was blowing smoke but I've changed my shifting technique and have been downshifting thru 4th & 3rd before I come a stop and I don't get anymore lever hang-ups. I never experienced a lever hang- up shifting 3rd to 1st.
 
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