wont stay in second

ScottaKR · Post by **ScottaKR** » Mon Dec 28, 2009 3:08 am

Took the KR1 out for a run around the block today after sorting out the running issues, got her into second and decided to open it up but as soon as it hit the powerband she jumped into nuetral. Tried it again a few times but it does it every time.

Any ideas people?

250 drummie · Post by **250 drummie** » Mon Dec 28, 2009 8:16 am

Does it do it in the other gears if so then I would say that your selector drum is not engaging fully. Check the position of your gear lever and make sure there is nothing fouling it. If all is well with the lever you will have to remove the clutch cover and inspect the arm on the drum. These can get damaged by muppets riding them in a past life. I have seen them snapped in half.

JanBros · Post by **JanBros** » Mon Dec 28, 2009 7:52 pm

or second gear is worn out. not the gear itself but the "blocks" on the side of the sliding gear-sprocket that hook into the fixed sprocket next to it, haven worn and are now rounded.

ScottaKR · Post by **ScottaKR** » Mon Dec 28, 2009 10:28 pm

Thanks guys.
I'll check the gear lever, but if there's no problems there I think I'll just throw another box in it. Otherwise I could be chaseing this one for ages I think.

TwoStroke Institute · Post by **TwoStroke Institute** » Tue Dec 29, 2009 3:47 am

I'll check the gear lever, but if there's no problems there I think I'll just throw another box in it. Otherwise I could be chaseing this one for ages I think.

Soap and water for you ! Ronded dogs are a cinch to fix and cheap as well. $75AUD to undercut dog and mating slot. Even a custom gear ratio is $250 for one or $500 for both driver and driven gears.

Tambo · Post by **Tambo** » Tue Dec 29, 2009 9:58 pm

ScottaKR wrote:Thanks guys.
I'll check the gear lever, but if there's no problems there I think I'll just throw another box in it. Otherwise I could be chaseing this one for ages I think.

I wouldn't go changing a whole box yet - you should be able to see the wear causing the problem on the engagement of the selector drum, or the dogs of the gear (as per Jan & Drummie). My money is on either of these, although there's an outside chance it could be gear shaft bearing that's gone, but that would be noisy, and cause lots of shifting issues

Keep at it !! Good luck.

Sheik Yerbouti · Post by **Sheik Yerbouti** » Wed Dec 30, 2009 3:30 am

Yeah sounds like drive dogs, TSI is right, its a pretty simple job to undercut them. But we used to charge $100

I'd go with the $75 option.

ScottaKR · Post by **ScottaKR** » Wed Dec 30, 2009 4:14 am

Sheik Yerbouti wrote:Yeah sounds like drive dogs, TSI is right, its a pretty simple job to undercut them. But we used to charge $100
I'd go with the $75 option.

Or I can just go though the spares I have here and dig out a good one.
Then I can spend the $75 I save on some Scotch to help ring in the new year.

$\:D/$ $\:D/$

Sheik Yerbouti · Post by **Sheik Yerbouti** » Wed Dec 30, 2009 9:05 am

Or I can just go though the spares I have here and dig out a good one.
Then I can spend the $75 I save on some Scotch to help ring in the new year.

I can't argue with that. Settle yerself doon with a nice bottle of Dimple then...

Sheik Yerbouti · Post by **Sheik Yerbouti** » Wed Dec 30, 2009 9:14 am

Or I can just go though the spares I have here and dig out a good one.
Then I can spend the $75 I save on some Scotch to help ring in the new year.

I can't argue with that. Settle yerself doon with a nice bottle of Dimple then...

ScottaKR · Post by **ScottaKR** » Tue Jan 05, 2010 12:37 am

Would a worn selector drum also cause it to not want to downshift properly?

symtec23 · Post by **symtec23** » Tue Jan 05, 2010 12:52 pm

My kr1 would do this and was also damm impossible to shift down from second to first. Ended up being a flogged out shift drum and dammaged dog teeth on second gear. Once I replaced complete box, it changes gears as smooth as butter. If you have a spare box, just swap it out as it will only get worse.

ScottaKR · Post by **ScottaKR** » Tue Jan 05, 2010 2:10 pm

symtec23 wrote:My kr1 would do this and was also damm impossible to shift down from second to first. Ended up being a flogged out shift drum and dammaged dog teeth on second gear. Once I replaced complete box, it changes gears as smooth as butter. If you have a spare box, just swap it out as it will only get worse.

Yeah, that's what I ended up doing this arvo. It no longer jumps out of gear, and it shifts up & down really well, but it's still not perfect. When the engines at idle (or below about 2k) in neutral, it sounds like someones dumped a bag of marbles in there.

Put it in gear or pick the revs up and the noise disapears completely. Not sure why it's only under those circumstances (shagged bearings perhaps?), but I think it may have to come out.
Maybe I can make one good gearbox out of the two using the gears from the first box and the selector/shift mechanism from the second box.

JanBros · Post by **JanBros** » Tue Jan 05, 2010 7:26 pm

Scott, sounds more like the flywheel is just a teeny bit loose.

better check that before you take out the gearbox again.

and if not that, is the cluch-basket beaaring still ok ?

garye345 · Post by **garye345** » Tue Jan 05, 2010 8:33 pm

JanBros wrote:Scott, sounds more like the flywheel is just a teeny bit loose.

better check that before you take out the gearbox again.

and if not that, is the cluch-basket beaaring still ok ?

+2 on that scott,mine did exactly the same.Does'nt cost any thing to tighten a bolt.

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