gearbox issue

[Mouser]

So, what I also noticed these 2 rides is that the gearbox is really hard to shift, compared to RGV, FZR...
I changed the gearbox oil, yes it is the correct one and there is enough too.

Thanks
Chris

[Luders]

Might be worn, I've never had any issues and have about 7-8 KR-1S gearboxes

[Mouser]

What could it be? Any idea?

[Luders]

When you say it's hard to shift, how exactly do you mean? Does it occur between and specific gear shifts?

[Mouser]

No, it's all the time in every gears hard to shift. Even whith the engine not running, I tested it by hand, it's hard to shift from 1-6.

[KR-1R]

.
.
first check the nut adjustment of clutch cable at clutch (engine) end
if its loose or not standard (5-6mm) this seems to affect leverage ratio and gear engagement
check you have 80-90° of the actuator arm
[consult 5-4 sevice manual for photos]

then adjust free play at handlebar lever end

[Mouser]

Ok, thanks KR-1E, I'll check that tomorrow!

Thanks
Mouser

[KR-1R]

the angle and linkage of the foot lever can make a big difference in how clunky the gears engage

do these first before you neef tto open engine

[Luders]

When you move the lever up and down in the free play area before the gear gets selected, is that okay?

[JanBros]

and check that the lever isn't worn where it pushes against the push rod.

[Mouser]

I adjusted the foot lever.

I adjusted the freeplay of the cable.

Nothing changed

The freeplay between the gears feels very easy, it's the engagment itself.

Could it be some part of the external shift mechanism (behind the ext. shift mech. cover)?

Thanks
Mouser

[Luders]

Unlikely, it sounds more like the relationship between the drum and selector forks.

Sounds like you're going to have to get in there and take a good look around I'm afraid, there's no easy solution.

[Mouser]

ok...

Most scaring question of course .

Do I have to take out the whole block?

Thanks
Mouser

[Luders]

No, but you do need to remove the clutch inner and outer cover

[Mouser]

Hi again,

So I had a good look at the outer shift mechanism.

You won't believe it but it was the spring tension which made the shifting so hard.

The spring which connects the lever to the outer part of the drum.

The lever disconnected the drum turn very easily with the hand.
I just tore the spring a bit to get it about 1-2mm longer.

Now the shifting is very smooth!

Thanks for the help anyway.
Mouser