Gearbox failure

[dirk]

Hi Guys

no luck with my KR

while driving i could found from one moment to another no more gear.
the Neutral lamp was out, but there was no gear in it.
i had to roll out the bike.
in standing, when I press down (or up) the shift lever and I turn the rear wheel, it feels as if a gear would be in there.
but I also hear something clacking.
if I release the shift lever, the rear wheel turns freely again. as if the idle would be in there.
it is impossible to insert a gear.

has one an idea?

cheers
Dirk

[DougB]

Could be a lot of things Dirk, but I'd start by taking the gear lever off and removing the cover from the shift selector casing. Make sure everything is in place (especially the selector drum end bolt) and any return springs.

If you get in there and all seems ok, remove the gear selector assy (this is the shaft that the gear lever front knuckle clamps onto) from the selector barrel. Turn the selector barrel using a socket on the end bolt and extension bar while turning the rear wheel slowly, check it goes through all the gears and has a neutral.

Let us know how you get on, Doug.

[Garry]

If you mean you can't select 1st or 2nd gear from neutral I have had this happen twice before

Luckily it was an easy fix

If you remove the small cover behind the gear lever (as Doug has said) - the problem each time was that
a return spring had broken

Hopefully this is all that is causing your trouble

[dirk]

Hi Guys

the spring is broken.



unfortunately, the mechanism of my spare engine is different (from KR1 ?).
the spring is much shorter.



i'm a little unsure
i can very easily and widely rotate the drum.
is that normal?
http://www.divweb.com/rd/mykawa/shift_drum_kr1s.m4v

cheers
Dirk

ADAC....

[JanBros]

i can very easily and widely rotate the drum.
is that normal?

it all depends on the position of the sprocketts on both gearbox axes. sometimes you can go through several gears at once, sometimes you can not engage a single one.
while turning the rear wheel, you should be able to engage each gear and check that (if you turn the rear wheel) the speed of the front gearbox axe slowes down the higher the gear you engage.

[dirk]

Thanks for the explanation Jan

what is the correct part number (long spring) for my engine?

springs are no longer available.

and now???

[500bernie]

Hi Dirk
Try Cradley kawasaki, they appear to have them in stock (check your model and frame number range, C3 UK are still available).

http://www.kawasakioriginalparts.com/ka ... 1991&ca=GB

Cheers
Bernie

[dirk]

Hi Bernie

Thanks for the address .
Unfortunately NLA

fits a spring from another motorcycle ?

is my ( long ) cracked spring from the KR1S or KR1 ?

cheers
Dirk

[KR-1R]

both springs are no longer available japan 92081-1709 92144-1448
stocks could be different in EU
many engineering shops sell partitioned boxes of extension compression tension spring assortment

you might look at side stand springs or brake pedal springs...
92081-1296 92145-0105

92144-1185

[JanBros]

it's a spring, just find one that fit's with some tension and it wil do the job.

[dirk]

it's a spring, just find one that fit's with some tension and it wil do the job.

I've already asked in some motorcycle shops.
nothing to find.
The problem is the long hook.

[JanBros]

make your own. springs can be bent

[dirk]

I have a spare spring.
Many thanks to Jarno! =D>

make your own. springs can be bent

Jan, i work in the IT.
should I gouge out an eye?

cheers
Dirk

[Garry]

When you fit the spring i would check that it does not rub against any moving parts

As i recall there are different ways of fitting it - and i think constant contact with the change mechanism
could have worn it through