KR-1S.co.uk Forum

it came out easier enough when I split everything down to get it all rebuilt. But now when I try to slide the casette back in, the clutch shaft pokes through Ok, but the output shaft snags on something inside tha case and stops it going all the way through. It came out easier enough.

I was thinking of splitting the halves again, putting the gearbox in, then torquing up again......groan

So much for JUST putting the gearbox in....Grrrr

Not sure if there is a knack. I found the same as you - only done my box a couple of times. Providing the cluster is correctly assembled, i inserted the cluster into the engine, with the gears in 'first gear' .

I think it was the selector rods not correctly locating in the holes at the clutch side. Having it in gear seemed to keep everything 'tight'

Hope that helps. Buz

Mine went in with no problem.

after spending a few hours scratching my head, shining a torch in the case and muttering under my breath, I eventually split the cases again.
I then stumbled upon the correct technique of getting the gearbox back in with ease.
Although, I had the circlips and washers in the correct order, I didn't take into account that one of them should go on the outside of the gearbox casing, so that when the shaft pokes through, its a washer, gear, washer, circlip combination.
Doh -

Anyway, all (nearly) back together now to finish off tomorrow

sorry, havent been here to reply sooner. i find that turning the offending shaft seems to help. in can be awekward when in situ but it gets easier. you may have to jiggle it a bit aswell. the hard bit it making sure you dont knock the sealant as you tilt the cassete past the frame/ignition gubbins/gear lever bracket ect. also irc i have used something to help get the shaft through the housing such as a screwdriver - this also helps take the weight, it gets heavy and turns into a bit of a juggling act.