Gearbox housing elements (models produced before 2000)
1 - clutch housing;
2 - secondary shaft;
3 - intermediate shaft;
4 - primary shaft;
5 - gear shift forks;
6 - oil tray;
7 - gearbox housing;
8 - Reverse light switch;
9 - 3rd gear engagement fork;
10 - back cover;
11 - 5th gear pinion;
12 - intermediate gear;
13 - breather;
14 - axis of the idler gear of the reverse gear;
15 - reverse gear parasitic gear;
16 - speedometer drive gear.
Mount the gearbox on a suitable stand or workbench.
Remove the back cover.
Remove the reverse light switch, gasket and bracket,
Unscrew the plugs, remove the springs and balls.
Remove the speedometer drive gear assembly and breather.
Remove the pin using a punch.
Remove the cotter pins from the input shaft and intermediate shaft lock nuts.
Engage the reverse gear of the main gear using the control levers.
Install the mandrel on the primary shaft. Screw a 10mm bolt into the hole on the clutch housing side and attach the handwheel handle to the mandrel to remove the lock nut.
After unscrewing the reverse intermediate gear shaft bolt, remove the gasket.
Disconnect the final drive housing from the clutch housing.
Remove the differential seal and guide.
After unscrewing the bolt, remove the spring washer and the stopper bracket.
Remove the stop ball assembly, gasket and seal.
Remove the 3 outer bearing races and spacers.
After unscrewing the bolt, remove the reverse gear shift lever assembly and the shift lever shoe.
Remove the idler shaft and idler gear.
Remove the shift mechanism pins, rods and forks (1, 2) of the shift mechanism.
Remove the bearing holder by unscrewing the two bolts.
Raise the input shaft assembly and remove the intermediate shaft assembly.
Remove the primary shaft assembly and secondary shaft assembly.
Secondary shaft elements (1)
Remove the differential drive gear assembly.
Remove 3 bearing rings and guide ring.
Remove the two oil seals, magnet and magnet holder.
Remove the control elements from the clutch housing as shown in the figure.
Caution: Only remove the controls in case of emergency, as the disassembly process involves cutting off the locking plate (4). A new locking plate will be required for reassembly.
Controls (models before 2000.)
1 - clutch housing;
2 - control fork;
3 - gear selection lever;
4 - locking plate.
Disassemble, clean and check the gearbox components.
Check the stems and forks for wear and damage. Replace if necessary.
The gearbox is assembled in the reverse order.
Rods and forks (models before 2000.)
1 - 1st - 2nd gear shift rod;
2 - fork;
3 - 3rd - 4th gear shift rod;
4 - fork;
5 - 3rd gear engagement rod;
6 - clip.
Gearbox shafts (models before 2000.)
1 - clutch housing;
2 - bearing holder;
3 - ring;
4 - oil seal;
5 - primary shaft;
6 - intermediate shaft;
7 - secondary shaft;
8 - differential;
9, 10, 11 - outer ring.