Elements of the gearbox housing (models up to 2000 release)
1 - clutch housing;
2 - secondary shaft;
3 - intermediate shaft;
4 - input shaft;
5 - shift forks;
6 - oil tray;
7 - gearbox housing;
8 - reverse lamp switch;
9 - fork of inclusion of the 3rd transfer;
10 - back cover;
11 - gear wheel of the 5th gear;
12 - intermediate gear;
13 - breather;
14 - axis of the parasitic reverse gear;
15 - parasitic reverse gear;
16 - speedometer drive gear.
Mount the gearbox on a suitable bench or workbench.
Remove the back cover.
Remove the reversing lamp switch, gasket and bracket,
Unscrew the plugs, remove the springs and balls.
Remove the speedometer drive gear assembly and breather.
Remove the pin with a punch.
Loosen the lock nuts on the input shaft and intermediate shaft.
Engage reverse gear with the control levers.
Install the mandrel on the input shaft. Screw a 10mm bolt into the hole on the side of the clutch housing and attach the handwheel handle to the arbor to remove the lock nut.
Remove the reverse idler shaft bolt and 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 stopper bracket.
Remove the stop ball assembly, gasket and seal.
Remove the 3 outer bearing races and spacers.
After removing the bolt, remove the reverse shift lever assembly, shift lever shoe.
Remove the idler shaft and idler gear.
Remove shift pins, stems and forks (1, 2) switching mechanism.
After unscrewing the two bolts, remove the bearing holder.
Raise the input shaft assembly and remove the intermediate shaft assembly.
Remove the input shaft assembly and output shaft assembly.
Elements of the output shaft (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 controls from the clutch housing as shown.
Attention: The removal of the controls is carried out in case of emergency, because. the disassembly process consists in cutting off the locking plate (4). When assembling, you will need a new locking plate.
Controls (models before 2000)
1 - clutch housing;
2 - control fork;
3 - gear selection lever;
4 - locking plate.
Disassemble, wash 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 - shift rod 1st - 2nd gear;
2 - fork;
3 - shift rod 3rd - 4th gear;
4 - fork;
5 - 3rd gear engagement rod;
6 - clip.
Gearbox shafts (models before 2000)
1 - clutch housing;
2 - bearing holder;
3 - ring;
4 - stuffing box;
5 - input shaft;
6 - intermediate shaft;
7 - secondary shaft;
8 - differential;
9, 10, 11 - outer ring.