Elements of the gearbox housing (models from 2000 release)
1 - back cover;
2 - gearbox housing;
3 - installation elements of the input shaft;
4 - installation elements of the intermediate shaft;
5 - differential mounting elements;
6 - clutch housing.
Disassembly
Disconnect the shift cable bracket.
After unscrewing the mounting bolts, remove the rear cover of the gearbox (arrow).
Remove the reversing lamp switch, gasket and bracket.
After unscrewing the plugs, remove the springs and balls.
Remove the breather.
Remove the pin with a punch.
Loosen the lock nuts of the input and intermediate shafts.
Rotate the shift and select levers to shift into 1st gear.
After moving the fifth gear synchronizer to the gear, unscrew the locknuts.
Remove the 5th gear shift fork from the cage.
Using a tool, remove the 5th gear synchronizer hub and needle bearing gear.
Using a tool, remove the 5th idle gear.
Remove bushing and circlip (with a screwdriver).
Loosen the reverse gear axle bolt.
Unscrewing the bolts (arrow), disconnect the final drive housing from the clutch housing.
Remove the oil pans from the crankcase.
Using the special tool, remove the bearing outer race. Remove bushing.
Remove the shift lever.
Remove the reverse gear with axle.
Extract the pins with a punch.
Remove the rods and remove the shift forks.
Remove the bearing cage.
Raise the input shaft assembly and remove the countershaft assembly (simultaneously).
Remove the differential drive gear assembly.
After unscrewing the bolt, remove the speedometer drive gear.
Using the special tool, remove the output shaft bearing outer race.
Using suitable tools, remove the input shaft and countershaft oil seal.
Setting elements for gear shift forks (models since 2000)
1 - shift rod for 1st and 2nd gears;
2 - fork 1st and 2nd gears;
3 - fork of 3rd and 4th gears;
4 - shift rod for 3rd and 4th gears;
5 - 1st gear fork;
6 - shift rod for 1st gear and reverse;
7 - pin;
8 - ball;
9 - spring;
10 - cork;
11 - reversing light switch.
Remove the output shaft oil pan.
Using a suitable tool, remove the input shaft seal from the crankcase.
Remove the control shaft from the crankcase.
Clean and wash the removed gearbox components.
Assembly
The gearbox is assembled in the reverse order.