Note. When replacing parts that directly affect the position of the final drive gear (tapered roller bearings, final drive pinion or gearbox housing), as well as in the absence of markings on the deflection driven gear «G» from the nominal position of the drive gear to the start of disassembly of the gearbox, measure the value «r», as below.
The arrow shows the marking of the gearbox
Drain the oil from the gearbox housing, clean the gearbox and place it on the assembly table.
Remove the gear selector.
Remove the selector rod assembly.
Having unscrewed the mounting bolts, disconnect the gearbox housing from the clutch housing.
Separation of the gearbox housing from the clutch housing
Use a screwdriver to remove the plastic plug from the gearbox rear cover.
Secure the input shaft in a soft metal vise and remove the hex bolt from the rear end of the input shaft.
Clamp the gearbox housing in a vise.
Turn away bolts of fastening of a back cover of a transmission.
Remove the rear cover of the gearbox housing, if necessary by sliding it with a plastic mallet, and remove the first inner race of the input shaft ball bearing.
Remove the gear carriage 2 using a double-lever puller (see photo) the V gear together with the second inner ring 1 of the input shaft ball bearing, then remove the blocking ring 3 of the V gear synchronizer.
Removing the tubular carriage synchronizer V transmission
Knock out the spring cotter pin from the 5th gear fork so as not to damage the fork rod seat in the crankcase wall.
Remove the circlip of the 5th gear synchronizer sliding clutch from the input shaft.
Removing 5th gear parts: 1 - the second inner ring of the bearing; 2 - gear carriage for switching on the V gear; 3 - blocking ring synchronizer V transmission; 4 - a bolt of fastening of the intermediate lever of a backing
Remove the 5th sliding gear together with the sliding clutch, hub, needle bearing and 5th shift fork.
Turn out persistent bolts 1 (see photo) fork stems.
Thrust bolts 1 of the fork rods and hex bolt 2 of the rear end of the secondary shaft
Clamp the gear wheel of the IV gear of the secondary shaft in a vice with soft metal pads and unscrew the hex bolt 2 from the end of the secondary shaft.
Press the 5th gear from the output shaft using a Kukko 20/10 de-lever puller.
Remove the shim for the 5th gear.
Fix the crankcase of the transmission box in a vise with pads made of our material.
Knock out the spring cotter pin from the 1st and 2nd shift fork rod driver while holding the fork rod with a hammer.
Removing the spring cotter pin from the leash of the shift fork rod of I and II gears
Rotate the stem driver up.
Knock out the spring cotter pin from the shift fork of III and IV gears. Remove the 3rd and 5th gear forks. Take out a pusher and a clamp spring.
Turn out a bolt of fastening of the intermediate lever of a backing.
Slightly push the input and output shafts out of the gearbox housing.
Remove the input shaft together with the shift fork III and IV gears.
Disconnect the reverse spring latch from the side of the output shaft and move it to the side. Remove the reverse lock.
Pull out the output shaft so that the rod and shift fork of 1st and 2nd gears can be removed
Remove the output shaft by turning it around the axis.
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