Gearbox housing type 016
- 1 - outer bearing ring;
- 2 - adjusting ring;
- 3 - bearing;
- 4 - gearbox housing;
- 5 - bolt;
- 6 - retainer plug;
- 7 - gasket;
- 8 - spring;
- 9 - retaining sleeve;
- 10 - thrust plate;
- 11 - retaining ring;
- 12 - bearing;
- 13 - crankcase cover;
- 14 - magnet;
- 15 - cork;
- 16 - gasket;
- 17 - retaining sleeve;
- 18 - spring;
- 19 - bolt;
- 20 - washer;
- 21 - spring clip;
- 22 - mounting plate;
- 23 - reverse gear axle;
- 24 - spring;
- 25 - reverse gear synchronizer;
- 26 - reverse intermediate gear;
- 27 - reverse gear lever;
- 28 - reverse lock;
- 29 - Reverse gear fork;
- 30 - activation rod;
- 31 - pin
Execution order
1. Clean the gearbox from dirt and wash the outside.
2. Unscrew the oil filler and drain plugs and drain the oil from the gearbox if this has not been done previously.
3. Loosen the mounting screw and remove the lever from the gear shift rod.
4. Unscrew three bolts 18 (see Fig. Gearbox type 016) and remove cover 16 with gasket.
5. Remove the 14-speed shifter assembly from the clutch housing.
6. Loosen the bolts 2 for fastening and disconnect the gearbox housing 1 from the clutch housing 7.
7. Knock out plug 45 from gearbox cover 41 using a suitable tool.
8. Secure the primary shaft 19 from turning using the splines and unscrew bolt 44 from the opposite end of the primary shaft.
9. Clamp the gearbox housing 52 in a vice.
10. Loosen the mounting bolts and remove cover 41 of the gearbox, pressing off the inner ring of the rear bearing of the primary shaft.
11. Press the second inner ring 39 of the rear bearing off the primary shaft.
12. Press hub 46 with the 5th gear ring gear.
13. Knock out pin 37 of the 5th gear fork.
14. Remove retaining ring 27 (see Fig. Primary shaft KP 016).
15. Remove gear 4 (see fig. Gearbox type 016) 5th gear with synchronizer and fork for engaging 36 5th gear.
16. Remove two rows of needle bearing 49.
17. Loosen the limiting bolts 29 of the fork rods
18. Engage one of the gears and secure the primary shaft from turning. Unscrew bolt 35 from the end of the secondary shaft.
19. Press gear 33 of the 5th gear off the secondary shaft and remove adjusting washer 32 of gear 33 of the 5th gear.
20. Knock out spring pin 24 from link 23 of the 1st and 2nd gear shift rod, placing a support under the rod so as not to damage the hole in the crankcase.
21. Knock out pin 27 from fork 28 for switching 3rd and 4th gears, placing a support under the rod so as not to damage the hole in the crankcase.
22. Remove the 3rd and 4th gear shift fork rod 21 from the crankcase.
23. Unscrew plug 15 (see Fig. Gearbox housing type 016) and remove retainer 17 with spring 18 from the crankcase.
24. Unscrew bolt 51 (see fig. Gearbox type 016) fastenings of the intermediate lever 53 for engaging reverse gear.
25. Extend the primary 19 and secondary 26 shafts as far as possible from the gearbox housing and remove the primary shaft 19 together with the fork 28 for switching 3rd and 4th gears.
26. Remove the reverse gear lock by moving the intermediate lever 53 for engaging the reverse gear to the side.
27. Remove secondary shaft 26 with rod 22 of fork 25 for switching 1st and 2nd gears.
28. Remove spring clip 21 (see Fig. Gearbox housing type 016) reverse synchronizer and unscrew bolt 19 securing plate 22.
29. Remove plate 22 and axle 23 with spring 24, synchronizer 25 and intermediate reverse gear 26 from the crankcase.
30. Unscrew the speedometer drive gear.
31. Unscrew bolt 3 (see fig. Gearbox housing type 016) fastening flange 12 of the axle shaft, fixing the flange through the holes for the fastening bolts using a rod or punch.
32. Loosen bolts 13 securing differential cover 11.
33. Remove differential cover 11 with sealing ring using two screwdrivers.
34. Remove differential 10 assembly from the clutch housing.