Carefully remove the motor cover. compartment in the "direction of the arrow" with the mounting bolts. Do not remove the motorcycle cover. compartment sharply or only on one side.
Remove noise insulation screens "1" and "2". Remove noise insulation "1" in the right wheel arch.
Unscrew the nuts of the outlet pipe "arrow".
Disconnect the system. exhaust pipe, loosen the clamp "arrow" and remove the exhaust pipe.
Unscrew bolts "1" and "2" and remove the mounting bracket.
Drain the coolant.
Remove the "arrow" seal. Remove individual parts "1, 2, 3" or the entire water drain box cover (depending on the release date).
Unscrew bolt "1" and remove the distribution block "in the direction of the arrow" from the tensioner. Disconnect plug connector "2" from the stretcher.
If present, remove spacer "3". To do this, unscrew bolts "1" and nuts "2".
For reinstallation, mark coolant hoses "1" and "2" and remove them from the pipes on the heater heat exchanger. Remove the coolant hoses from the front wall of the water drain box and route them to the engine. compartment. Additionally, the coolant hoses can be disconnected from the engine coolant pipes, allowing the coolant hoses to retain their installation. position on the front wall of the water drainage box. Disconnect the brake booster vacuum line connection from the front wall of the plenum box and remove the front wall of the plenum box.
Unscrew bolt "3" of the connecting rod from the side of the water drainage box. "Pos. 1, 2" do not take into account.
Remove the air casing. filter. Unscrew nuts "1, 2, 3" of the turbocharger and tie up the filter.
Unscrew the bolts "3...6" that connect the gearbox and engine and are accessible from above. Bolts "3" and "5" additionally secure the line holders. Secure these holders to the engine.
Unscrew the starter bolt "1". Remove the spacer sleeve "2" between the starter and the gearbox.
Disconnect all hoses and wires running in the area of the engine mounting eyes of the "10-222 A" crossmember. Install the "10-222 A" crossmember with the "10-222 A/3" on the left and right shock absorber strut cups, as shown in the figure. Connect the "10-222 A/11" lead screws to the rear engine lugs on the left and right.
Disconnect the cardan joint from the steering gear only when the front wheels are installed straight ahead. Do not change the position of the steering wheel and steering gear again; if necessary, secure the steering wheel with adhesive tape. Unscrew the "arrow" bolt of the universal joint. Press the steering gear cardan joint and move it fully upward.
If the subframe, steering gear, or subframe crossmember are not properly installed, the vehicle must not be driven! Remove nut "1" of the power steering hydraulic line. Loosen the "arrow" bolts and remove the subframe crossmember.
Remove bolt "2" of the power steering hydraulic line. Remove bolts "1" and "arrows" and remove the subframe crosspiece.
To engage the gear, remove the shift shaft "1" and shift the gearbox lever "2" forward in the "direction of the arrow".
Remove cover "1" under the gearbox "arrow".
Unscrew the 3 bolts "arrow" of the driven disk, to do this, turn the crankshaft using both front wheels respectively through 120° in the direction of engine rotation.
Unscrew the arrow bolts and remove the heat-insulating shield of the right drive shaft. For better understanding of the montage. the position is shown with the gearbox removed.
Unscrew the left and right drive shafts from the shafts with the gearbox flange.
Vehicles with start-stop system: Disconnect the plug connection of the neutral position sensor of the gearbox "G701" "1" and release the cable.
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Unscrew bolt "2" and tie the clutch slave cylinder to the side of the motorcycle. compartment. On the clutch pedal after removing the working cylinder. do not press the clutch. Unscrew nut "1".
Do not press the shift lever "1" with a crowbar or knock it down with a hammer. The gearshift lever must be removed using the T40160 puller. Install the T40160 puller and remove the gearshift lever.
Remove the front mount from the engine by unscrewing bolts "1". Ignore items "2" and "3".
Install the engine and gearbox lift with gearbox mount "T40173" under the gearbox and secure with tension belt "1", as shown in the figure. When fixing the tension belt, make sure that the electrical wires on the gearbox are not pinched.
Unscrew the bolts of the tunnel cross member "arrow".
First, lower the transmission using a lift by dimension "a." Dimension "a" = maximum 80 mm. Preliminarily, lightly tighten the lead screws of the "10-222 A" crossmember. To access the threaded pins with the vehicle raised, use the "VAS 5085" stepladder.
Disconnect wire "A" from the gearbox "arrow". Remove bracket "B" with plug "C" of exhaust gas temperature sensor 4 "G648" from the gearbox and secure it at the top.
Disconnect plug connection "1" of gear detection sensor "F208" using puller "T40138" and release the electrical wire. Unscrew bolt "2" of the gear shift fork rod. Bolt "3" is already unscrewed.
Unscrew bolt "3" of the starter from the engine side. Remove the starter from the gearbox and leave it in the mounting position. position. There is no need to disconnect the starter cables.
Unscrew the remaining bolts "7...10" connecting the engine/gearbox. Press the gearbox away from the engine approx. by 20 mm. Using the left running screw of the gearbox mounting "T40173", tilt the gearbox to the right downwards and guide it past the particulate filter "arrow A". In doing so, push the gearbox slightly to the left. Then carefully lower the gearbox, guiding it past the steering mechanism and the final drive cover on the subframe "arrow B". When lowering, check that the cable is not pinched on the upper side of the gearbox. When lowering, ensure that the drive shafts move freely.
In case of replacement of the removed gearbox, it is necessary to transfer the following parts to the new gearbox: holder "1" of the fastening plate of the system. exhaust system, tunnel cross member with gearbox cushion and gearbox support.
If necessary, remove the clutch module.
