2. Remove the clutch release lever and release bearing from the crankcase (domes) clutch.
3. Unscrew the plug and remove the control spring and ball from the retainer sleeve located on the wall of the clutch dome (gearshift drive components are shown in the accompanying illustration).
1 - switching rod; 2 - washer; 3 - retaining ring; 4 - ball; 5 - bolt; 6 - plug; 7 - clutch of the latch; 8 - sealing ring; 9 - spring; 10 - latch; 11 - cylindrical pin; 12 - reverse / 5th gear shift rod; 13 - plunger; 14 - shift fork 3/4 gears; 15 - percussion lever; 16 - shift fork 1/2 gears; 17 - reverse gear fork; 18 - selector bracket; 19 - 5th gear engagement fork; 20 - nut; 21 - clutch
Loosen the fixing bolt and remove the retainer sleeve. Remove the o-ring and discard it.
Note. If the control spring and ball are not removed earlier, when the clutch is removed, they may fall inside the transmission.
4. If not removed earlier, remove the spring and ball from the hole in the mating surface of the extension housing with the gear lever control housing.
5. Use a drift to knock out the cylindrical pin of the selector bracket on the shift rod.
6. Give fixing bolts and by means of a hammer with a soft head remove an extension casing and an arm of the selector from transmission. Remove the oil seal from the extension housing, discard it.
7. Give the fixing bolts and remove the top cover with the gasket, for which put the lever through the hole for the installation of the release lever in the clutch dome. Remove the seal from the cover and discard it.
8. Remove the retaining rings from the outer race of the input shaft bearing and from the shift rod. Remove the washer from the stem.
9. Supporting the rear of the output shaft, use a soft-faced hammer to separate the clutch dome from the carrier plate. Remove the thrust bearing and shim from the front end of the intermediate shaft.
10. Clamp the carrier plate in a vise with soft jaws and give the bolt securing the reverse / fifth gear shift rod to the reverse gear fork. Remove the stem from the carrier plate.
11. Use a punch to knock out the cylindrical pin that secures the percussion lever and the retainer on the shift rod. Remove the shift rod from the carrier plate and remove the shock lever and retainer, as well as the shift forks 1/2, 3/4 and reverse, noting the installation position of the components.
12. Using a punch, remove the 5th gear fork roll pin from the shift shaft. Remove the stem and remove the fork.
13. Using a blade-type feeler gauge, measure the end play of the 1st, 2nd, 3rd, and reverse gears on the output shaft. Also measure the end play of the 5th gear on the countershaft. If the axial play of any of the gears is out of range (see tables of sizes and adjustments at the end of the guide), carefully check the relevant components for signs of wear, replace defective parts.
14. Remove the reverse gear coupling from the hub, remembering the installation direction of its fit. Remove the retaining ring from the end of the driven shaft, then use a hammer to remove the C-shaped retaining half rings (see illustration).
1 - carrier plate; 2 - retaining ring; 3 - driven gear of the 5th gear; 4 - clutch; 5 - bearings; 6 - hub; 7 - holder; 8 - reverse driven gear; 9 - synchronizer clutch; 10 - remote bushing; 11 - C-shaped retaining half rings; 12 - extension casing; 13 - 5th gear drive gear; 14 - sliding key; 15 - blocking ring; 16 - reverse drive gear; 17 - reverse gear synchronizer cone; 18 - synchronizer blocking ring; 19 - washer; 20 - intermediate shaft reverse gear; 21 - pin; 22 - thrust washer; 23 - intermediate reverse gear
15. Remove the circlip and washer from the rear end of the intermediate shaft, then use a puller to remove the bearing and reverse gear.
16. Remove the gear, bearings and thrust washers from the intermediate shaft of the reverse gear, remembering the installation position of the latter.
17. Position a puller behind the reverse gear and remove the bearing, spacer, reverse hub, reverse gear and roller bearings from the driven shaft. Try to remember the installation position of the components.
18. Remove the fifth gear synchronizer clutch with locking rings and sliding keys for fifth and reverse gears. Try to remember the mounting positions of the clutch and sliding keys.
19. Using a puller, remove the reverse gear roller bearing clutch from the driven shaft.
20. Install the puller behind the fifth gear and remove the reverse cone, fifth gear and reverse countershaft at the same time.
21. Install the carrier plate in the press, supporting it with support plates and alternately squeeze the driven and intermediate shaft out of the plate. Remember the position of the gear wheel of the fifth gear of the driven shaft. After removing the intermediate shaft, remove the input shaft and remove the roller bearings and spacer from the driven shaft.
22. Give bolts and remove the holder of the bearing from a bearing plate.
23. Remove the washer, ball, first gear and roller bearing from the driven shaft.
24. Place the output shaft in a press with the 2nd gear pinion supported, and remove the 1st gear roller bearing clutch, 1/2 gear synchronizer assembly, and 2nd gear with roller bearing.
25. Remove the circlip from the front end of the output shaft, then place the shaft in a press with the third gear pinion supported by support plates. Remove the 3/4 synchro assembly, 3rd gear and roller bearing.
26. Install the intermediate shaft in the press and remove the rear thrust bearing, remembering the installation direction of its fit. Remove the circlip from the front end of the intermediate shaft, then remove the bushing, cone spring, toothed ring and ball.
27. Remove the circlip and washer from the input shaft. Install the input shaft in the press, supporting the bearing with support plates and remove the latter.
28. Using a suitable mandrel, remove the bearings from the carrier plate, extension housing and clutch housing.
Gear Lever Assembly Components
1 - spring; 2 - bolts; 3 - lower saddle; 4 - retaining ring; 5 - washers; 6 - gear lever; 7 - upper saddle; 8 - clamp; 9 - protective cover