Transmission section
Remove primary and secondary shafts.
Input shaft bearing at the front of the crankcase: Knock out the radial bearing with a tool.
Attention: When installing, make sure that the shoulder faces the clutch.
Replacing the intermediate shaft bearing:
- Loosen the retaining ring with a punch.
- Take out a lock ring.
- Remove spacer.
- Knock out the outer race of the bearing with a punch.
Bearing in crankcase cover:
- Remove the bolt (1).
- follow the spring (2).
Remove the rocker switch.
Remove the hexagon socket bolt.
Pull the shift lever up, watch the released rollers.
Installation note
Remove the detent spring, insert the shift lever with the mounting tool. Tilt the lever outward, bring the end of the spring into position. In this position, push the lever down. Before removing the mounting tool, secure the shift lever with a hexagon socket bolt.
Remove the lock lever and bearing retainer plate.
Remove the pad.
Knock out the radial bearing with a drift, taking into account the spacer.
Determining the size of the spacer washer:
- Measure the seating depth in the crankcase with a depth gauge.
- Measure the width of the bearing.
- From the difference in both dimensions, find the thickness of the spacer. The gap must be zero.
Installing the bearing in the crankcase cover:
- Heat the cover in the bearing area to 80°C.
- Install the distance ring. Install the radial bearing.
intermediate shaft bearing:
- Insert the thick side of the puller into the bearing shell.
- After putting on the sleeve, install the eat.
- Press out the bearing race.
Attention: When installing: insert the bearing shell so that the slot in the shell matches the bosses on the crankcase.
Drive in the bearing race. Check intermediate shaft end play.
Insert the circlip into the front of the crankcase.
Insert the required spacer.
Drive in the bearing shell with a punch. The oil groove must line up with the groove in the crankcase.
Insert the intermediate shaft with roller bearings into the crankcase cover. Insert the front of the crankcase and secure with two bolts diagonally.
Center the front with the centering pin.
Remove the oil filler bolt.
Install the gauge on the clutch side so that the gauge of the gauge can come into contact with the countershaft gear.
Moving along the axis with a screwdriver through the oil drain hole of the intermediate shaft, measure the play. It should be 0.13-0.23 mm. In case of deviations, take another distance washer.
Install the gear set.
Determine the size of the input shaft spacer.
Install the required spacer and circlip.
Set the gap to 0-0.09 mm.
Install the special key on the gear lever from below and turn it 90°counterclockwise. Then push up the spherical cup.
Remove the rubber boot from the body and from the console and pull it up together with the gear lever. If there is, unscrew the clip for the vibration damper (counterweight) on the shift lever and remove it.
Installation
Lubricate the spherical cup of the gear lever with grease.
Insert the shift lever with spherical cup so that the protrusion or arrow on the spherical cup points towards the support trunnion, i.e. opposite to the direction of movement.