Before starting disassembly, we will once again point out that a number of special tools are required, without which work can only be done with considerable difficulty. The corresponding part numbers for these tools are indicated in the appropriate places in the text, but you should first try to find them or rent them.
Drain the gearbox oil before disassembly. To do this, use a key for bolts with an internal hexagon (17 mm), to remove the drain plug on the underside of the gearbox housing. Remove all dirt from the outside of the gearbox.
Basic disassembly of the gearbox housing
Gearbox Wiring Diagram
1 - bolt, tightened with a torque of 14 nm
2 - washer
3 - gearbox cover (modified)
4 - seal
5 - bolt, tightened with a torque of 25 Nm
6 - guide pin
7 - shift fork, 5th gear
8 - M10 bolt, tightened with a torque of 80 Nm
9 - sleeve (modified)
10 - gear shift clutch, 5th gear
11 - synchronous shift sleeve, 5th gear
12 - spring
13 - synchronizing ring, 5th gear
14 - gear shift gear, 5th gear
15 - needle roller bearing
16 - gear shift gear, 5th gear
17 - bolt, tightened with a torque of 25 Nm
18 - guide pin
19-O-shaped O-ring
20 - bolt, tightened with a torque of 25 Nm
21 - bearing shell
22 - gearbox housing
23 - cork
24 - drive flange
25 - blocking ring
26 - bolt, tightened with a torque of 25 Nm
27 - switching mechanism
28 - clutch housing
29 - sleeve
30 - cork
31 - magnet
32 - tachometer drive
33 - O-shaped O-ring
34 - guide sleeve with seal
35 - bolt, tightened with a torque of 14 Nm
36 - bolt, tightened with a torque of 25 Nm
37, 38 - bolts, tightened with a torque of 30 Nm
39 - bushing of the starter motor shaft
If changes are indicated, they must be taken into account if they affect the repair of the gearbox. In the following description, reference is made to Figs.
Open the gearbox cover (3) and remove the seal (4). The lid shown in the picture is flat. As a result of the modification of the gear mounting for fifth gear, the cover is now higher. If the gearbox cover (3) mounted with the gearbox installed, after installation, check the oil level in the following way.
The gearbox is filled with oil up to the edge of the filler hole and the plug is screwed in again.
Visitor comments