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Gear-changing mechanism

Gear-changing mechanism

To dismantle


When dismantling the gear-changing mechanism, the selector shafts must be in their neutral positions.


1. Clamp the gear-changing mechanism in a vice with soft jaws.

2. Drive out the expanding pin for the gear-changing lever's shaft.


3. Drive out the shaft and take out the gear-changing lever.

Important

The detent balls fall out of the gear-changing mechanism during dismantling.


4. Place a finger in front of the seat of the catch ball and pull out the reverse gear shaft. Put all catch balls and springs in a safe place.


5. Take out the other shafts with balls and springs in the same manner. Start with the 5th selector shaft.


Important

There are extra detent balls between the selector shafts (selector interlock balls).


Then remove the 3rd/4th gear shaft and finally the 1st/ 2nd gear shaft. Collect the two pins in the 5th and 3rd/4th gear shafts.

6. If forks and actuators need to be replaced, tap out the clamping pins and remove the forks and actuators. Note the positions for refitting. Clamping pins should always be replaced when refitting. Check the condition of all parts as regards wear. Replace worn or defective parts.



To assemble


1. Fit forks and drivers to each shaft if they were removed.

2. Start with the 1st/2nd shaft. Insert the spring and ball in the bearing bracket. Press down the ball using a drift and move the shaft to neutral position.


3. Insert the detent ball for the selector interlock device on the 3rd/4th shaft.


4. Insert the spring and ball. Fit the pin in the 3rd/4th gear selector shaft. Check that it runs easily in the shaft. Press down the ball with a drift and insert the 3rd/4th gear shaft to its end position.

Important

3rd/4th fork should be threaded over the 1st/2nd selector shaft on assembly.


5. Insert the detent ball for the selector interlock device on the 5th shaft. Then insert spring and ball for the 5th selector shaft. Fit the pin in the 5th shaft and check that it moves easily in the shaft. Press down the ball using a drift and move the shaft to neutral.


6. Insert the detent ball for the selector interlock device on the reverse shaft.


7. Insert spring and ball for the reverse shaft. Press down the ball using a drift and move the shaft to neutral.

8. Place the selector lever with springs and sleeves in the bearing bracket. Press in the shaft and tap in the expanding pin.



Taking selector lever to pieces


The selector lever must have been removed first.


1. Push down one of the springs and remove the circlip. Lift off and collect the spring and sleeve.

2. Do the same on the opposite side to remove the other spring and sleeve.


Fitting



1. Fit springs to selector lever.

Important

1st/2nd sleeve and spring are shorter.


2. Press down the spring and the sleeve and fit a new locking ring on the selector lever. Do the same on the opposite side to refit the other spring and sleeve. Fit a new locking ring.