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Gear-changing mechanism

Gear-changing mechanism



1. Ball

2. Pin


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. Hold a finger over the detent ball seat and pull out the reverse gear selector shaft. Keep all detent balls, expanding pins and springs.

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 wheel and finally the 1st/2nd shaft. Keep the 2 pins from the 5th and 3rd/4th shaft.

6. If the forks and drivers need replacing, tap out the expanding pins and remove the forks and drivers. Note positions for refitting. Expanding pins should always be replaced for assembly.


Check all components for wear. Change any parts which are worn or defective.


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 spring and ball. Fit the pin in 3rd/4th selector shafts and check that it moves easily in the shaft. Press down the ball using a drift and move the shaft to neutral.

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.



Selector lever


The selector lever must have been removed first.

To dismantle


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

2. Remove the other spring and sleeve in the same way.


To assemble



1. Fit springs to selector lever.

Important

1st/2nd sleeve and spring are shorter.


2. Press down the spring and sleeve and fit a new circlip to the selector lever.


3. Fit the second spring and sleeve in the same way. Fit a new circlip.