Gearbox
Clamp the driving shaft and the driven shaft in vices (using protective jaws). Remove
the gears and check if the following parts show signs of wear or seizure:
• Needle roller cages.
• Bearing surfaces of the driving shaft, driven shaft and idler gears.
• Gear couplings.
• Sides of all gear teeth.
• Tooth profile of the driving and driven shafts and of the related gears.
• Check that the profiles of all the gears can move smoothly.
Thoroughly clean all the parts and replace any faulty components.
Always fit new Seeger rings whenever the transmission is repaired.
Assembling the driving shaft
– Clamp the driving shaft in a vice with its grooved end facing downwards (use pro-
tective jaws).
– Carefully oil all the components before assembling them.
– Fit needle roller cage 2, top it with 5th-speed idler gear 1 with the front couplings fa-
cing upwards.
– Insert thrust washer 3 (25.2x32x1.5 mm) and Seeger ring 4 with the sharp edge fa-
cing upwards.
– Fit 3rd-/4th-speed double sliding gear 5 with the smaller gear at the bottom and then
fit Seeger ring 6.
– Fit toothed washer 7 (25.2x32x1.5 mm) and needle roller cage 8.
– Fit 6th-speed idler gear 9 with the slot facing upwards.
– Fit 2nd-speed fixed gear 10 with the shoulder at the bottom and thrust washer 11
(17.2x30x1 mm).
– Finally check that all the gears can move smoothly.
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