DS 19 OPERATION No. DS 330-1 : Work on the gearbox. Op. DS 330-1 191
TOOLS
51 To remove the 1st speed selector lever
a) Unscrew the lever spindle (23) until the lever is free from its trunnion, the fork being in contact with the 1st
speed pinion on the bevel pinion shaft. (The head of the spindle becomes forced against the front edge of the
gearbox support arm which twists it slightly. It is unnecessary to remove the spindle).
Hold the end of the lever with the left-hand.
b) Using a small iron wire hook, held with the right-hand, grip the spindle of the fork (24) and turn the fork
towards the top, at the same time holding the lever with the left-hand in a horizontal position. (The lever is
3
/4
free from the fork spindle). Let go the lever. Hold the hook with the right-hand. Hold the fork and lever by the
fork spindle boss with the left-hand. Disengage the hook. Move the assembly towards the front by easing the
end of the lever, using a hook held in the right-hand. When the fork boss of the lever passes the spindle (23),
disengage the lever.
Refitting.
52 To fit the 1st speed selector lever
a) Using a hook held in the right-hand, raise the spindle on the fork towards the top (the pinion being positioned
towards the front). Using the middle finger of the left-hand, hold the trunnion, disengage the hook.
b) Offer up the lever horizontally in the box, the boss for the fork spindle towards the rear, the long part of the
boss towards the top. Hold the lever in this position between the thumb and index finger of the left-hand and
try to engage the lever on the trunnion. Engage the lever approximately 8 mm.
c) Hold the end of the lever using a hook held in the right-hand and ease the assembly back until it rests on the
pinion. It is sometimes necessary to push the pinion back with a screwdriver. Turn the assembly to its normal
position by raising the lever with a hook.
d) Engage the lever on its spindle. Screw the spindle holding the lever in order to avoid binding.
Tighten the spindle (23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm spanner
53 Put the pinions in neutral position. Put the cover in position : the fork of the 3rd and 4th speed being fitted with
its shoes (stick with grease to avoid dropping the shoes), lower the cover vertically; make sure that the forks
engage in the grooves of the sliding gears and the 1st speed lever in the groove of the fork. Fix the cover by
its 2 positioning screws, then by the other. screws and studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm box spanner
54 Fit the pipe assembly bracket by engaging the studs in the slots of the rear pipe assembly flange. Tighten the
nuts of the pipe assembly fixing studs (plain and spring washers). Connect the pipe assembly . . . . . . . . . . . . . 8-14 mm box spanners
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