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First check
trueness, th
en
fit
the
seal
ring
«
L
..
(OR
type)
between
housi
ng
and
shaft
;
then
fit
the
flanged
shaft
..
H
lO,
and
the
seat ring
..
I
..
(OR
type)
.
Now fit
the
flanged
shaft
.
already
complete with
:
flange, seal
ring
"
F
". bea
ring
..
E
", seeger ring
sealing for
bearing
and flange
,
on the shaft
..
0
..
and
seal
ring
«C .. (OR
type)
.
Rotate
the
shaft
to
ensu re
the al ignment be-
tween
lIanged shaft
hole
and
housing threaded
hole (through
the
gea
r
hole) and screw
in
the
screws
according
the
access sequence.
Remember
to
re-fit
the
oi
l
passages
"
G
"
and
the
pipe
«a
",
on
l
o Ihe
housing.
using
the
proper
screw.
REMOVAL OF THE CLUTCH
ASS.Y
FROM
THE GEARBOX HOUSING
Take off the
ring
securing
the
clutch ass.y
to
its housing, using
the
special
tool
(0<
A
"
in
fig. 279
- 55900400) and
sc
rew
in
the pressure
plate
rod until
the plates
are free
in
the hous-
ing
.
At this
stage
remove
the ri
ng
securing
the
plates.
using
screw
drive "B
..
(fig. 279)
then
sli de out (fig
.
280)
externally
toothed plates
..
B
»;
loosen counternut
..
C
..
,
adjuster nut
"
0
..
and
take
off the
rod
..
E
"
w
ith bushing
..
F
" and
bearing" G
",
the spring pusher
..
H
..
with
springs "I
..
and
shims
"L
..
:
first
take
out
the
ci rcli
p
0<
N
".
th en rem
ove
the pin
"
M
".
the lever
..
0
..
with
cap
"
p
.. and the
lever
return spring ..
a
".
REMOVAL OF THE CLUTCH HOUSING
To
remove the clutch housing from the
shaft.
fit
tool 189118
50 (59
in
fig. 281) on
the
hous-
ing and
using
tool
n.
1492
7600
(30 in
fig.
281)
undo the
nut securing
the housing
to
the
shaft.
then slide
out
the housing with the
seal
ring
(OR
type).
REMOVAL OF THE GEARBOX HOUSING
COVER
(fig.
282)
First
drain the
oil
,
take
off the bollom ..
A
"
,
the
element
..
B
",
the
spacer
..
C
".
the
seal ring
..
0
..
(OR ring). the
drain plug
with
the alumi-
nium washer
..
E
".
th
e
cap with
w
asher
spring
and
gear
stop pin
..
F
»;
then
loosen
the
screws
"
G
..
and take
off
the
cover ..
H
..
and the
gasket
..
I
".
REMOVAL OF BEARINGS FROM THE
GEARBOX
HOUSING
COVER
-
using puller
18906550.
remove
the
ball
bearing
(62
in fig
.
283):
-
if
the ball
beari ng is
locked
on the
shaft
(due to
the spacer),
use
puller
189273
50
(67
in
fig
.
285) to
remove bea ring and
spa-
cer
for layshaft;
-
using
puller
14-91 31
00 (39 in
fig
.
284) re-
move the
roll er
bea rings.
RE-FITTING OF BEARINGS ON THE
GEARBOX
HOUSING COVER
-
press the roller bearings
on
the cover. using
punch 14929200
(41 in
fig
.
286)
;
142
-
press the
ball bearing
on
the
cover,
using
punch 18928950
(64
in
fig.
287);
-
press
the
ball
bearing
seal ring
on
the
co-
ver ,using punch 189291
50
(63
in
fig. 288)
.
REMOVAL
OF SHAFTS,
GEAR
,
SLEEVE,
FORK
AND
FORK
CONTROL SHAFT
ON THE
GEARBOX HOUSING
(fig.
289-290)
Remove the
space
r
ring
..
A
...
the gear on the
layshaft
..
8
.. ,
the
main
shaft
"
C
",
the
clutch
shaft ..
0
..
(if
some
resistance is
found in re-
moving the
clutch shaft, using a leather mallet
tap
from
outside to
inside).
First
loosen the securing screw
on
the fork
"
F
", then remove
the
fork
control shaft
..
E
".
Remove the fork
"G
to
from the
sleeve,
the
sleeve
"
H
..
from
the tayshaft, then the
lay-
shaft
"
I
..
from
its
seat
on
the gearbox
hous-
ing.
l
inally
remove the
low
speed gear
..
L
D.
REMOVAL OF
BEARINGS
FROM THE
GEARBOX HOUSING
Using
puller 12913700 (40 in
lig.
291)
.
remove
the
bearing lor clutch
,
main
and layshalts
.
First lIallen the wings of
the
securing
plates.
then loosen
the
screws and remove the
piece se-
curing
bearing
to gearbox housing.
RE-FITTING
OF
BEARI
NGS
AND SECURING
RING ON
THE GEARBOX HOUSING
To re-lit
the bearings on
the
gearbox
housing
use the special
tool 14928900
(43
in
lig.
292)
.
Fit
the
clutch shaft
bearing, set
the securing
piece
and lock
the
screws with
securing
plates;
then
bend
the plate wings on the
screws.
Now
press the cluth
shaft
securing ring.
using
punch
14929400 (47 in fig.
293).
RE-FITTING OF
SHAFTS,
SLEEVES,
FORK
WITH
CONTROL
SHAFT,
AND GEARS
ON
THE GEARBOX
HOUSING
Before
litti
ng
the layshall
..
A
"
on
the
gearbox
housing
.
lit
the
low
speed
gear
..
B
..
and
the
shi
m
"C"
with
the
bevelled side facing the
gear
on
the
shaft itself
(see
lig. 294)
.
Then
fit
the
clutch shalt
..
0
"
in
fig.
289,
the
main shalt
..
C" in
fig.
289,
the
sleeve
"
H
..
in
fig.
289
on
the
layshalt
;
the
fork
..
G
to
fig.
289
on the sleeve
..
H
"
in
fig.
289; the
control
shaft
«
E
"
in
fig.
289
(wit
h
lever in horizontal
posi·
tion) on the
fork;
then
secure
the
shaft
to the
fork, using the
screws ..
F
N
in lig. 289.
the
drive
speed"
B
"
and
the
shim
..
A
".
Then
fit
th
e
throwout
bearing
"A" in
fig
.
295
and one or
more
shims
..
B"
in
lig.
295.
Clearance between shim
and
bearing
on
gear-
box housing
cove r:
mm 0,15
-+
0.20.
RE-FITTING
OF
THE
GEARBOX
HOUSING
COVER ON THE
GEARBOX HOUSING
(Iig
.
282)
Fit
a new
gasket
"
I
"
between housing
and
cover. then
fit
the cover
..
H
"
and secure it to
the
housing
with
screw
s
"
G
", screwing in
crossed sequence
;
then
lit the gear
stop
pin
and
the
spring and lock
the
securing
cap
with
aluminium washer"
F
..
onto
th
e
gearbox
hou-
sing
cover.
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