Gearbox assembly: gear selector levers

7.1 -

1	Return spring

Washer

3	Special screw

4	Ratchet unit

5	Gear stopper bolt

Gasket

7	Gear stopper spring

Ball

Circlip

10	Fork return spring

11	Shim thk. 0.5

12	Shim thk. 0.2

Circlip

Nut

15	Gearbox drum control fork

16	Gear lever pin

17	Shaft with gear lever

18	Gear lever return spring

23	Locating ring

24	Stop plate

25	Shim thk. 0.2

26	Shim thk. 0.5

27	Complete gear selector lever

Spare parts catalogue


Gearchange

Caution

Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.

Removing the gear selector levers


Operations	Reference See Section
Remove generator cover and flywheel/generator assembly	N 8, Flywheel - generator
Remove clutch housing	N 6.3, Disassembling the primary drive gears

Undo the complete gear selector lever (25) retaining screws (18) and (20).

Remove screws (18) and (20), washers (19) and (21) and slide out gear selector lever complete with control shaft, spring and plate.

Caution

Visually inspect gear selector fork (14) mating surface with gear selector for wear.

Disassembling the gear selector levers

When one or more components of the lever need replacing, disassemble as shown in the picture.

Removing the gear stopper and ratchet

Undo the gear stopper bolt (5) and remove seal (6), spring (7) and gear ball (8).

Undo clutch-side casing screw (3) and remove ratchet (4), washer (2) and spring (1).

Reassembling gear stopper and ratchet

Slide ratchet (4), washer (2) and spring (1) on the gear stopper bolt (3).

Position gear stopper to clutch-side casing. The end of the spring (1) must locate behind the casing rib.

Tighten the bolt (3) to the specified torque (Sect. C 3, Engine torque settings).

Thoroughly grease and then fit ball (8), spring (7) and seal (6) into gear stopper (5).

Tighten gear stopper to the specified torque (Sect. C 3, Engine torque settings).

Reassembling the gear selector lever

If the gear selector lever has been taken apart, insert the spring (17) on the shaft (16) as shown in the photograph.

Insert plate (23) and shim (24) and fit circlip (9) to secure in place.

Position the lever with respect to plate (23). The lever pin should be centred to the shoulders of the plate; loosen check nut (13) and turn eccentric pin (15) to set the position.

Tighten the lock nut (13).

Place the spring (10) between shaft (16) and fork (14).

Insert the circlip (12).

Reassembling the gear selector lever

Position the complete gear selector lever (25) into the chain-side casing.

Position the gearbox drum selector fork in the centre of the drum rollers.

Temporarily fit gear change lever (or a service lever) and shift to third gear.

Fit plate part no. 88713.1091 to the fork shaft pins (see figure).

Align the notch (A), which marks the centreline of the fork shaft pawl, with the end of the plate (B).

Then tighten (Sect. C 3, Engine torque settings) the gear selector lever retaining screws (18) and (20).

With the gearbox in neutral, check that lever travel is the same when shifting up and down. The same should apply when a gear is engaged.

Operate the gear change lever and turn the sprocket at the same time to check that all the gears engage when shifting up and down.

Remove gear change lever.


Operations	Reference See Section
Refit clutch housing	N 6.3, Refitting the primary drive gears and checking meshing play
Refit flywheel/generator assembly and generator cover	N 8, Refitting flywheel / generator assembly