General view of the five-speed gearbox and gear shift mechanism
Gears and shafts of a five-speed gearbox
1 - retaining ring; 2 – an axis of an intermediate gear wheel of a backing; 3 – an intermediate gear wheel of a backing; 4 – a sealing ring of a primary shaft; 5 - bearing; 6 - input shaft; 7 – a lock ring of the bearing; 8 – a leading gear wheel of 5th transfer; 9 - retaining ring; 10 - gear wheel of the 2nd gear; 11 - retaining ring; 12 - thrust ring; 13 - gear wheel of the 3rd gear; 14 – a blocking ring of the synchronizer; 15 - sliding clutch of the synchronizer; 16 - spring; 17 - synchronizer hub, 18 - cracker; 19 - gear wheel of the 4th gear; 20 - gear wheel of the 5th gear; 21 - base plate; 22 - a special retaining ring; 23 - oil deflector; 24 - secondary shaft; 25 - gear wheel of the 1st gear; 26 - reverse gear; 27 - holder of satellites; 28 - side gear; 29 - the axis of the satellites; 30 - satellite; 31 – differential tapered roller bearing; 32 - the drive gear of the speedometer drive; 33 - differential box, 34 - main gear driven gear; 35 - convex special spring washers; 36 - pin; 37 - speedometer drive guide; 38 - driven gear speedometer drive
The five-speed gearbox differs from the four-speed only by adding an additional gear and synchronizer, using a modified gear selection mechanism.
Dismantling a five-speed gearbox is similar to disassembling a four-speed gearbox (see subsection 8.1.2.3.1) except for the following minor differences.
1. Unscrew the 5th gear lock, remove the spring and the locking pin.
2. After unscrewing the bolts and removing the rear cover from the crankcase, unscrew the pinch bolt (indicated by an arrow) and disconnect the selector mechanism from the axle of the 5th gear lever.
3. Remove the 5th circlip and then the 5th gear together with the synchronizer and selector fork.
4. Remove the retaining ring securing the 5th gear to the input shaft and use a puller to remove the gear from the shaft.
5. Unscrew and remove the 5th gear housing (9 bolts).
6. Remove the bearing circlips for the input and output shafts of the gearbox.
7. Subsequent disassembly is the same as for a four-speed gearbox.
Disassembly and assembly of shafts and differential
8. The disassembly and assembly of the shafts and differential is the same as for the four-speed gearbox. The difference is only when disassembling the 5th gear synchronizer, in which the blocking crackers of the synchronizer hub are fixed with a blocking plate.
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