Dismantling of a secondary shaft of a transmission

Dismantling the output shaft

1. Remove the circlip and slide the 3rd/4th synchronizer together with the 3rd gear from the front of the mainshaft using a puller if necessary. Separate the gear and synchroniser, then remove the 3rd gear synchronizing ring.



2. Remove the outer ring from the second gear, then remove the two dowel rings.


3. Slide the 2nd gear over the front of the input shaft and remove the 2nd gear timing ring.

4. Mark the mutual position of the hub of the synchronizer of the first and second gears and the sleeve relative to each other and the location of the fork groove, then move the sleeve forward from the hub and remove the clamps and springs. The synchronizer hub must not be removed from the output shaft.



5. Remove the speedometer drive gear from the back of the output shaft.

6. Remove the 5th gear timing unit and 5th driven gear from the input shaft.

7. Remove the circlip holding the mainshaft bearing, then place the middle crankcase on blocks of wood and pull the mainshaft through the bearing.



8. Remove the ring, first gear and first gear timing ring.

9. If necessary, remove the retaining ring and remove the bearing from the middle crankcase using a metal tube. Remove the synchronizers, after noting the relative location of the hub and sleeve. Slide the bushing off the hub and remove the locking rods and springs.