7.1 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
 Parts catalogue
 Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the gearchange mechanism
 
Remove the alternator cover and flywheel/alternator assembly
Unscrew and remove the gear selector mechanism (21) retaining bolts (18) and (20).
Remove the bolts (18) and (20), and the spacer (19) and withdraw the gear selector mechanism complete with the gear lever shaft, spring and stop plate.
 Important
Visually inspect the gear selector claw (14) for wear, particularly around the area where it contacts the selector drum.
Disassembly of the gear selector mechanism
If it is necessary to renew any components, disassemble the gearchange mechanism as shown in the exploded view.
Reassembly of the gearchange mechanism
If the components of the gearchange mechanism were dismantled on removal, fit the spring (17) on the shaft (16) in the position indicated in the photo. Grease the threaded end of the eccentric gearchange lever pin (15) and install it on the upper part of the gearchange lever, securing it with the nut (13). Screw the nut on by hand (do not tighten).
Insert the shaft (16) in stop plate (23) and washer (24) and secure with circlip (9).
Ensure that the shaft with lever (16) is positioned correctly relative to stop plate (23). The edges of the plate must be equidistant from the pin of the lever; to adjust the position, loosen the locknut (13) and turn eccentric pin (15).
Position the spring (10) between the shaft (16) and the fork (14).
Fit the ring (12) to secure the assembly.
Check that the spring (10) is installed correctly as shown in the figure.
Tighten the nut (13) to the specified torque (Sect. C 3, Engine torque settings).
Disassembly of the gear interlock plunger and pawl assembly
 
Unscrew the interlock plunger screw (5) and remove seal (6), spring (7) and detent ball (8).
Unscrew the clutch-side crankcase screw (3) and remove the pawl (4), washer (2) and spring (1).
Reassembly of the gear interlock plunger and pawl assembly
On the special bolt (3), fit the gear pawl lever (4), orienting it as shown in the figure, the washer (2) with the square edge side (D) facing the clutch-side crankcase, and the spring (1), positioning it so that the hook end (A) is facing the gear pawl lever. Locate the hook end (A) of the spring on the gear pawl lever as shown in the figure.
Apply threadlocker to the bolt thread.
Start the bolt in the crankcase half. Position end (B) of the spring so that it rests against rib (C) of the crankcase half, as shown in the figure. Tighten the bolt (3) to the specified torque (Sect. C 3, Engine torque settings). Check that the spring functions correctly by manually moving the gear pawl lever.
Apply grease and then fit the ball (8), spring (7), and seal (6) into interlock plunger (5) and screw the interlock plunger assembly into the crankcase.
Tighten the gear interlock plunger to the specified torque (Sect. C 3, Engine torque settings).
 
Refitting the gearchange mechanism
Locate the gearbox drum selector claw in the centre of the gearbox roller bearings.
Position the gearchange mechanism (21) in the chain-side crankcase.
Fit the bolts (18) and (20) with the spacer (19).
Temporarily fit the gearchange lever (or a service lever) and the front sprocket, and put the gearbox in neutral.
Fit the service tool no. 88713.3334 on the selector claw.
Position the service tool so that the locating dowel (A) engages the hole in the tool and pin (B) of the tool is engaged in the selector claw, applying hand pressure at point (C) and pressing to the right.
In this position, tighten first the gearchange mechanism retaining bolt (18) and then bolt (20) to the specified torque (Sect. C 3, Engine torque settings).
Remove the service tool and check that the pin (D) on the selector drum is aligned with mark (E) on the selector claw.
With the gearbox in neutral, check that the lever travel is the same when shifting up and down. The same should apply when a gear is engaged.
Operate the gearchange lever and turn the front sprocket at the same time to check that all the gears engage when shifting up and down.
Remove the gearbox lever.
 
Refit the flywheel/alternator assembly and alternator-side crankcase cover