Disassembly into main components
1. Clean the outside of the gearbox with kerosene and dry.
2. Remove the clutch elements (lever, release bearing, clutch cover).
3. Drain the oil through the drain plug and install it back.
4. Remove the reverse gear and V gear lever, having previously noted its position relative to the shaft.
5. Remove the circlip and washer from the shaft.
6. Turn away bolts of fastening and remove a cover of fastening of the mechanism of a gear change, previously having removed leads.
7. Remove the bolts securing the front cover to the gearbox housing, noting the position of the shims for adjusting the bearing axial play.
8. Block the output shaft flange and loosen the special nut with a slotted wrench.
9. Using a puller, remove the drive flange.
10. Disconnect the rear cover mounting bolts and remove it.
11. Remove the speedometer drive worm gear from the driven shaft.
Removing the input shaft from the gearbox housing
1 - input shaft
2 - nut with a longitudinal slot
3 - bearing
4 - oil deflector
Four-speed gearbox
1. Remove the reverse gear from the intermediate shaft.
2. Take out an intermediate shaft of a backing and disconnect an intermediate gear wheel from a fork of a choice of transfers.
3. Remove the nut from the rear end of the intermediate shaft and remove the reverse gear.
Note. To facilitate disassembly, temporarily replace the output shaft flange, install the locking rod and engage the highest gear (IV or V).
4. When in neutral, remove the shift forks from the sliding sleeves of the synchronizers.
5. Using a beard, remove the cylindrical pin from the reverse gear fork retainer, remove the switch shaft.
6. Bend back lock washers, turn away bolts of fastening of lock plates and turn away a nut from the forward end of a secondary shaft.
7. Using a puller, remove the mounting plates of the support bearings and remove the intermediate shaft bearings.
8. Similarly, remove the front and rear bearings of the output shaft.
9. Install a metal tube on the rear end of the countershaft to secure the 1st gear gear in the needle bearing.
10. Lift the rear end of the output shaft and remove the input shaft through the front of the crankcase.
11. Remove input shaft, IV gear synchronizer ring and needle bearing.
12. Move the 3rd and 4th gear synchronizer clutch to the 3rd gear position.
13. Slide the intermediate shaft back and remove it through the crankcase side window.
14. Slide the secondary shaft back and remove it through the side window of the crankcase.
Five-speed gearbox
1. Remove the shift forks from the synchronizer slots.
2. Remove the nut from the rear end of the driven shaft. To keep the driven shaft from rotating, temporarily move the synchronizer clutches to simultaneously engage two gears at once.
3. Turn away bolts of fastening of an intermediate case and remove it together with bearings. In the event of a tight fit, the bearing can be left on the countershaft.
4. Remove the gear wheel of the 5th gear from the intermediate shaft with a puller.
5. Turn out bolts of fastening of an intermediate case to the main and remove a lining.
6. Knock out the cylindrical pin from the detent of the gear shift, reverse gear / V gear with a drift and slide the pawl to the extreme forward position.
7. Pull out the reverse stop/V gear mandrel with spring and detent ball through the side window.
8. Disconnect the intermediate shaft from the reverse gear, freeing the latter from the inclusion fork.
9. Remove the intermediate shaft along with the V gear, needle bearing and synchronizer ring.
10. Remove the reverse gear, the 5th gear synchronizer and the 5th gear needle bearing ring with a puller.
11. Remove the reverse/V gear fork from the crankcase.
12. Remove the feather key from the intermediate shaft and remove the gasket and reverse gear from the splines.
13. Inspect the gasket installed between the synchronizer and the reverse gear for defects.
14. Remove both segment keys of a secondary shaft.
15. Turn off a bearing nut of a forward end of a secondary shaft, using simultaneous inclusion of two transfers for shaft fixing.
16. Remove the bearing cap from the rear of the crankcase and take out the axial adjustment shims.
17. Take out an internal lock ring and the bearing of a leading shaft. Remove the crankcase bearing and oil sprinkler.
18. Remove the rear output shaft bearing.
19. Fix the gear wheel of the 1st gear with a metal mandrel from displacement from the needle bearing.
20. Remove the ball bearing (if he stayed) from the crankcase or remove from the front of the output shaft. If a roller bearing is installed, then you need to use a soft-faced hammer to drive the output shaft back together with the roller bearing and tapered bush (if there is one). At the same time, the assistant lifts the input and intermediate shafts.
21. Remove input shaft and bearing, IV gear synchronizer ring and needle bearing. In this case, the intermediate shaft is located at the bottom of the crankcase.
22. Move the synchronizer clutch of III and IV gears to the position of III gear and, having shifted the intermediate shaft back, remove it through the side window of the crankcase.
23. Move the secondary shaft back and remove it through the side window of the crankcase.