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
 Spare 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 gear selector lever
 
Remove the generator cover and flywheel-generator assembly
Undo the gear selector mechanism (21) retaining screws (18) and (20).
Remove screws (18) and (20), spacer (19) and withdraw the gear selector mechanism complete with the gear lever shaft, spring and 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 lever
If it is necessary to renew any components, disassemble the gearchange mechanism as shown in the exploded view.
Reassembly of the gear selector lever
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 lock nut (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.
Then tighten the nut (13) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm) (Sect. 3 - 3, Engine torque settings).
Disassembly of gear interlock plunger and pawl assembly
 
Unscrew the interlock plunger screw (5) and remove the seal (6), the spring (7) and the detent ball (8).
Unscrew the clutch-side crankcase screw (3) and remove the pawl (4), the washer (2) and the spring (1).
Refitting the pawl assembly and the gear interlock plunger
On the special screw (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 half, 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 screw thread.
Start the screw 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 screw (3) to a torque of 18 Nm (Min. 16 Nm - Max. 20 Nm) (Sect. 3 - 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), the spring (7), and the seal (6) into the interlock plunger (5) and tighten the interlock plunger assembly into the crankcase.
Tighten the interlock plunger to a torque of 30 Nm (Min. 27 Nm - Max. 33 Nm) (Sect. 3 - 3, Engine torque settings) and screw in the interlock plunger into the crankcase.
 
Refitting the gear selector lever
Position the gearbox drum selector fork in the centre of the gear rollers.
Position the whole gear selector lever (21) into the chain-side crankcase half.
Insert the screws (18) and (20) with the spacer (19).
Temporarily fit gear change lever (or a service lever) and sprocket and shift to neutral gear.
Place the tool 88713.3334 on the gear claw.
Place the tool inserting the pushrod (A) into the tool hole, block the pin (B) of the tool in the gear claw pressing with the hand in the point (C) towards the right.
In this position, tighten first the screw (18) to a torque of 36 Nm (Min. 34 Nm - Max. 38 Nm) and then the screw (20) to a torque of 16 Nm (Min. 15 Nm - Max. 17 Nm), securing the gear selector lever (Sect. 3 - 3, Engine torque settings).
Remove the tool and check that the pin (D) placed on the gear drum is axially to the notch (E) on the gear 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 gear change lever.