2. Install the gearbox vertically up.
3. Remove the six nuts securing the rear cover.
4. Loosen the bolt and...
5.... remove the clutch cable bracket.
6. Gently knock down the back cover with a rubber mallet.
Note. Remove the gasket carefully, since an undamaged gasket can be reinstalled during assembly.
7. Remove the rear cover from the gearbox housing.
8. Remove the seal.
9. Engage 3rd or 4th gear.
10. Loosen the 5th gear fork bolt and engage 5th gear.
Note. To fix the shafts from turning, it is necessary to simultaneously engage 5th gear and 3rd or 4th gear. To engage 5th gear, move down the synchronizer sleeve along with the fork (the fork mounting bolt must be unscrewed) so that the splines of the coupling engage with the ring gear of the gear.
11. Make sure the shafts do not rotate.
12. Loosen the nut on the output shaft.
13. Loosen the nut on the output shaft.
Note. The nuts on the shafts are tightened with a large torque, so you need to apply a lot of effort to loosen.
14. Loosen the nut on the input shaft.
15. Loosen the nut on the input shaft.
Warning. Remove the synchronizer carefully. Make sure that the synchronizer sleeve does not come off the hub: the spring-loaded synchronizer locking balls may crumble.
16. Pry the 5th gear synchronizer by the hub with screwdrivers...
17....and remove it along with the fork. Pull the plug out of the clutch.
18. Remove the 5th gear synchronizer ring.
19. Loosen the 5th gear with a screwdriver...
20....and remove it from the output shaft.
21. Remove the needle bearing thrust washer.
22. Remove the 5th gear needle bearing.
23. Loosen the 5th gear with a screwdriver...
24....and remove it from the input shaft.
25. Using an impact screwdriver, remove the four bearing plate mounting screws.
26. Remove the bearing plate.
27. Pry with screwdrivers and remove the 5th gear needle bearing bush from the output shaft.
28. Remove the thrust washer from the output shaft.
29. Remove the input shaft bearing circlip. To do this, press the retaining ring against the bearing ring with one screwdriver, and remove the ring from the groove with the other screwdriver.
30. Remove the output shaft bearing circlip in the same manner.
31. Loosen the retainer plug.
32. Carefully remove the detent ball with spring. Remove two more retainers in the same way.
33. Loosen the two screws and...
34.... remove the rear support of the power unit.
35. Loosen the reverse lock plug. Tilt the box and remove the retainer ball with the spring.
36. Remove the 12 nuts and bolt securing the gearbox housing to the clutch housing.
37. Using a large screwdriver, carefully separate the clutch and transmission housings.
Note. Between the crankcases there are three places where you can insert a screwdriver so as not to damage the sealing gasket. Alternately insert a screwdriver into these slots and gently shake until the crankcases are separated.
38. Remove the gearbox housing.
39. Loosen the 1st and 2nd shift fork mounting bolt.
40. Raise the stem and remove it together with the 1st and 2nd shift fork.
41. Loosen the 3rd and 4th shift fork mounting bolt.
42. Disengage the head of the rod from engagement with the lever...
43....and remove it along with the fork.
44. Rotate the 5th gear fork shaft, pulling its head out of the lever. Pull out the stem.
45. Remove the snap ring.
46. Remove the reverse gear fork.
47. Remove the reverse gear with axle.
48. Slightly shaking, take out at the same time the primary and secondary shafts.
When both shafts of the gearbox are removed, the inner races of the front bearings remain on the shafts.
49. Take out the driven gear of the final drive together with the differential.
50. Remove the three bolts securing the gearshift mechanism.
51. Remove the gearshift mechanism.
52. Carefully remove the seal.
Be careful not to damage the seal when removing. An undamaged gasket can be reused when assembling the gearbox.
53. Press the output shaft front bearing out of the clutch housing. To do this, you can use the puller foot or similar tool.
Press out the front input shaft bearings and oil seal only when replacing them or replacing the clutch housing.
54. To replace the input shaft front bearing, press out the oil seal.
It is impossible to press out the input shaft seal without damaging it. Therefore, when replacing the input shaft bearing, you will need a new oil seal.
55. Press the bearing into the crankcase by applying force to the bearing outer race.
56. Remove the magnet from the clutch housing.
57. Loosen the nut securing the speedometer drive housing.
58. Pry off the case with a screwdriver...
59.... and remove the housing with the driven gear of the speedometer drive.
Note. If during operation traces of oil leakage through the hole for the speedometer drive were noticed, replace the rubber sealing ring on the drive housing.
60. Remove the driven gear with the speedometer drive shaft from the housing.
61. Push the O-ring out of the speedometer drive housing.
62. Remove the reverse light switch from the gearbox housing.
63. Slide the protective cover of the gearshift linkage from the flange on the gearbox.
64. Remove the opposite edge of the protective boot from the hinge flange.
65. Loosen the pivot bolt...
66....and remove the pivot from the stem.
67. Remove the protective cover from the stem.
68. Loosen the bolt securing the lever to the shift rod inside the clutch housing.
69. Remove the lever and rod from the clutch housing.
70. If during operation traces of oil leakage through the hole in the clutch housing under the gearshift rod were noticed, replace the rod seal.