Gearbox assembly: gear selector levers

7.1 -

1	Return spring

Washer

3	Special screw

4	Ratchet unit

5	Gear stopper bolt

Gasket

7	Gear stopper spring

Ball

Circlip

10	Fork return spring

Shim

Ring

Nut

14	Gearbox drum control fork

15	Gear lever pin

16	Shaft with gear sel.lever

17	Gear lever return spring

22	Locating ring

23	Stop plate

Shim

25	Complete gear selector lever

Parts catalogue


1100	gearchange
1100S	gearchange

Caution

Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.

Removing gear selector levers


Operations	Reference - See Section
Remove generator cover and flywheel/generator assembly	N 8, Removing the generator cover
Remove the clutch cover complete with clutch housing and primary drive gear	N 6.2, Removing the clutch cover

Undo the complete gear selector lever (25) retaining screws (18) and (20).

Slide out gear selector lever complete with control shaft, spring and plate.

Caution

Visually inspect gear selector fork (14) mating surface with gear selector for wear.

When one or more components of the lever need replacing, disassemble as shown in the exploded view.

Reassemble the lever; fit the eccentric pin (15) so that the lever (16) is centred to the shoulders of the stop plate (23).

Then tighten nut (13) to the specified torque (Sect. C 3, Engine torque settings).

Removing the gear stopper and ratchet

Undo the gear stopper bolt (5) and remove seal (6), spring (7) and gear ball (8).

Undo clutch-side casing screw (3) and remove ratchet (4), washer (2) and spring (1).

Reassembling gear stopper and ratchet

Slide ratchet (4), washer (2) and spring (1) on the gear stopper bolt (3).

Position gear stopper to clutch-side casing. The end of the spring (1) must locate behind the casing rib.

Tighten the bolt (3) to the specified torque (Sect. C 3, Engine torque settings).

Position gear stopper to clutch-side casing. The end of the spring (1) must locate behind the casing rib.

Tighten the bolt (3) to the specified torque (Sect. C 3, Engine torque settings).

Thoroughly grease and then fit ball (8), spring (7) and seal (6) into gear stopper (5).

Tighten gear stopper to the specified torque (Sect. C 3, Engine torque settings).

Reassembling the gear selector lever

Position the gear selector lever (25) together with control shaft, spring and plate into the chain-side casing.

Position the gearbox drum selector fork in the centre of the drum rollers.

Temporarily fit gear change lever (or a service lever) and front sprocket and shift to second gear.

Fit plate part no. 88713.1091 to the fork shaft pins (see figure).

Align the notch which marks the centreline of the fork shaft pawl, with the end of the plate.

Then tighten (Sect. C 3, Engine torque settings) the gear selector lever retaining screws (18) and (20).

With the gearbox at rest position, check that lever travel is the same when shifting up and down. The same should apply when a gear is engaged.

Operate the gear change lever and turn the sprocket at the same time to check that all the gears engage when shifting up and down.

Remove the lever and sprocket you had installed previously.


Operations	Reference - See Section
Fit the clutch cover complete with clutch housing and primary drive	N 6.2, Refitting the clutch cover
Refit flywheel/generator assembly and generator cover	N 8, Refitting flywheel / generator assembly