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 alternator-side crankcase cover and flywheel-alternator assembly
Unscrew and remove the fixing screws (18) and (20) of the complete gear selector lever (21) and collect the spacer (19).
Remove the gearchange mechanism complete with the 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.
 
If it proves necessary to change components, disassemble the gear selector lever as shown in the exploded view.
Reassemble the gear selector lever orienting the eccentric pin (15), suitably lubricated, in such a way that the lever arm (16) is positioned centrally with respect to the shoulders of the stop plate (23).
Check that the spring (10) is installed correctly as shown in the figure.
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), spring (7) and the detent ball (8).
Unscrew the clutch-side crankcase half screw (3) and remove the pawl (4), washer (2) and spring (1).
 
Refitting the gear interlock plunger and pawl assembly
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). Manually move the gear stopper to check for proper spring operation.
Grease and then fit the ball (8), spring (7), and seal (6) to the gear interlock plunger (5).
Tighten the lug to a torque of 30 Nm (Min. 27 Nm - Max. 33 Nm) (Sect. 3 - 3, Engine torque settings).
 
Refitting the gear selector lever
Position the gearbox drum selector fork in the centre of the gear rollers.
Position the gear selector lever (21) together with control shaft, spring and plate 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 engine pinion and shift to neutral gear.
Place the tool 88713.3334 on the gear claw.
Place the tool 88713.3334 inserting the clutch rod (E) into the tool hole, block the pin (F) of the tool in the gear claw pressing with the hand in the point (G) (claw stroke lock plate) towards the right, as shown in photo.
Tighten the screw (18) in this position to a torque of 36 Nm (Min. 34 Nm - Max. 38 Nm) and screw (20) to a torque of 16 Nm (Min. 15 Nm - Max. 17 Nm) (Sect. 3 - 3, Engine torque settings).
Warning
Make sure that the gear selector lever fixing screws (18) and (20) are those indicated in our spare parts catalogue. They must be screws of class 12.9 in order to respect the tightening torque indicated above (Sect. 3 - 3, Engine torque settings).
 
Start tightening the first screw (18), and continue with screw (20).
Remove service tool no.
Check that the pin (H) placed on the gear drum is axially to the notch (L) on the gear claw (with gear in neutral).
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 previously installed lever and sprocket.
 
Refit the flywheel/alternator assembly. and alternator side crankcase cover
 
 
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