Inspecting the final drive To check wear of the final drive, carry out a visual inspection of the front sprocket (12) and rear sprocket (5). If the teeth are found to worn as shown in the figure (dotted line), the sprocket must be renewed. To check the amount of wear on the...
Removal of the front sprocket Undo the screws (14) and remove the sprocket cover (13). Slacken the chain ( Adjusting the chain tension ). Engage a low gear and unscrew the two screws (10) on the sprocket retaining plate (11). Remove the plate (11) from the gearbox output shaft....
Refitting the front sprocket Check that the splines of the gearbox output shaft and the sprocket are in perfect condition. Hook the chain (9) onto the sprocket (12). Install the front sprocket on gearbox output shaft (B) as shown in the figure. Push the sprocket beyond the...
Removal of the rear sprocket Operation Section reference Slacken the chain Adjusting the chain tension Remove the rear wheel Removal of the rear wheel Slide the complete rear sprocket flange (2) off the rear wheel. Remove the sprocket flange spacer (15). Hold the pins (1) at...
Refitting the rear sprocket If the bearings (4) were removed, to reinstall them, heat the sprocket flange (2) to a temperature of 180 to 200°C. Immediately after heating the flange, install the two bearings (4) in the housing. Fit the circlip (7) in the groove in the sprocket...
Removal of the APTC clutch Operation Section reference Drain the engine oil Changing the engine oil and filter cartridge Remove the clutch-side crankcase cover Removal of the clutch-side crankcase cover Screw the three tools 88713.2591 into the relative bores in the hub....
Disassembly of the clutch hub-plates-centre assembly Unscrew the three tools 88713.2591. Withdraw the hub (13) and the plates (7) from the clutch centre (10). Recover the three springs (12). Remove the clutch plates (7) from the hub (13). Caution! When removing the plates, keep them in the same order...
Overhaul and inspection of the APTC clutch components Clearance between the clutch drum and friction plates Insert a friction plate (C) in the clutch drum (A) and measure the clearance (S) with a feeler gauge. The clearance "S" must not exceed 0.6 mm. If it does, renew the plates and, if necessary, the...
Reassembly of the clutch hub-plates-centre assembly Install the three springs (12) on the pin (E) on the drum (10). Install the clutch plates (7) in the hub (13) starting with one of the 11 friction plates (F) and alternate with the 10 driven plates (G). Install the clutch plate assembly (7) with hub...
Refitting the APTC clutch Locate the spacer (11) on the drum (A). Position the hub-plates-drum assembly (B) inside the drum (A). Note: Position the last friction plate (M) so that it is offset relative to others. Locate the lock washer (9) on the gearbox input shaft, seating...
Clutch assembly: primary drive gears 1. Clutch drum/Primary drive gears; 2. Inner ring; 3. Inner bearing; 4. Spacer; 5. Threaded ringnut; 6. Lock washer Caution! Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in...
Removal of the gearchange mechanism Operation Section reference Remove the alternator-side crankcase cover and flywheel/alternator assembly Flywheel - alternator Remove the clutch drum Removal of the primary drive gears Undo and remove the gear selector mechanism (25) retaining screws...
Disassembly of the gear interlock plunger and pawl assembly Unscrew the interlock plunger screw (5) and remove seal (6), spring (7) and detent ball (8). Unscrew the clutch-side crankcase screw (3) and remove the pawl (4), washer (2) and spring (1).
Refitting the gear interlock plunger and pawl assembly Fit the pawl (4), washer (2) and spring (1) on the retaining screw (3). Fit the assembled unit on the clutch-side crankcase half, locating the end of the spring (1) behind the crankcase rib. Tighten the screw (3) to the specified torque ( Engine...
Reassembly of the gearchange mechanism 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...
Refitting the gearchange mechanism Position the gearchange mechanism (25) in the chain-side crankcase. Locate the gearbox drum selector claw in the centre of the drum rollers. Temporarily fit the gearbox lever (or a service lever) and engage third gear. Fit the plate 88713.1091 in...
Removal of the gearbox assembly Operation Section reference Separation of the crankcase halves Separation of the crankcase halves Withdraw the selector fork shafts (30). Move the forks (28) and (29) to disengage them from the slots in the selector drum (13). Withdraw the selector...
Disassembly of the gearbox shafts Place the shaft in a vice in such a way as to facilitate the disassembly operations. Caution! Take care not to invert the positions of the shims on reassembly: this would potentially lead to jamming when using the gear selector control, making it...
Overhaul of the gearbox Check the condition of the front coupling dogs of the gears. They must be in perfect condition and with no sign of wear on the edges of the teeth. The idler gears must rotate freely on their shafts. When refitting, make sure the circlips are...
Inspection of the gear selector forks Visually inspect the gear selector forks. Bent forks must be renewed as they may lead to difficulties in gear changing or may suddenly disengage when under load. Use a feeler gauge to check the clearance of each fork in its gear groove. If the...
Inspection of the gear selector drum Use a gauge to measure the clearance between fork pin and the slot on the selector drum. If the service limit is exceeded, determine which part must be renewed by comparing these dimensions with those of new components ( Gearbox ). Also check the...
Reassembly of the gearbox shafts Figure 1 shows all the parts to be reassembled on the gearbox input shaft (2), with the calculated end shims (1) and (11) ( Shimming the shafts ). Figure 2 shows all the parts to be reassembled on the gearbox output shaft (25), with calculated end...
Reassembly of the gearbox To reassemble the gearbox components follow the procedure under relating to " Reassembly of the crankcase halves ". As a final practical test, ensure that with the gearbox in neutral the front coupling dogs (A) of sliding gears (B) are equidistant...