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Author Subject: Gearbox?clutch
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #26
Next up remove the top mount, undo the big 19mm nut and washer.

Then the 2 3mm nuts either side and remove the rubber buffer, (its easier when putting the gearbox back on)

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Posted 24th May 2005 at 20:43
Welly Forum Admin

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Post #27
Next, let the gearbox down, slowly, it will rest on the bricks under the gearbox, and the axle stand

Be carefull as its a lot of weight

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 24th May 2005 at 20:56
Welly Forum Admin

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Post #28
Next remove the bell housing bolts, theres a few off them.

They are quite long, and a mixture of 17mm bolt, and 8mm hex bolts
This is what you are looking for

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Posted 24th May 2005 at 21:07
Welly Forum Admin

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Post #29
Bolt No 1

17mm

Lower front

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Posted 24th May 2005 at 21:08
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #30
Bolts 2 & 3

2 is 17mm

3 is 8mm hex and lower starter motor

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Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

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Posted 24th May 2005 at 21:09
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #31
4 & 5

4 is 17mm and the upper left most

5 is a 8mm hex, and the last starter motor bolt

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Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

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Posted 24th May 2005 at 21:10
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #32
Number 6

This will already be removed, its the bolt from the cover plate..

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Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

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Posted 24th May 2005 at 21:12
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #33
Bolt 7

8mm hex, bit of a bugger to get at this one

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________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 24th May 2005 at 21:16
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #34
Bolts 9 & 10

both 8mm Hex, and facing the other way to the others

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Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

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Posted 24th May 2005 at 21:18
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #35
Once all the bolts are undone, its just a case of wiggling the box backwards and off..

If you keep the jack under the box, you can lower the jack all the way and reaching from the top, swing the box away...

Hey presto box off

BE CAREFULL of the aircon pipe at the bottom of the rad

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 24th May 2005 at 21:21
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,796

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Post #36
To remove the clutch, you will need to undo 6 6mm hex bolts, that hold the cover plate in place.

Undo them evenly, as there is a lot of force in the coverplate.
Once off you can remove the clutch and see the fly wheel for all its gloryBig grin

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 24th May 2005 at 21:25
Welly Forum Admin

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Post #37
While the box is off, gently rub the coverplate with some wet and dry to buff the surface up slighty.

And whilst the box is off, you might as well, grease up the fork ends


Remove the fork by pulling up and away

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 24th May 2005 at 21:35
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #38
You wanna clean and grease this little dude up..Its the bottom of the fork

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 24th May 2005 at 21:37
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #39
Thats about it...

When putting back together, grease the splines up on the gearbox shaft, it helps to allign the splines.

Use the same method when putting the box back on, lift the rear up on to a axle stand, and jack the front up and slide forward..

Again watch the rad and aircon pipes....

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 24th May 2005 at 21:43
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,796

Status: Offline

Post #40
now bolt it all back together, Dont forget to fill up with oil (75/80) and take it steady for the first 100 milesBig grin Big grin

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 24th May 2005 at 21:45

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