Remove the gearbox rear cover.
Loosen the bolts securing the intermediate housing to the gearbox housing and remove the intermediate housing together with the input and output shafts.
Install the intermediate housing on the KM 113 2 stand with the KM 552 tool.
Loosen the fastening bolts and use a lever to separate the bracket for fastening the fifth gear fork from the intermediate crankcase.
Engage any two gears at the same time (e.g. 3rd gear and reverse gear), remove the retaining ring installed in front of the 5th gear synchronizer, and remove the 5th gear synchronizer from the secondary shaft using a KM 161 A puller and KM 161 2 hooks.
Remove the gear of the 5th gear from the secondary shaft, the split needle bearing, slightly expanding it, the retaining ring of the thrust half rings and the thrust half rings.
Remove the retaining ring installed in front of the 5th gear drive gear, and using the KM 553 puller, remove the 5th gear gear from the input shaft.
Remove the bearing support together with the stopper from the intermediate housing. If it is necessary to replace the stopper, knock the axle out of the support.
Using tools KM 458, KM 328 1 and KM 328 5, remove four stoppers and fixing springs from the intermediate crankcase.
At the same time, engage II and V gears, unscrew the fixing bracket bolts.
Engage 3rd gear and remove the retaining clip.
Remove the III-IV shift rod and fork from the intermediate crankcase, as well as the reverse gear rod and fork.
Remove the 5th gear fork.
Remove the circlips from the input and output shafts. Remove the secondary and primary shafts with the reverse intermediate gear, the fork and the shift rod of 1st and 2nd gears, the slider for engaging the 5th gear.
Otherwise, disassembling a 5-speed gearbox is carried out in the same way as disassembling a 4-speed gearbox.
Warning. The hubs of the synchronizer coupling of I-II, III-IV gears are fixed with a retaining ring and washer, all needle bearings of the shafts are split type. A thrust needle bearing is installed in front of the driven gear of the 1st gear.
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