2. If necessary, remove the gear lever shaft radial bearing using a suitable extractor (photo).
3. Use pliers to remove the locating roller bearing circlip (photo). If it is pinched, tap the bearing lightly inward. Remove the gaskets and knock out the bearing from the inside with a metal tube.
4. Using a metal tube, knock out the input shaft bearing from inside the housing (photo).
5. Clean all components, replace as needed.
6. If the main housing or locator has been replaced, perform the following procedure to determine the locator roller bearing spacer.
7. Place the rear crankcase on the bench, install the location mechanism in it with the 5th gear up.
8. Temporarily install the roller bearing, without the positioner shims, into the main housing. With the circlip in position, knock the bearing out until it contacts the circlip.
9. Position the main cowling on the rear crankcase, insert the bolts shown in Fig. 6.8. Tighten them with a torque of 25 Nm.
10. Install a test indicator on the 5th gear of the location mechanism (photo). Set the indicator to zero.
11. Insert a screwdriver through the hole for the oil drain plug, move the positioning mechanism up (photo). Record indicator readings (side play), then subtract 0.20 mm from it to determine the shim thickness required for the positioner roller bearing. Side play should be 0.15-0.25 mm, gaskets are available in thicknesses of 1.7, 1.8, 2.0, 2.1 and 2.2 mm.
12. Remove the location mechanism.
13. Install the positioner roller bearing to the main housing with spacers (photo). With the circlip in position, tap the bearing outward until it contacts the spacer.
14. Drive the new gear lever shaft bearing into the housing (photo).
15. Install the reverse gear assembly, shaft and spring, making sure the short end of the spring is in the housing and the long end is on the block. Insert and tighten the bolt.
16. The input shaft bearing is not installed at this stage.
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