Clutch housing components of the F5M22 gearbox
1 - clutch housing; 2 - secondary shaft; 3 - intermediate shaft; 4 - primary shaft; 3 - gear shift forks; 6 - oil tray; 7 - gearbox housing; 8 - Reverse light switch; 9 - 5th gear engagement fork; 10 - back cover; 11 - 5th gear pinion; 12 - intermediate gear; 13 - breather; 14 - axis of the idler gear of the reverse gear; 15 - reverse gear parasitic gear; 16 - speedometer drive gear.
Mount the gearbox on a suitable stand or workbench.
Remove the back cover.
Remove the reverse light switch, gasket and bracket.
Unscrew the plugs (arrow), remove the springs and balls (arrow in the figure XS12.025).
Remove the speedometer drive gear assembly (arrow) and breather (Figure XS12.026).
Remove the pin using a punch.
Remove the cotter pins from the input shaft and intermediate shaft lock nuts.
Engage the reverse gear of the main gear using the control levers.
Install a drift on the primary shaft. Screw a 10 mm bolt into the hole on the clutch housing side and attach the flywheel handle to the drift to remove the lock nut.
After unscrewing the reverse intermediate gear shaft bolt, remove the gasket.
Disconnect the final drive housing from the clutch housing.
Remove the differential seal and guide.
After unscrewing the bolt, remove the spring washer and the stopper bracket.
Remove the stop ball assembly, gasket and seal.
Remove the 3 outer bearing races and spacers.
After unscrewing the bolt, remove the reverse gear shift lever assembly and the shift lever shoe.
Remove the idler shaft and idler gear.
Remove the shift pins, shift rods and shift forks (1, 2).
Remove the bearing holder by unscrewing the two bolts.
Raise the input shaft assembly and remove the intermediate shaft assembly.
Remove the primary shaft assembly and secondary shaft assembly.
Secondary shaft elements (1)
Remove the differential drive gear assembly.
Remove 3 bearing rings and guide ring.
Remove the two oil seals, magnet and magnet holder.
Remove the control elements from the clutch housing (see Fig. XS12.039).
ATTENTION: Remove the control element only in case of emergency, since the disassembly process involves cutting off the locking plate (4). A new locking plate will be required for assembly.
Disassemble, wash and check the gearbox components.
Check the rods and forks for wear and damage. Replace if necessary (Figure XS12.036).
The gearbox is assembled in the reverse order.
Controls
1 - clutch housing; 2 - control fork; 3 - gear selection lever; 4 - locking plate.
Gearbox rods and fork F5M22
1 - 1st - 2nd gear shift rod; 2 - fork; 3 - 3rd - 4th gear shift rod; 4 - fork; 5 - 5th gear engagement rod; 6 - clip.