Overview photos: A view of the rear of the transmission.
gregory bender
http://www.thisoldtractor.com/gtbender
Here is the series of photos I took during the disassembly of the transmission on my I-Convert project bike. Assembly is pretty much the reverse. It should go without saying that all the parts were fastidiously cleaned and new o-rings and seals were fitted throughout.
Overview photos: A view of the rear of the transmission.
Overview photos: Here is the shift arm and how it was originally positioned.
Overview photos: Here is the vent. I never did remove this from the case. Just cleaned it thoroughly in place.
Overview photos: Note use of multiple aluminum crush washers to prevent the acorn nuts from bottoming out before making a tight seal.
I began disassembly with removing the converter cover from the 2 speed gear box. I didn't know how critical the position of the bronze bushing was. So I took several shots from different angles.
Another photo of the bronze bushing.
Another photo of the bronze bushing.
Another photo of the bronze bushing.
Another photo of the bronze bushing.
Finally I felt confident enough to remove the bronze bushing from the shaft.
Remove the 6 bolts that secure that converter cover to the 2 speed gearbox. The converter cover will then seperate from the 2 speed gearbox.
This is the clutch input hub that interfaces with the clutch plates.
Rotate the clutch input hub until the bolts are visible through the access holes.
Remove each of the 5 bolts and withdraw the assembly. The outer piece should slide right off.
Note the o-ring and the holes that must align with the passageways in the previous photo during assembly. You can see that I've already started to separate the two pieces that are held together by the 5 bolts.
Another view of the same.
Another view of the same.
With the two pieces separated, you can completely remove the front piece, exposing the bearing. I think there was also a snap ring and an o-ring around the shaft, but I failed to take a photo of them.
Remove the bearing.
Remove the seal, note the direction that it must be installed.
Remove the bottom plate.
Here is the seal and several of the passwages.
Drive the seal out.
Here is how it must be positioned during assembly.
A view of the converter cover.
A closer view of the fittings for the oil lines. Notice the bottom one is a smaller diameter than the top one. I removed both of these. That about covers the removal and disassembly of the convert cover.
With the convert cover removed and disassembled, I turned my attention to the 2 speed gearbox. Here is the stack of clutch plates installed.
Another view of the cluthc plates.
Here is the snap ring that must be removed. In order to do that, we must first take the pressure off of the clutch and intermediate plates.
I used the clutch throw out bearing adjustment nut at the rear of the transmission to take the pressure off of the clutch and intermediate plates.
First, remove the smaller jam nut from the back of the transmssion.
I also removed the adjustment nut and the lever so I could clean and lubricate the threads. Also, I wanted to remove the rubber boot from the lever so it would be easier to tighten the adjustment nut.
I put the lever back on with the adjustment nut. I then tightened the adjustment nut to compress the clutch springs and take the pressure off of the clutch plates. Go slow here. You may need to completely remove the adjustment nut, then clean and lubricate the threads so that you don't destroy the threads in the process.
Another view of the same.
With the large snap ring removed, you can withdraw all of the clutch and intermediate plates.
Here is the stack of clutch and intermediate plates. I kept them in the original order thoroughout cleaning and reassembly. I probably shouldn't matter, but when resuing used parts I like to error on the side of same-ness.
Remove the adjustment nut.
And withdraw the clutch throw out bearing pull rod from the front of the gearbox.
Another view of the pull rod being removed.
The throw out bearing came out easily.
Another view of the throw out bearing being removed.
This is the special insert that fits inside the throw out bearing.
Remove the pressure plate. Note the 6 springs and the thin washers. The washer fit on the pressure plate, not in the basket.
Another view of the pressure plate with thin washers and springs.
The lip of the nut will have been peened into the slot in the shaft. Pry the peened portion away from the shaft.
And remove the nut.
Remove the basket. Mine came off pretty easily without much fuss.
A seal runs on this surface, be sure to clean and dress it properly.
With the clutch basket removed, you can now see the front of the gearbox and the seal.
Note the seal.
And the o-ring.
Before we remove the seal or o-ring, however, lets disassemble the gear box. Start be removing the speedometer drive gear.
Remove the gear drive.
And use a small magnet to withdraw the hardened steel washer down inside that hole.
Set the transmission up on end. Remove the spring loaded plug that holds gear selector pawl in place.
Remove the crush washer.
Withdraw the spring and selector pawl.
Remove the drain plug along with its crush washer.
Remove all of the bolts that secure the cover to the case.
Remove the cover from the case.
Now set the transmission up on end and turn your attention to the output shaft.
Remove the snap ring.
The inside of the cover.
The gears inside the transmission.
A closer view.
