Gear Stack Rebuild

• Large Flat Head Screwdriver
• Marker
• 14 MM Wrench
• Feeler Gauges (2 Sets)
• External Snap Ring Pliers

Put the Drive Shaft part of the Gear Stack into the vice

Remove the Circlip

Remove the Shoulder Washer

Remove 1ST Gear

Clean the oil off the gear

Mark which ever side you prefer but remember which one it was (this will come in handy when putting it back together

Remove 3RD and mark it

Remove 2ND and mark it

Remove 1ST and mark it

Inspect all the Gears for any defects

Inspect the inner portion of each gear for defects

Pull the Selector Spindle all the way up

• NOTE: The Selector Spindle is REVERSE threaded
• Use your 14MM Wrench to loosen it
• Use a Screwdriver to keep the Drive Shaft form spinning

Remove the Selector Spindle

Remove the washer

• Place two fingers on the Rounded sides of the Cruciform
• Push on the Square side of the Cruciform with a screwdriver
• Until it is straight up and down

Pull it out

• Inspect the tips of the Cruciform
• Notice thedifrence between an old one (your right) and a new one (your left)

Inspect the splines on the Drive Shaft replace if they are messed up

Inspect the threads on the Drive Shaft replace if they are messed up

This side is up

• Hold the NEW Cruciform by one of the Rounded sides
• Place it in the Drive Shaft

Spin it down

A small dab of grease will help the washer stick

Note: The washer has a bevel on it this will face up

Place the washer on the Selector Spindle

Slide the Cruciform all the way up

Screw the Selector Spindle into Cruciform remember the threads are REVERSE

Make sure the shaft travels up and down freely

• Install 4TH Gear
• Remember which side your marks were on so you put the gears back on the correct way

Install 3RD Gear

Install 2RD Gear

Install 1ST Gear

Install shoulder washer

• Install circlip with circlip pliers.
• check tolerance of shoulder washer to make sure it is still with in specs for your scooter
• specs coming soon!

finsihed