MBW GPR135 - Manual (Page 16)

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Refer to BASEPLATE ASSEMBLY, page 28.
15. Remove the plastic plugs (#1) from the threaded
holes in the shaft covers (#7, #9, #12 & #18). This
can be done using a #2 phillips screwdriver lightly
tapped into the center of the plug and unthreading it
as a screw.
16. Clean all dirt from the threaded holes in the shaft
covers which were not plugged and “chase” the
threads with a 5/16-18 UNC thread tap.
17. Remove the covers from the idler shaft (#8) ends of
the baseplate by removing the flange screws (#23)
and using two 5/16-18 x 2” long screws to press off
the covers by installing them into the threaded holes
cleaned in the previous steps. Turn both screws
evenly to prevent binding of the cover in the bore.
18. Note: Make sure the bearings and their inner
races are kept as a matched set.
19. Remove the idler shaft (#8) and idler gear (#11) from
the baseplate.
20. Press the inner bearing races from the ends of the
idler shaft (#8).
21. Press the idler gear (#11) off the idler shaft (#8) and
remove the key. (#12).
22. Repeat steps 16 and 17 for the input shaft covers.
23. Remove the input shaft (#16) as an assembly from
the baseplate.
24. Slide the input gear (#10) to one end of the input shaft
and remove the helix pin (#11) from the input shaft
and slide out the helix pin carrier (#9) as a
subassembly.
25. Press the inner bearing races from the ends of the
input shaft (#16).
26. Slide the input gear (#10) off of the input shaft (#16).
27. Remove the roller bearings (#4) from the shaft covers
(#7, #9, #18 & #12) by removing two 5/16” flange
head bolts (#21) from the covers and use a 1/4” x 2”
long pin punch to “tap” the bearings out of the covers.
Alternate between the access holes evenly to
prevent binding of the bearings in the covers.
Refer to LOWER SHAFT ASSEMBLY, page 30.
28. Note: performance of the following steps will
require replacement of the ball bearings (#3).
M-B-W recommends replacement of these
bearings as a set at every complete disassembly
or rebuild.
29. Remove the internal retaining ring (#8) from the helix
pin carrier (#9) and remove the shift shaft (#10) and
bearings (#3) as a subassembly from the carrier.
30. Remove the e-clip retaining ring (#5) securing the
bearings to the shift shaft.
31. Secure the bearings in a vice and press out the shift
shaft (#10). Note the position of the spacer
washer (#7).
Handle Disassembly Procedure
Refer to Main Assembly, page 22.
1. Disconnect the hydraulic line (#22) from the fitting in
control head (9) of the handle. Use a drain pan to
catch the hydraulic oil.
2. Remove the four hex head flange screws (#28)
securing the handle shock mount (#19) to the engine
deck (#21).
3. Remove the handle assembly from the main
assembly.
4. Disconnect the throttle cable (#18) from the engine.
5. Remove the four flat head socket screws (#39)
securing the spindle mounts (#11) to the
shockmounts (#19).
Refer to Handle Assembly, page 28.
6. Remove the two flat head socket screws (#21)
securing the throttle lever (#7) to the handle and
remove the throttle lever and throttle cable as a
subassembly from the handle.
7. Remove the four hex head flange screws (#31)
securing the handle mounts (#4) to the handle (#8)
from inside the tube.
8. Remove the two jam nuts (#32) securing the
threaded rod (#2) to the handle and remove the
handle bumper shockmount (#3) and threaded rod.
9. Drive the spirol pin (#29) from the control handle
(#17) and separate the control handle from the
control shaft (#20).
10. Remove the four hex head flange screws (#30)
securing the handle bars (#11 and #12) to the handle
(#8) and remove the handlebars from the handle.
11. Remove two self tapping screws (#1) from handle
tube (#8) and remove tube cap (#13)
12. Remove retaining rings (#6) from control shaft (#20)
and two flange lock screws (#24) from shift bracket
(#10) and slide control shaft (#20) out of handle tube.
13. Remove bearings (#14) from handle tube (#8).
14. Remove four flange lock screws (#27) from control
head (#9) and slide control head out end of handle
tube (#8).
15. Remove shoulder bolts (#18), washer (#26) and
locknuts (#22) from shift linkage (#16).