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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 26.
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 (#2) from the fitting (#1)
in control head of the handle. Use a drain pan to
catch the hydraulic oil.
2. Disconnect the throttle cable (#19) from the engine.
3. Remove the two hex head flange screws (#24)
securing the throttle lever (#15) to the handle and
remove the throttle lever (with bracket) and throttle
cable as a subassembly from the handle.
4. Remove the four hex head flange screws (#29)
securing the handle mount to the engine deck (#4).
5. Remove the handle assembly from the main
assembly.
Refer to HANDLE ASSEMBLY, page 28.
6. Remove the four flat head socket screws (#35)
securing the spindle mounts (#21) to the
shockmounts (#11).
7. Remove the four hex head flange screws (#34)
securing the shockmounts to the handle (#22) from
inside the tube.
8. Remove the two jam nuts (#33) securing the
threaded rod (#10) to the handle and remove the
handle bumper shockmount (#12) and threaded rod.
9. Remove the two socket head cap screws (#28) from
the control handles (#18) and separate the control
handles from the control head (#13).
10. Remove the six hex head flange screws (#32)
securing the handle bars (#19 and #20) to the handle
and remove the handlebars and the control head
from the handle.
Control Head Disassembly Procedure
Refer to HANDLE ASSEMBLY, page 28.
1. Note the position of the threaded holes in the
pinion shaft (#24).
2. Remove the hydraulic fitting (#1) and the adapter
fitting (#23) from the shaft guide housing (#16).
3. Remove the four hex head flange screws (#29)
securing the shaft guide housing (#16) to the control
head housing (#13). Be sure to note the locations
of the O-rings for the assembly.
4. Remove O-ring (#7) from the shaft guide housing.
5. Remove the pipe plug (#8) and seal washer (#9) from
the control head housing.
