Re Aasemble the Gearbox
All parts should be clean with seals and bearings replaced if required. Mount the gearbox halfcase with the bolt threads in a vice clamping by the suspension arm. Install the crown wheel, middle gear and then drive gear. Apply loctite master gasket or similar to the sealing surface. Put in 200ml SAE90 gear oil. Put top half on and match using 2 x 5mm drill shanks.
Install and tension bolts.

Diss Assembly the Gearbox
Mount the gearbox in a vice clamping by the suspension arm with the bolts facing up. Remove the brake nut and the bolts around the middle of the case. Tap with a hammer to break the master gasket glue and lift off the upper case. Remove the drive gear and middle gear and then lift out the crown wheel assembly.

Replace an Axle seal
The axle seal can only be replaced by dismantling the gear box. Remove the c-clips ( there is sometimes 2 on earlier models ) from the axle shaft inside the gearbox. Remove the axle shaft. Remove the seal and clean seal surface and install new seal and lubricate. You may need to use a copper hammer. Polish the axle shaft where the seal and bearing runs and reinstall axle shaft with new c-clips.

Replace a Drive Boot
The drive boot can be replaced in the scooter without removing the transaxle or while the transaxle is out of the scooters. Remove the front trailing arm bolt and the lower stub axle bolt and fold the stab axle of the axle shaft. Replace drive boot using lots of lithium grease. Important. Make sure that the rear wheels have the correct preload. You must be able to just turn the axle collar. Adjust using copper shims. See How

Refit the TransAxle
The transaxle goes back in as a complete assembly. All repairs or maintenance should have already been done. Sit in place and install 3 mount bolts. Connect trailing arms and shock mount. Refit motor and brake assemblies. Refit wheels and tyres. Important. Make sure that the rear wheels have the correct preload. You must be able to just turn the axle collar. Adjust using copper shims. See How

Remove the Transaxle
The transaxle comes out easliy. Remove the wheels, motor and brake assembly. Remove the shock mounting bolts, trailing arm bolts. Then on the top side of the transaxle remove the 3 mount bolts. On eallier models this is the 4 spider arm nuts. The transaxle comes out as a complete unit. Do not dissassemble suspension arms and bushes whilst the transaxle is in the scooters.

Refit the Tiller Shroud
The tiller shroud is easy to refit in a few minutes. Connect the keyswitch and charger. Then peel off the shroud and position correctly. Fit the indicators and side screws loosely at first. Make sure you have the correct wiring for left and right indicators. refit the headlight using the retaining springs. refit the rear cover, throttle boots and top dash. Install front basket.

Remove the Tiller Shroud
Access the Electronics
The tiller shroud is removable in a few minutes. Remove the basket and bracket, flip back the top dash and remove the throttle boots. Remove the rear panel and from behind unhook the headlight retaining springs. Remove the indictors and 2 side screws. Peel the tiller off taking note of the Keyswitch and charger connectors.

Change a Tyre
Here I am using a 10mm and 12mm socket bar in a vice. Use lots of liquid soap. On the smaller 4 inch rim there is a cut out that acts as a slot to rotate the tyre off the rim through the cutout. The tyre must be taken off over the smaller inside bead. Important. Make sure that the rear wheels have the correct preload. You must be able to just turn the axle collar. Adjust using copper shims. See How