Install the reverse intermediate lever mounting bolt.
Move the intermediate reverse lever in the direction indicated by the arrow in the photo. and screw the bolt securing the lever in the crankcase until it stops in the intermediate lever. In this case, the bolt and the threaded bushing of the intermediate reverse lever must be in line.
Move the intermediate reverse lever towards the bolt. Loosen the bolt until it clicks, i.e. before passing through the start of the thread. In any case, the bolt must be backed out by at least 1/4 turn.
Reverse Intermediate Lever Adjustment
Tighten the reverse intermediate lever bolt to 3.5 kgf·m.
Engage reverse several times and check for ease of operation of the intermediate reverse gear.
Engage reverse.
Install the output shaft.
Install the 1st and 2nd gear shift fork with the stem and fully bury the output shaft.
Replace the spring latch and turn off the reverse gear.
Remove the circlip of the cylindrical roller bearing inner race from the input shaft.
On the press, press using a puller with dimensions of 12-75 mm (e.g. Kukko 17/1) inner ring of a tapered roller bearing.
Reinstall the input shaft and insert the 3rd and 4th gear fork into the cylindrical groove of the synchronizer sliding sleeve.
Deepen the input shaft completely.
Install the yoke pins.
Installing the fork stem locks
Install, having previously lubricated, the stem of the shift fork of III and IV gears together with a cracker.
Insert the spring cotter pins into the holes of the 3rd and 4th and 1st and 2nd gear shift forks.
Install the fork steerer thrust bolts with new cardboard spacers.
Clamp in a vise with pads made of soft material the gear wheel of the fourth gear of the secondary shaft.
Size measurement «A» to determine the thickness of the shim of the V gear of the output shaft
Measure the size «A» (see photo) and determine the thickness of the shim according to the following table:
Size «A», mm | Adjusting washer thickness, mm |
8,35-8,64 | 1,10 |
8,65-8,94 | 1,40 |
8,95-9,24 | 1,70 |
9,25-9,54 | 2,00 |
9,55-9,84 | 2,30 |
Install the selected shim.
Heat up to 120°C gear V of the mainshaft gear and install it in place, using a mounting sleeve if necessary. The shoulder of the 5th gear must be directed towards the final drive gear.
Pressing the 5th gear
Install the washer and screw the hex bolt into the rear end of the output shaft, tightening the bolt with a torque of 5 kgf·m.
Clamp the input shaft in a soft padded vice so that both shafts are vertical.
Lightly grease the input shaft bearing cylindrical rollers and slide them out.
Heat the inner ring of a cylindrical roller bearing to about 120°C and press the ring onto the shaft. If necessary, press it in to the stop using the mounting sleeve.
Determine the thickness of the circlip of the inner ring of the cylindrical roller bearing. Pick up the thickest ring and put it in place. The axial clearance must not exceed 0.05 mm.
Determining the Thickness of a Tapered Roller Bearing Retaining Ring
Install the 5th gear sliding gear with synchronizer sleeve, needle bearing and yoke.
Insert the spring cotter pin into the hole of the 5th gear fork.
Install the synchronizer circlip and 5th gear synchronizer blocking ring.
Heat the 5th gear to a temperature of about 120°C and put it on the end of the input shaft. In case of difficulty, press it with the mounting sleeve until it stops.
Press on the second inner race of the ball bearing with a mandrel.
Install the dowel sleeves and a new seal.
Install the gearbox rear cover.
Press on the first inner race of the ball bearing with a mandrel.
Torque tighten the input shaft hex bolt to 5 kgfm.
Tighten bolts of fastening of a back cover of a transmission the moment of 2,5 kgfs m
Insert a new plug into the hole in the gearbox rear cover.
Apply a thin layer of sealant to the mating surfaces of the gearbox and clutch housings and connect them.
Press the mounting sleeves into the crankcase holes and tighten the fastening bolts to a torque of 2.5 kgf·m
Apply a thin layer of sealant «D3» the mating surfaces of the clutch housing and selector rod, and reinstall the selector rod assembly.
Install the lever on the gear selector shaft, while the end notch of the lever should come to the level of the rod at an angle of 90° (see photo).
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