Note. When pressing, make sure that the fork of I and II gears moves freely, if necessary, release it from jamming with light blows of a mallet. When doing this, make sure that the fasteners remain in place.
The position of the latches of the shift fork rods will be transmitted
Install yokes I and II on the stem.
gear leash and insert the spring pin.
Install the reverse intermediate gear on the axle and press the axle.
Install the input shaft in the gearbox housing.
Extend the 3rd and 4th shift fork shaft until the 3rd and 4th shift fork can be inserted into the cylindrical groove of the synchronizer sliding sleeve. Move the yoke stem to the neutral position and fix the yoke on the stem with a spring cotter pin, while holding the stem with a hammer so as not to damage the hole in the crankcase cover.
Install a new gasket and connect the gearbox housing to the clutch housing.
Press in the dowel pins and tighten the gearbox housing mounting bolts to a torque of 2.5 kgf·m.
Install the input shaft mounting cross member to the clutch housing.
Press the input shaft ball bearing into the socket of the clutch housing with the closed part of the separator towards the crankcase. Install the thrust washer and circlip onto the ball bearing.
Remove the cross bar.
Engage 1st gear and reverse, tighten the nut at the end of the secondary shaft to a torque of 10 kgf·m and lock it.
Set the fork stems to the neutral position.
Carefully slide the 3rd and 4th shift fork shaft in the direction of the 3rd gear until the latch, pre-lubricated with a thin layer of grease, can be put in place. Return fork stem to neutral position.
Warning. Move the fork stem only as far as necessary to avoid falling out of the synchronizer cotters, since in such a case the fork will not be set to the neutral position. If crackers fall out, you will have to disassemble the gearbox again, insert crackers into the grooves of the synchronizer hub (this is possible only in a strictly defined position of the synchronizer blocking ring) and slide over the sliding sleeve.
Select the thickness of the adjusting rings for the correct installation of the rear bearings of the primary and secondary shafts.
Install the parts in the gearbox rear cover:
- install the spring on the gear selection rod, while the leg of the spring should rest against the lever on the gear selection rod;
- install the adjusting ring of the rear output shaft bearing into the groove of the gearbox cover.
- screw two threaded studs into the gearbox housing cover to center the rear gearbox cover,
- set the fork rods to a neutral position and put a gasket of the required thickness;
- slide the selector rod leash into the cutouts of the fork rods.
Section of the rear cover of the gearbox: 1 - back cover; 2 - curly spring; 3 - gear selection lever; 4 - stem of the reverse fork; 5 - a rod of a fork of switching of I and II transfers; 6 - a rod of a fork of switching of III and IV transfers
Push the rear cover onto the mounting studs in the gearbox housing, move the rear cover to the right and tighten its fastening bolts with a force of 2.5 kgf·m.
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