Note. When pressing on, make sure that the fork of I and II gears moves freely, if necessary, release it from jamming with light blows of a mallet. At the same time, make sure that the fasteners remain in place.
Install the leash on the fork rod of I and II gears and insert the spring pin.
Install the reverse intermediate gear on the axle and press the axle in.
Install the input shaft into 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 fork stem to the neutral position and fix the fork 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 ball bearing of the input shaft into the seat of the clutch housing with the closed part of the separator on the side of the crankcase. Install the thrust washer and circlip onto the ball bearing.
Remove crossbar.
Engage 1st gear and reverse, tighten the nut at the end of the secondary shaft with a torque of 10 kgf·m and secure it.
Set fork rods to neutral position.
Carefully push 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 to the required distance in order to avoid falling out of the synchronizer crackers, 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 and 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.
Install differential.
Select the thickness of the adjusting rings for the correct installation of the rear bearings of the primary and secondary shafts.
Install the parts of the rear cover of the gearbox:
- 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 bearing of the output shaft into the groove of the gearbox cover;
- screw two threaded studs into the gearbox housing cover for the rear gearbox cover;
- set the fork rods to a neutral position and put a gasket of the required thickness;
- insert the leash of the gear selector rod into the cutouts of the fork rods.
Push the rear cover onto the mounting studs in the gearbox housing, move the rear cover to the right and tighten the bolts of its fastening with a force of 2.5 kgf·m.
Section of the rear cover of the gearbox:
1 - back cover;
2 - curly spring;
3 - gear selection lever;
4 — a rod of a fork of inclusion of a backing;
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.
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