2. Install input shaft.
A) Apply grease to the 13 roller needle roller bearing and insert it into the input shaft.
b) Push the input shaft onto the output shaft, ensuring that the grooves of the synchronizer ring match the synchronizer crackers.
3. Install the idle gear in the intermediate plate while holding the idle gear and installing the idle gear rear bearing.
4. Using pliers, install the bearing circlip.
Note: Be sure to ensure that the retaining ring is flush with the surface of the intermediate plate.
5. Install the rear bearing housing and tighten the screws.
- Tightening torque: 18 Nm
6. Install the reverse gear lever bracket and tighten the bolts.
- Tightening torque - 18 Nm
7. Install ball and spacer.
8. Insert the 5th idle gear into the No. 3 hub clutch.
A) Install the synchronizer lugs and the No. 3 hub clutch onto the 5th idle gear.
b) Install the springs under the synchronizer crackers.
Note: It is necessary to install the springs under the synchronizer crackers in such a way that the end of one spring does not coincide with the end of the other spring.
9. Install the 5th idle gear with #3 hub hub assembly and needle roller bearings.
A) Apply gear oil to the needle bearing rollers.
b) Install the 5th idle gear with #3 hub bushing and needle roller bearings.
10. Install the synchronizer ring and fifth gear synchronizer hub.
A) Slide the synchronizer ring onto the fifth gear synchronizer hub.
b) Using a press and a 22 mm socket wrench, press in the 5th gear synchronizer hub so that the grooves of the synchronizer ring fit exactly into the synchronizer nuts.
Note: After installing the 5th gear synchronizer hub, gently hit it as shown in the figure, applying a load of 1.5 to 2.0 kg.
11. Install the lock nut.
A) Engage gears.
b) Install and tighten the lock nut.
- Tightening torque - 118 Nm
V) Lock the lock nut.
G) Disengage gears.
12. Measure the axial clearance of the intermediate gear of the fifth gear.
- Normal clearance - 0.10-0.30 mm
13. Establish a scene of inclusion of transfer of a backing on an arm.
14. Install the reverse idle gear.
A) Install the reverse idle gear onto the shaft.
b) Align the reverse gear pin with the reverse idler gear groove, and insert the idler gear shaft into the intermediate plate.
V) Install the intermediate gear shaft retainer and tighten the bolt.
- Tightening torque - 17 Nm
15. Install the shift fork No. 1 into the groove of the hub coupling No. 1 and insert the shift fork rod into the fork through the intermediate plate and put on the shift head of the first and second gears.
16. Install pins.
A) Apply grease to the pins.
b) Using a magnetic finger and a screwdriver, install the pin into the intermediate plate.
17. Install shift fork shaft No. 2 and shift fork No. 2.
A) Install the pin in the shaft hole.
b) Install the No. 2 shift fork into the No. 2 hub clutch groove, and insert the No. 2 shift fork stem into the aligned holes of the shift fork and intermediate plate.
18. Using a magnetic finger and a screwdriver, install the pin into the intermediate plate.
19. Install shift rod #3.
A) Install the pin in the shaft hole.
b) Install the shift fork stem and reverse gear shift rod head to the reverse shift gate through the intermediate plate.
20. Install shift fork shaft No. 4, shift fork No. 3 and detent balls.
A) Slide the hub sleeve as shown.
b) Install the No. 3 shift fork into the No. 3 hub clutch groove, and insert the No. 4 shift fork stem into the No. 3 shift fork.
V) Using a magnetic finger and a screwdriver, insert the retainer ball into the intermediate plate and install the No. 4 shift fork stem into the intermediate plate.
G) Using a magnetic finger and a screwdriver, insert the detent ball into the reverse gear shaft head hole and install the No. 4 shift fork shaft into the shaft head.
21. Check gear shift.
A) Engage first gear.
b) The shafts of the shift forks No. 2, 3, 4 must not move.
22. Install split pin and bolt.
A) Using the special tool and a hammer, insert the slotted pin into the reverse gear engagement gate, the reverse gear engagement knob, and the No. 2, 3 shift forks.
b) Install and tighten the bolt on the No. 1 shift fork.
- Tightening torque - 20 Nm
23. Using pliers and a hammer, install the four circlips on the shift forks.
24. Install retainer balls, springs and screw plugs.
A) Apply sealant to the screw plugs.
b) Install the retainer balls, screw plugs and tighten them with the special tool.
- Tightening torque - 19 Nm
Note: Install the short spring on the bottom of the intermediate plate.
25. Open the vise, remove the intermediate plate and remove the bolts, nuts and washers.
26. Install the gearbox housing on the intermediate plate with a new gasket.
27. Using pliers, install the two bearing circlips.
28. Install the front bearing housing with a new gasket, apply sealant to the threaded parts of the bolts. Screw in the bolts and tighten them.
- Tightening torque - 17 Nm
29. Install the crankcase extension with a new gasket and tighten the bolts.
- Tightening torque - 37 Nm
30. Install shifter housing assembly with new gasket and tighten with bolts.
- Tightening torque - 17 Nm
31. After installing the shift housing, check the following:
A) That the primary and secondary shafts rotate smoothly.
b) That switching can be smoothly carried out in all positions.
32. Install the clutch housing.
A) Install the clutch housing and tighten the bolts.
- Tightening torque - 37 Nm
33. Establish the switch of a lantern of a backing.
- Tightening torque - 37 Nm
34. Install the speedometer driven gear.
35. Install the release fork and bearing.
Apply grease to the surface of the following parts:
- Release fork and hub in the places of their contact with each other.
- Release fork and pusher in the places of their contact with each other.
- Release fork mounting hinge.
- Splined part of the clutch disc.