2. Install the gear selection and engagement lever and shaft.
a) Install the gear selection and engagement lever, two springs and seat.
b) Install the shaft.
c) Using a hammer and special tool, screw in the split pin.
3. Install the outer gear shift lever and boot. Insert the pin and tighten the nut.
4. Install the outer and inner gear selector lever.
a) Install the inner gear selector lever.
b) Install the outer gear selector lever and washer.
c) Install the pin and tighten the nut.
5. Insert the hubs of couplings #1 and #2 into the hub bushings and insert the synchronizer crackers into their grooves. Install the springs under the synchronizer crackers.
Warning: The springs must be installed under the synchronizer crackers in such a way that the end of one spring does not coincide with the end of the other spring.
6. Install the third gear pinion and hub coupling No.2 onto the secondary shaft.
a) Apply transmission oil to the shaft and needle bearing.
b) Place the synchronizer ring on the gear and align the grooves in the ring with the synchronizer crackers.
c) Insert the needle bearing into the third gear gear.
d) Using a press, install the third gear pinion and hub coupling No.2.
7. Install the retaining ring.
a) Select a retaining ring to ensure minimum axial play and install it on the shaft.
8. Measure the third gear axial clearance.
- Nominal clearance - 0.1 -0.25 mm
9. Install the second gear pinion and hub coupling No.1.
a) Apply transmission oil to the shaft and needle bearing.
b) Place the synchronizer ring on the gear and align the grooves in the ring with the synchronizer crackers.
c) Insert the needle bearing into the second gear gear.
d) Using a press, install the third gear pinion and hub coupling No.2.
10. Install the retaining ring.
a) Select a retaining ring to ensure minimum axial play and install it on the shaft.
11. Install the spacer sleeve and first gear.
a) Install the spacer sleeve on the secondary shaft.
b) Apply transmission oil to the needle bearing.
c) Assemble the first gear pinion, synchronizer ring and needle bearing.
d) Install the assembly unit on the secondary shaft and align the grooves in the ring with the synchronizer crackers.
12. Install the first gear thrust washer onto the secondary shaft and align it with the pin.
13. Using a special tool, install the secondary shaft central bearing.
14. Measure the axial clearance of the first and second gears.
Nominal clearance:
- First gear - 0.10-0.45 mm
- Second gear - 0.10-0.25 mm
15. Install the fifth gear using a special tool and a press.
16. Install the secondary shaft in the intermediate plate by pressing the secondary shaft and lightly tapping the intermediate plate. Install the retaining rings.
17. Install the input shaft.
a) Apply transmission oil to the needle bearing and install it on the input shaft.
b) Place the primary shaft on the secondary shaft, ensuring that the grooves of the synchronizer ring match the synchronizer crackers.
18. Install the intermediate shaft.
19. Install the reverse gear selector lever bracket and tighten the bolts.
- Tightening torque - 18 Nm
20. Install the reverse gear selector lever onto the bracket.
21. Install the reverse idler gear and shaft.
a) Align the reverse gear selector pin with the intermediate gear groove and insert the shaft into the intermediate plate.
22. Install the rear bearing housing.
a) Align the rear bearing housing with the idler gear shaft groove and tighten the bolts.
- Tightening torque - 18 Nm
23. Insert the fifth gear intermediate gear into the coupling of hub No.3.
a) Install the synchronizer crackers and hub coupling No.3 on the fifth gear intermediate gear.
b) Install the springs under the synchronizer crackers.
Warning: The springs must be installed under the synchronizer crackers in such a way that the end of one spring does not coincide with the end of the other spring.
24. Install the ball and thrust washer.
25. Install the fifth gear intermediate gear with the hub coupling No.3 assembly and needle bearing.
a) Apply transmission oil to the needle bearing.
b) Install the fifth gear intermediate gear with hub coupling No.3 and needle bearing.
26. Install the synchronizer ring and the fifth gear synchronizer hub.
a) Install the synchronizer ring onto the synchronizer hub.
b) Using a press and a tool head, press in the fifth gear synchronizer hub so that the grooves in the synchronizer ring exactly match the synchronizer crackers.
Note: After installing the fifth gear synchronizer hub, gently hit it as shown in the figure, creating a load of 1.5-2.0 kg.
27. Install the lock nut.
a) Engage the gears.
b) Install and tighten the lock nut.
- Tightening torque - 127 Nm
c) Using a hammer and chisel, tap the lock nut into place.
d) Disengage the gears.
28. Measure the axial clearance of the fifth gear intermediate gear.
- Nominal clearance - 0.10 - 0.35 mm
29. Install the speedometer ball and pinion gear.
30. Using a special tool, install the secondary shaft rear bearing.
31. Install the shift fork rod No.4, the reverse gear shift rod head and the shift fork No.3.
a) Install gear shift fork No.3 into the groove of hub coupling No.3.
b) Insert the rod of the gear shift fork No.4 into the fork through the intermediate plate and put on the reverse gear engagement fork.
c) Install the reverse gear engagement rod head and the locking ball onto the gear shift fork rod No.4.
32. Install the shift fork rod No.3.
a) Using a magnetic pin and a screwdriver, install the locking ball into the intermediate plate.
b) Install the pin into the shaft hole.
c) Insert gear shift fork No.1 into the groove of hub coupling No.1.
d) Insert the shift fork rod No.3 through the reverse gear fork and the intermediate plate.
33. Install the shift fork rod #2, fork and rod head.
a) Using a magnetic pin and a screwdriver, install the locking ball into the intermediate plate.
b) Install the pin into the shaft hole.
c) Insert gear shift fork No.2 into the groove of hub coupling No.2.
d) Insert the shift fork rod No.2 through the shift forks No.1 and No.2 and the intermediate plate.
34. Install the split pins into the piston rod head and the reverse gear engagement fork.
35. Install the shift fork rod No.1.
a) Using a magnetic pin and a screwdriver, install the locking ball into the intermediate plate.
b) Insert the shift fork rod No.1 through the fork No.1 and the intermediate plate.
36. Checking gear shifting.
a) Engage first gear.
b) The rods of gear shift forks No.2, 3, 4 should not move.
37. Install the retaining rings using a hammer and round-nose pliers.
38. Tighten the mounting bolts.
- Tightening torque - 20 Nm
39. Install the retainer balls, springs and threaded plugs.
a) Apply sealant to the threaded plugs.
b) Install the locking balls, threaded plugs and tighten them with a special tool.
- Tightening torque - 19 Nm
40. Install the magnet into the intermediate plate.
41. Release the vice, remove the intermediate plate and remove the bolts, nuts and washers.
42. Install the gearbox housing,
a) Apply sealant as shown in the figure.
b) Install the crankcase onto the intermediate plate. Use a hammer if necessary.
43. Install the retaining rings of the front bearings of the primary and intermediate shafts using round-nose pliers.
44. Install the front bearing housing.
a) Apply sealant to the housing as shown in the figure and install it on the gearbox housing.
b) Apply sealant to the bolts and tighten them.
- Tightening torque - 17 Nm
45. Install the extension housing.
a) Apply sealant to the extension housing and screw it to the intermediate plate.
- Tightening torque - 37 Nm
46.Install the side cover.
Apply sealant as shown in the picture and bolt to the gearbox housing.
47. Install the shift mechanism housing.
a) Apply sealant as shown in the figure.
b) Apply sealant to the bolts and screw the housing to the gearbox housing.
- Tightening torque - 17 Nm
48. After installing the shift mechanism housing, check the following:
a) That the primary and secondary shafts rotate smoothly.
b) That switching can be carried out smoothly in all positions.
49. Install the clutch housing.
a) Install the clutch housing and tighten the bolts.
- Tightening torque - 36 Nm
50. Install the reversing light switch.
- Tightening torque - 44 Nm
51. Install the speedometer drive driven gear.
52. Install the release fork and bearing.
Apply consistent grease to the surface of the following parts:
- The release fork and hub at the points of their contact with each other.
- The release fork and pusher at the points of their contact with each other.
- Release fork mounting hinge.
- Splined part of the clutch disc.