2. Compose the intermediate and secondary shafts and hold this assembly with a rubber bandage.
3. Install the reverse idle gear so that its annular boss points towards the input shaft.
4. Use the next rubber band to hold this knot.
5. Position the entire assembly in the gearbox housing.
6. Slide the speedometer drive gear together with the spacer sleeve onto the output shaft.
7. Check if the intermediate shaft is correctly installed in the crankcase. Finally set its position with tool 16.042.
8. Insert the reverse idler gear shaft rear bolt and tighten by hand.
9. Remove the speedometer drive gear and spacer.
10. Insert the magnet into the gearbox housing.
11. Remove rubber band.
12. Insert the 3rd-4th gear forks with the undercut pointing downwards, then the 5th and reverse forks.
13. Insert the fork shaft for 3-4 gears, 5th gear and reverse gear.
14. Install the clutch housing on the gearbox housing, inserting three spacers 25 mm thick between the planes of connection of both housings.
15. Lubricate the joint planes with sealing paste.
16. Remove the three spacers and connect the crankcase with tool 16.041.
17. Insert two bolts connecting both crankcases into the holes and carefully connect them finally.
18. Insert the remaining eight connecting bolts and tighten all bolts to the correct torque.
19. Install spacer and speedometer gear onto output shaft.
20. Using a bushing of the correct diameter, install a new O-ring on the propshaft front joint flange.
21. Install the propshaft front joint flange onto the output shaft.
22. Screw in a new flange nut on the rear end of the output shaft, first lubricating the thread surface of the nut with sealing paste. After securing the propshaft front joint flange, tighten the nut to the correct torque.
23. Lubricate the threads of the selector stopper bolt with sealing paste, screw in the bolt and tighten it to the appropriate torque.
Attention! The sealing paste must not get inside the gearbox.
24. Push the bushing of the selector stopper into the crankcase as far as it will go.
25. Install ball, tappet and selector stop spring.
26. Lubricate the threads of the selector stopper plug with sealing paste, screw the plug into the clutch housing and tighten it to the appropriate torque.
27. Screw in the front bolt of the reverse idle gear axle into the clutch housing and tighten both bolts to the appropriate torque (front and rear).
28. Install a new set spring ring on the input shaft.
29. Install a new O-ring on the clutch release bearing guide bush, install the bush inside the clutch housing and tighten its bolts to the correct torque.
30. Install a new O-ring on the countershaft bearing nut.
31. Screw in the intermediate shaft bearing nut at the front of the clutch housing and tighten to 15–20 Nm.
32. Mark the position of the nut in relation to the clutch housing and unscrew it by 60°.
33. Pin two protrusions located near this nut.
34. Check if the intermediate shaft bearing rests on the adjusting nut. This nut must not be turned by hand. Otherwise, repeat the last three operations after unscrewing the nut.
35. Install the intermediate shaft bearing nut fixing plate and tighten the fixing plate fixing bolt.
36. After applying a small amount of grease to the splines of the input shaft and the clutch release bearing guide sleeve, install the clutch release bearing together with the clutch release forks on the input shaft.
37. Screw in the oil drain plugs and tighten them to the correct torque.
38. Fill the gearbox with the correct amount of appropriate gearbox oil.
Visitor comments