Assembling the gearbox

If you do not make adjustments endplay primary and secondary shaft and differential, adjust as described.

Gearbox assembly procedure is as follows:

check that the internal and external surface of the gearbox housing and clutch were clean;

if necessary, replace the starter shaft sleeve, which with the help of a stripper Xpress with the old shaft sleeve and a mandrel (length of pipe of suitable diameter) press in the new bushing and lubricate it. The sleeve can be replaced without removing the gearbox;

Position the clutch so that the side with which the clutch is installed, appeared at the bottom;

Lubricate differential bearings and install the differential gear drive of a speedometer in the crankcase;

Set the output shaft in the gearbox. Check that the studs bearing support were installed O-rings, and the flat part of the support has been directed to the reverse gear;

set the transmission input shaft;

replace the helical reverse gear, then install the shaft backing. Enter the spur gear teeth of the reverse engagement with a corresponding gear on the secondary shaft;

setting the fork reverse gear on the spur gear backing, align the hole in the plug holder with the threaded hole in the crankcase and screw the bolt holder forks, tightened its demanded moment;

the gasket and the holder of the shaft (Fig. 8.43) reverse gear;

Set the main unit shift forks, with forks tips should be established in the grooves of sliding rings of the synchronizer;

temporarily remove the stud M8h100 holder shaft reverse gear selector plate and align. Plugs gear must be in the groove sliding sleeves;

Install the magnet into the slot in the transmission housing;

Apply a thin coat of sealant to the mating surface of the gearbox housing, align the gearbox housing and the clutch and screw bolts, having tightened their moment regulated;

after assembly of the gearbox shaft holder set screws reverse, which first cross-screw screw 1 (see. Fig. 8.43). remove the threaded rod, screwed into the transmission housing, and screw longitudinal screw 2. Tighten in sequence, first the screw 2, then screw 1. This requires Togh screwdriver. Use only new screws;

Install guide sleeve (Fig. 8.44) release bearing and fix its bolts, having tightened their demanded moment. When you install the release bearing guide sleeve, you must install a new O-ring;

to align the axes of the forks (Fig. 8.45) and setting pins of plugs of inclusion of transfers set a screwdriver through the window transmission and orient the switching mechanism to be able to set the pins;

Install the shaft gear selection mechanism (Fig. 8.46) to the neutral position, and set the shaft so that the projection on it located in a recess on the housing. Move the shaft so that the pin shaft in the hole lever forks gear and tighten the bolts regulated shaft torque;

Install the cover over gear selection and tighten the cover bolts torque regulation;

replace the cover shaft gear selection mechanism;

establish a transmission clutch housing down;

Install the counter shaft fifth gear, pre-heat it to 100 ?� C;

Install the input shaft needle bearing leading fifth gear, then install the gear and synchronizer ring lock;

Set the spring on the lock ring of the synchronizer;

set the synchronizer hub and the sliding sleeve of the synchronizer so that the bevelled teeth on the sliding sleeve facing toward fifth gear (Fig. 8.47);

Place the washer on the slave and master fifth gear and fix their bolts, preliminary having put on a carving of bolts the means interfering their otverchivaniyu. When tightening the bolts, lock gear fifth gear pinion against rotation, while the fifth gear and the reverse gear;

install and adjust the plug 1 (Fig. 8.48), the fifth gear. Pre-set the forks tips fifth gear into the groove of the sliding sleeve of the synchronizer pins plug and screw the fifth gear;

including fifth gear, put on two opposite sides between the sliding sleeve and the synchronizer gear fifth gear two probes and a thickness of 1.2 mm by pressing on the back of the fifth gear fork in the direction of the transmission housing, tighten the bolt lever movement forks fifth gear ( Fig. 8.49);

Clean the surface of the gearbox housing, mating with the lid of the fifth transfer, install the gasket and the cover of the fifth transfer and secure cover bolts, having tightened their moment regulated;

Install the speedometer drive;

if necessary, install new O-rings of the differential;

Install the new lock ring on the drive flange, apply the sealing lips of the sealing rings of differential layer of grease and install the drive flange to the transmission to the accurate fixing of the retaining ring (Fig. 8.50);

the lever and clutch release bearing;

Install the transmission mounting support;

Install the bracket shift cable.