Adjustment dimensions of the position of the gear shift levers of the 4-speed gearbox*
A = 142.0 mm
B = 58.0 mm
C = 111.0 mm
* The gear shift lever is in neutral position.
1. Insert the primary shaft into the crankcase and engage it with the front end of the secondary shaft.
2. Remove the mandrel from the secondary shaft, then, supporting the primary shaft, press the rear bearing onto the secondary shaft and into the crankcase seat.
3. Turn the gearbox so that the intermediate shaft meshes with the gears of the primary and secondary shafts, then press in the front and rear bearings with a mandrel.
4. Engage two gears simultaneously, screw the nut onto the front end of the intermediate shaft and tighten it to a torque of 8.0 kgf·m. If provided, lock the nut by pinning its flange into the groove of the shaft.
5. Put the transmission in neutral, then install the bearing end clearance adjusting shims and the pressure plate on the rear wall of the crankcase and tighten the bolts. If replacing the bearing, adjust the end clearance of the bearing outer ring within 0.0-0.05 mm; to check clearance, measure the distance from the bearing retaining ring and the pressure plate shoulder to the mating surface. If provided, lock the bolts with the tabs of the lock washers.
6. Place the reverse gear on the rear end of the intermediate shaft, then with two gears engaged, screw on the nut and tighten it to a torque of 8.0 kgf·m. If provided, lock the nut by pinning its flange into the groove of the shaft.
7. Insert the reverse gear engagement shaft and at the same time install the locking pin onto the shaft. Align the holes and secure the locking pin with a cylindrical pin.
8. Insert the reverse gear fork into the annular groove of the reverse gear intermediate gear and press it into the crankcase wall using light hammer blows. The chamfer on the end of the axle should be at the top. If a synchronizer locking ring is installed, the groove should face the intermediate shaft.
9. Using a mandrel, press the reverse gear onto the secondary shaft.
10. Insert the gear shift forks into the grooves of the synchronizer clutches through the side window of the crankcase and engage neutral.