Adjusting dimensions of the position of the gear levers of the 4-speed gearbox*
A = 142.0 mm
H = 58.0 mm
C = 111.0 mm
* The shift lever is in the neutral position.
1. Insert the input shaft into the crankcase and engage it with the front end of the output shaft.
2. Remove the mandrel from the output shaft, then, while supporting the input shaft, press the rear bearing onto the output shaft and into the crankcase seat.
3. Turn the gearbox so that the intermediate shaft engages with the gears of the primary and secondary shafts, then press the front and rear bearings with a mandrel.
4. Engage two gears at the same time, 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 caulking its shoulder into the shaft groove.
5. Turn on the neutral, then put the gaskets for adjusting the end clearance of the bearing and the pressure plate on the rear wall of the crankcase and tighten the bolts. In case of bearing replacement, adjust the end play of the outer ring of the bearing within 0.0-0.05 mm; To check the clearance, measure the distance from the bearing circlip and pressure plate shoulder to the mating surface. If provided, lock the bolts with the tabs of the lock washers.
6. Put 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 caulking its shoulder into the shaft groove.
7. Insert the reverse gear shaft and at the same time install the retainer on the shaft. Align the holes and secure the stopper with a roll pin.
8. Insert the reverse gear fork into the annular recess of the reverse idle gear and press lightly with a hammer into the crankcase wall. In this case, the flat at the end of the axis should be at the top. If a synchronizer blocking ring is installed, the groove must face the intermediate shaft.
9. Using a mandrel, press the reverse gear onto the output shaft.
10. Insert the shift forks into the grooves of the synchronizer couplings through the side window of the crankcase and turn on the neutral.