Adjusting dimensions of the position of the gear levers of the 5-speed gearbox *
A = 168.0 mm
H = 86.0 mm
C = 95.0 mm
* The shift lever is in the neutral position.
5-speed gearbox shift lever position adjustment
1 - thrust pin
2 - thrust plate
3 - bolt
1. Insert the input shaft and engage it with the output shaft.
2. While your assistant lifts the output and input shafts, lift the countershaft and (on boxes with tapered roller bearings) slide it forward so that the bearing rests against the crankcase wall. Install rear (and front) intermediate shaft bearing, pressing them into the crankcase with a mandrel.
3. Install the flinger and bearing on the input shaft, then use a mandrel to press the bearing into the crankcase wall until it stops. When installing the bearing, support the output shaft and make sure that the 4th gear synchronizer ring remains in place.
4. Place the inner circlip on the input shaft.
5. Remove the pipe from the output shaft and, supporting the input shaft, install the rear bearing into the crankcase using a drift.
6. Put the synchronizer clutches in the position of switching on two gears simultaneously, then screw the bearing nut onto the front end of the intermediate shaft and tighten it with a torque of 8.0 kgf·m. If provided, caulk the collar of the nut into the groove of the shaft.
7. Engage the neutral gear, then place the end play adjusting shims and pressure plate into the crankcase rear wall and tighten the bolts. In case of bearing replacement, adjust the end clearance of the outer ring of the bearing within 0.0-0.05 mm. To determine the clearance, use a vernier caliper to measure the distance between the bearing circlip and the pressure plate shoulder and mating surface. If provided, lock the bolts with the tabs of the lock washers.
8. Place spacers on countershaft and press reverse gear onto splines, then hammer key into groove.
9. Press the segment keys into the grooves of the secondary shaft with a hammer.
10. Using a mandrel, press the reverse gear onto the output shaft, then install the spacer. The required thickness of the spacer washer is selected depending on the length of the selector rod according to the table below.
Marking of a rod of a choice of transfers (at the end of the fork) | Distance washer thickness, mm |
red label | 3,8 |
No label | 3,9 |
white mark | 4,0 |
1. Insert the fork of the reverse and V gear selection rod into the slot of the V gear synchronizer clutch, then slide them into the crankcase and onto the output shaft. At the same time, install the lock on the gear selector bar through the crankcase window.
2. Heat the V gear needle bearing ring (enough warmth of the hand) and put it on the output shaft until it stops against the synchronizer assembly, pulling the output shaft back.
3. Place the synchronizer ring on the V gear cone.
4. Install the reverse idle gear into the shift fork, then insert the idle gear shaft into the gear and into the crankcase.
5. Center the reverse and 5th gear selector rod and insert the detent ball and spring with a light coat of grease. Insert the retainer into the retained crankcase.
6. Align the retainer with the hole in the selector shaft and insert the cotter pin into the hole.
7. Install intermediate housing with new gasket. Apply sealant to the threads of the bolts, screw in and tighten them by hand. The locating pin of the reverse idle gear shaft must be on the outside to install it in the crankcase cutout.
8. Intermediate housing must be centered on intermediate plate before final tightening of bolts. To do this, remove the bearings from the plate, install the plate on the crankcase and make sure that the bearings fit freely into the plate seats. Replace the crankcase and tighten the outer bolts. Remove the intermediate plate and bearings and tighten the inner bolts.
9. Using a mandrel, press the 5th gear onto the end of the intermediate shaft.
10. Put a new gasket on the intermediate plate, installing bearings on it, then put the plate on the locating pins, passing the secondary and intermediate shafts through it, install and tighten the bolts.
11. Temporarily lock the intermediate shaft by turning on two gears at the same time, then screw the nut onto the intermediate shaft and tighten it to a torque of 8.0 kgf·m. If provided, lock the nut with a caulk.
12. Insert the shift forks into the grooves of the synchronizer couplings through the side window of the crankcase.