- install the gear of the 1st gear and the needle bearing on the shaft;
- Install the retaining ring and thrust washer on the bearing with a chamfer towards the bearing:
- holding the retaining ring in a compressed state with a tool made from improvised materials (see photo), install the secondary shaft in the hole in the intermediate crankcase;
- install the primary and secondary shafts, as well as the rod and fork of switching I-II gears, into the holes of the intermediate crankcase;
- reinstall the reverse gear rod and fork, the V gear engagement slider and the III-IV gear shift rod and fork;
- install the fixing bracket on the intermediate crankcase, screw in new bolts with heads having capsules with a locking compound, and tighten them;
- install the bracket for the 5th gear shift fork with a stopper on the intermediate crankcase so that one of the locking tabs of the stopper is located against the cutout of the III-IV gear shift rod, install and tighten new mounting bolts with heads having capsules with a locking compound;
- install 8 intermediate crankcase four plugs of clamps with sealers; one long plug for the 3rd and 4th gear shift rod retainer and three short plugs;
- assemble the intermediate crankcase completely using tool KM 554. To do this, use tool KM 466 3 to press on the large gear of the V transmission with the protruding part of the hub towards the ball bearing. Using the KM 334 tool, press the 5th gear synchronizer, preheating the synchronizer to 100°C, controlling the heating temperature with a thermochromic pencil. The synchronizer spring must be on the gear side. Replace retaining rings with new ones;
- install the bracket on the intermediate crankcase, screw in new fastening bolts with a capsule with a locking compound and tighten them to the specified torque;
- install a fully assembled intermediate crankcase (without rear gearbox cover) on the gearbox housing, wrap and tighten the mounting bolts to the specified torque;
- screw a cylindrical bolt into the rear end of the input shaft and push the shaft until it stops;
- carefully insert the input shaft into the gear block by hand;
- secure the shaft with a new retaining ring;
- install the gearbox rear cover on the intermediate housing, screw in the mounting bolts and tighten them to the specified torque.
Further assembly of the 5-speed gearbox is carried out in the same way as the 4-speed gearbox.
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