Note. Parts installed in the gearbox must be lubricated with gearbox oil.
When assembling a 4-speed gearbox
- put a roller bearing on the secondary shaft with a small cage diameter towards the drive gear. Insert thrust washers and lock washer into the shaft groove. Install a single-row needle bearing on the shaft and put the IV gear on the bearing;
- install the synchronizer ring on the fourth gear;
- heat up to a temperature of 100°C the hub assembly with the sliding clutch of the synchronizer of III-IV gears, controlling the heating temperature with a thermo-chromic pencil. Press the hub assembly with sliding sleeve onto the shaft. Lock the synchronizer clutch hub with a new retaining ring, making sure that one hundred crackers enter the grooves of the synchronizer blocking ring. Install thrust washer;
- install a double-row split needle bearing on the output shaft and put the 3rd gear gear on it. Place thrust half rings in the groove of the shaft and fix them with a retaining ring;
- install the needle bearing on the shaft and put the 2nd gear on the bearing.
- heat the hub assembly with the synchronizer clutch of I-II gears to a temperature of 100°C and press onto the shaft with a spur gear towards the gear of the 1st gear. Lock the synchronizer clutch hub with a new retaining ring;
- install a blocking ring on the synchronizer of 1st and 2nd gears, put a needle bearing on the secondary shaft and install the 1st gear gear,
- install thrust needle bearing;
- install a retaining ring on the secondary shaft to ensure its fixation in the rear cover. Heat the washer to a temperature of 100°C and press it onto the shaft with a large diameter to the thrust needle bearing;
- install a ball bearing on the secondary shaft with the closed end outward and put a new circlip on the bearing;
- put a new retaining ring on the rear end of the input shaft, ensuring its fixation in the rear cover of the gearbox;
- Press on the input shaft rear ball bearing with the closed side of the bearing facing out. Install washer and new retaining ring;
- press the input shaft into the gear block with a small diameter towards the bearing.
When assembling a 5-speed gearbox
- install the retaining ring of the gear unit of the input shaft into the annular groove of the intermediate crankcase;
- install the primary and secondary shafts;
- install the rod and fork of the 5th gear, and then the rod and the shifter of the III-IV gears in the intermediate crankcase;
- install the fixing bracket on the intermediate crankcase, screw in new bolts with heads. having capsules with a locking composition, and «pull them;
- install the V gear engagement fork bracket with the stopper on the intermediate crankcase as follows. 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 fastening bolts with heads that have capsules with a locking compound.
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