Output shaft assembly
After installing the 1st gear gear, install the 1st and 2nd gear synchronizer and retaining ring. Make sure. that the annular groove of the synchronizer clutch is on the side of the gear of the 2nd gear. 3rd gear retaining rings are available in three thicknesses, choose the ring according to the size of the groove. The output shaft bearing shims are also available in three thicknesses. The groove in the outer ring of the bearing, into which the adjusting ring is installed, must face outward.
Gearbox Assembly
After installing the reverse idle gear, engage the gears of the shafts (pic. 3.39), insert the forks into the grooves of the couplings and install the shafts in the gearbox housing.
Install the fork axle. axle bushing, bushing circlips and locking brace. Install the magnetic washer. Install a new gasket on the gearbox housing, make sure the magnet is in the correct position and tighten the bolts securing the gearbox housing to the clutch housing. Attach the rear support bracket to the gearbox housing. Select the adjusting rings of the shaft bearings that are suitable in thickness, put a wooden spacer on the crankcase and, lifting the shafts with a screwdriver supported by the spacer, install the adjusting rings in the annular grooves of the outer bearing rings. Install the 5th gear housing. Position the adjusting rings as shown in fig. 3.40.
Tighten the crankcase mounting bolts. Lubricate the circlip groove of the 5th gear. The marks of the gear flange and the central hole of the shaft must be the same color. Install the V gear on the input shaft, using tool 16.031, install a new circlip of suitable thickness. Install the driven gear of the 5th gear together with the synchronizer and the shift fork on the output shaft and secure it with a retaining ring, the thickness of which corresponds to the groove. Install the pin and spring and wrap the 5th gear shift pin retainer, having previously applied sealant to the retainer.
Reinstall the V gear engagement mechanism and adjust it as follows: set the gear selector rod to the neutral position, turn it clockwise until it stops and pull it towards you; slide the synchronizer sleeve and fork onto the gear of the 5th gear. Use a screwdriver to turn the gear selector rod clockwise until it stops, press it down and hold it in this position (pic. 3.41); lift the 5th gear engagement finger so that there is a gap between the 5th gear engagement pin and the stopper: holding all the parts in this position, tighten the turnbuckle nut.
Finish assembling the gearbox as described for the four speed gearbox.
Removal, installation and adjustment of the gear shift drive
To facilitate the adjustment of the drive, turn on the reverse (not 4th gear). After installing the shift lever cup, engage reverse.
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