Gearbox shaft elements
1 - retaining ring;
2 - remote washer;
3 - remote washer;
4 - bearing;
5 - input shaft;
6 - synchronizer ring;
7 - needle bearing separator;
8 - retaining ring;
10 - sliding clutch 3/4 gear;
11 - spring;
12 - ball;
13 - cracker;
14 - switching clutch;
15 - gear 3rd gear;
16 - needle bearing cage;
17 - remote bushing;
18 - needle bearing separator;
19 - second gear gear;
20 - retaining ring;
22 - sliding clutch;
23 - switching clutch;
24 — gear wheel of the first transfer;
25 - needle bearing cage;
26 - needle bearing separator;
27 - reverse gear;
28 - synchronizer ring;
29 - sliding clutch;
30 - switching clutch;
31 - retaining ring;
32 - needle bearing separator;
33 - synchronizer ring;
34 - gear wheel of the first gear;
35 - bearing;
36 - remote washer;
37 - adjusting washer;
39 - output shaft flange;
40 - nut with collar;
41 - safety plate;
42 - retaining ring;
43 - remote washer;
44 - roller bearing;
45 - intermediate shaft;
46 - roller bearing;
47 - retaining ring;
48 - reverse gear;
49 - needle bearing cage;
50 - the axis of the intermediate gear;
51 - spring washer;
52 — bolt М8х25;
53 - secondary shaft.
Withdrawal
Remove the PTO flange using the tool (replace the safety plate).
Remove the mounting plate and cover. Remove springs and balls.
Remove the pin with the reverse gear needle bearing.
Remove the shift lever pin.
1 - pin;
2 - lever;
3 - switching rod.
Remove the shift fork stem.
Remove the shift lever. Engage fourth gear and knock out the pin.
Remove the shift control shaft. The gasket comes out too.
Knock out the 3/4 shift fork spacer pin.
Remove forward pull. Keep an eye on the pin.
Engage 2nd gear and reverse together.
Remove the primary, secondary and intermediate shafts.
Place a block under the grips of the puller so as not to damage the surface. When extruding, make sure that the rod does not jam.
Attention: For version with springs of different lengths: shorter spring (15.9 mm) belongs to the shift rod 5th gear/reverse.
Installation
Insert shift forks 3/4, 1/2 gear and 5 gear and/reverse.
Remove all locking balls from the crankcase.
Insert the large diameter roller bearing outwards.
Lubricate the snap ring and retainers.
Heat the inner race of the radial bearing with warm air to 80°C. Engage second gear and reverse and insert the input and output shafts into the crankcase cover.
Align shift rod.
Insert the shafts completely with the tool and bushing. Be careful not to jam the shift rod.
Set the tie rods to neutral. Insert the 3/4 gear link through the fork.
Insert lubricated spacer pin (6) in 3/4 gear. Locking elements of the shift shafts.
Locking elements of the shift shafts
1 - spring;
2 - cover;
3 - spring;
4 - finger;
5 - lever;
6 - retainer;
7 - ball;
8 - ball;
9 - spring.
Move the rod to the hole, the groove on the shaft should be facing up.
Insert two detent balls into the 1/2 and 5th gear/reverse linkages.
Insert the 3/4 gear link until it locks.
Drive a 6x24 spacer pin into the 3/4 shift fork. While doing this, hold the fork.
Insert three locking balls with springs.
Install the flat gasket cover.
Drive in the shift pin of the switch pin completely.
Stick four lubricated rollers on the shift control shaft.
Move the shift control shaft while inserting the shift pin. The groove on the shaft points outward.
Secure the pin to the shaft with a 6x24 spacer pin. Hold the shaft while doing this.
1 - groove;
2 - pins;
3 - lever.
Install the shift fork stem with the groove on the stem facing up.
Insert shift lever. Fine slotted cutting is directed upwards.
Install the pin.
Coat the crankcase around the reverse pin with silicone grease.
Install reverse pin with gear and needle bearing. Fasten the pin with a bolt.
Install the reverse gear mounting plate while pushing outward.
Install the input shaft flange. Insert the collar nut.
Install the safety plate.
Gear shift fork
1 - spring washer;
2 - cylindrical bolt;
3 - fastening ring;
4 - shaft;
5 - retainer;
6 - finger 6x34;
7 - lever;
8 - spring;
9 - ball;
10 - latch;
11 - cover;
12 — cover D=12 mm;
14 - spacer pin;
15 - shift rod 5th gear / reverse;
16 - shift rod 3/4 gear;
17 — draft of switching 1/2 transfer;
18 - clamp 1/2 gear;
19 - cork;
20 - spring;
21 - locking pin;
22 - spacer pin 6x28;
23 - roller;
24 - switching control shaft.