Insert locking pin 4 through the hole in the left wall of the crankcase and insert rod 4 (figure 300) I/II gears simultaneously with the installation of the primary shaft.
Figure 300. Gear selection mechanism (inside the gearbox): 1 - III/IV gear forks; 2, 7 - pins; 3 - III/IV gear engagement rod; 4 - I/II gear rod; 5 - rod; 6 - I/II gear forks; 8 - retainer; 9 - reverse gear lever; 10 - bushing; 11 - spring; 12 - guide bushing; 13 - bolt M10x32; 14 - spring washer; 15 - emphasis; 16 - gear selection rod; 17, 18 - bolts; 19 - wings; 20, 21 - bushings; 22 - spring; 23 - casing
Insert the rod 3 of the III/IV gear into the hole on the right side of the crankcase simultaneously with the primary shaft. Locking pin 4 (see figure 283) must be located between the I/II gear and III/IV gear rods.
Insert the second locking pin.
Insert the reverse rod into the next left hole.
Insert the spring lock parts of the rods into the holes in the sequence shown in figure 283. Screw in the screw plugs with gaskets, as well as the plug of the locking pins on the side. The device for locking the rods is shown in Figure 301.
Figure 301. Gear selection mechanism rod locking device: 1 - III/IV gear rod; 2 - locking pin; 3 - I/II gear rod; 4 - reverse rod; 5 - plug; 6, 8 - bushings; 7 - spring; 9 - gasket; 10 - screw cap
After placing and installing the main gear (see description below) you can start connecting both parts of the gearbox housing (figure 302, 303). These operations are performed in the reverse order of disassembly. If the clutch side of the housing has been replaced, adjust the bearing preload.
Figure 302. Section of the gearbox housing from the clutch side: 1 - air tube; 2 - bolt; 3 - washer; 4 - guide bushing; 5 - screw cap; 6 - air tube fitting; 7 - washer; 8 - bolt M12x68; 9 - bushing; 10 - gasket; 11 - sealing ring; 12 - guide bushing; 13 - bolt; 14 - spring ring; 15 - shield; 16 - switch; 17 - pusher; 18 - drain plug; 19 - gasket; 20 - bolt M8x45; 21 - oil seal; 22 - gearbox housing on the 1st clutch side; 23 - bushing
Figure 303. The second part of the gearbox housing: 1 - gasket; 2 - double-sided bolt with flange; 3 - screw cap; 4 - cover gasket; 5 - gearbox cover; 6 - bolt; 7 - screw cap; 8 - switch; 9 - plug: 10 - crankcase; 11 - magnet; 12 - oil drain plug; 13 - gasket
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The mating surfaces of both parts of the crankcase must be coated with sealant before joining (for example D3). Install the pins before tightening the bolts. Insert both drive shafts into the splines of the differential gears and tap them in with a rubber mallet. The right shaft is longer and should be installed from the clutch housing side. Hold the flange (see figure 279), tighten the bolts to a torque of 25 Nm.
Replaced bolts must match the original ones, even if the flange was replaced.
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