- All threaded holes into which self-locking screws have been inserted must be cleaned of residues of threadlocker.
- All self-locking screws and nuts must be replaced.
- It is necessary to install the missing centering sleeves in the cylinder block, which determine the relative position of the engine and gearbox.
- Check the correct position of the spacer on the engine.
- Clean the splines on the input shaft and lubricate them with a thin layer of grease so that the clutch disc slides easily over them.
1. Align the gearbox with the engine and install it on the alignment sleeves.
2. Tighten the lower screws securing the gearbox to the engine (arrows).
3. Install the transmission console with new screws (2) (see fig. VC4.025).
Tightening torque: 60 Nm + 90°.
4. Move the power unit to the mounting position.
5. Screw on the left support of the power unit with new screws (1).
Tightening torque: 40 Nm + 90°.
6. Screw the right motor support with new screws (arrows) (see fig. VC 4.024).
7. Install and tighten the upper screws securing the gearbox to the engine.
8. Screw on the oscillator with new screws (A, B and C) (see fig. VC 4.023).
9. Install flywheel guard (A) behind the right gearbox flange (arrows) (see fig. VC 4.022).
10. Attach the drive shafts to the gearbox,
11. Fix the front bracket of the exhaust system to the crate (arrows) (see fig. VC 4.021).
12. Attach the exhaust system and straighten it.
13. Install the drive shaft guard (arrows) (see fig. VC4.020).
14. Install the starter.
15. Install bracket (2) electrical wiring and tighten the nut (1) (see fig. VC4.019).
16. Connect the reverse light (3).
17. Tighten the top starter mounting screw.
18. Connect ground to top starter screw (1) (see fig. VC4.018).
19. Attach connector (2) and cable (3).
20. Install the slave cylinder and tighten the screws (arrows).
21. Install piping (A) in the gearbox bracket (IN).
22. Screw the bracket for fastening the support cables to the gearbox with screws (arrows).
23. Install the shift lever (A) and tighten the nut (4).
24. Install the gear selector (IN) and secure it with a lock washer (3).
25. Lubricate the pins of the levers.
26. Secure the shift cable and gear select cable with new lock washers (1 and 2, respectively).
27. Adjust the gearshift mechanism.
28. Check transmission oil.
29. Install the left fender liner.
30. Install the soundproof casing under the power unit.
31. Install the battery with the shroud and bracket.
32. Install the air filter housing assembly.
33. Install the engine cover.
Tightening torques depending on engine type
Pos. | Screw | Quantity | Torque |
1 | М12хб5 | 3 | 80 Nm |
2 | М12х55 | 1 | 80 Nm |
3 | М12х170 | 1 | 80 Nm |
4 | М12х80 | 2 | 80 Nm |
5 | M10x60 | 2 | 40 Nm |
Pos. | Screw | Quantity | Torque |
1 | М12х65 | 2 | 80 Nm |
2 | М12х150 | 1 | 80 Nm |
3 | М12х170 | 1 | 80 Nm |
4 | М12х60 | 3 | 40 Nm |
5 | M10x30 | 1 | 80 Nm |
Pos. | Screw | Quantity | Torque |
1 | М12х55 | 2 | 80 Nm |
2 | М12х150 | 2 | 80 Nm |
3 | М12х60 | 3 | 40 Nm |
4 | М12х65 | 1 | 80 Nm |
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