DISASSEMBLY AND REASSEMBLY



Disassembly steps


1.
 Pin


2.
 Plug


3.
 Gasket


4.
 Spring


5.
 Detent
<<A>>
 >>F<<
 6.
 Self-locking nut
<<B>>
 >>E<<
 7.
 Bearing


8.
 Reduction gear


9.
 Collar


10.
 Output shaft assembly


11.
 Needle bearing


12.
 Washer


13.
 Gearshift 3RD and 4TH sub lug


14.
 Equip snap ring


15.
 Equip pin


16.
 Gearshift shaft lever


17.
 Synchronizer ring


18.
 Shaft rail (4TH)

>>D<<
 19.
 Snap ring


20.
 Synchronizer key


21.
 Gearshift 3RD and 4TH fork and 3RD and 4TH synchronizer sleeve

>>C<<
 22.
 3RD and 4TH synchronizer sleeve


23.
 Gearshift 3RD and 4TH fork

>>B<<
 24.
 Bushing
<<C>>
 >>A<<
 25.
 3RD and 4TH synchronizer hub and 3RD speed gear


26.
 3RD and 4TH synchronizer hub


27.
 Synchronizer outer ring


28.
 Synchronizer cone


29.
 Synchronizer inner ring


30.
 3RD speed gear


31.
 Needle bearing


32.
 Counter 3RD gear

DISASSEMBLY SERVICE POINTS

<<A>> SELF-LOCKING NUT REMOVAL

1.The hole on the gearshift shaft should be positioned as shown.
2.Engage the 3rd synchronizer sleeve into the 3rd position, and the 4th synchronizer sleeve into the 4th position, respectively.
3.Insert a tool into the hole on the gearshift shaft.

4.Turn the gearshift shaft approximately 7°.
5.Slide down the gearshift shaft to engage it into the 2nd position.
6.Make sure that the input shaft and the countershaft are counter-held.
7.Using the special tool lock nut wrench (46) (MD998810) to remove the self-locking nut.

<<B>> BEARING REMOVAL
Using the special tools to remove the bearing.

  • Bearing puller (MD998020)
  • Bearing installer (MB991203)

<<C>> 3RD AND 4TH SYNCHRONIZER HUB AND 3RD SPEED GEAR REMOVAL
Using the special tools to remove the 3RD and 4TH synchronizer hub and 3RD speed gear.

  • Side bearing puller (MB990810)
  • Claw (MD999566)

REASSEMBLY SERVICE POINTS

>>A<< 3RD AND 4TH SYNCHRONIZER HUB AND 3RD SPEED GEAR INSTALLATION
1.Using special tools to install the 3RD and 4TH synchronizer hub and 3RD speed gear.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (40) (MD998819)
2.Press the input shaft with a press and install the 3RD and 4TH synchronizer hub and 3RD speed gear.

>>B<< BUSHING INSTALLATION
1.Use special tool, Installer bar (MB990938), install the bushing.
2.Press the gearshift 3RD and 4TH fork with a press and install the bushing.

>>C<< 3RD AND 4TH SYNCHRONIZER SLEEVE INSTALLATION

The identification groove on the 3rd and 4th synchronizer sleeves should face towards the clutch housing when the sleeves are inserted into the gearshift 3rd and 4th forks, respectively.

>>D<< SNAP RING INSTALLATION
1.Install the thickest snap ring that can be fitted in the snap ring groove of the input shaft.
2.Make sure that the 3RD and 4TH synchronizer sleeve end play meets the standard value.
Standard value: - 0.01 - 0.09 mm

>>E<< BEARING INSTALLATION

1.Check the installation direction of the bearing, and put it on the countershaft.
2.Use special tools to install the bearing.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (42) (MD998820)
3.Press the countershaft with a press and install the bearing.

>>F<< SELF-LOCKING NUT INSTALLATION

1.The gearshift 3rd and 4th rails should protrude by approximately 54.8 mm. When the rails are at this position, the transmission shift position is at neutral. If the protrusion amount deviates significantly from approximately 54.8 mm, adjust it by sliding up or down the respective rail(s).

2.The hole on the gearshift shaft should be positioned as shown.
3.Engage the 3rd synchronizer sleeve into the 3rd position, and the 4th synchronizer sleeve into the 4th position, respectively.
4.Insert a tool into the hole on the gearshift shaft.

5.Turn the gearshift shaft approximately 7°.
6.Slide down the gearshift shaft to engage it into the 2nd position.
7.Make sure that the input shaft and the countershaft are counter-held.
8.Using the special tool lock nut wrench (46) (MD998810) to install the self-locking nut.
9.
caution
  • Do not damage other parts.
  • Do not apply the excessive load to shaft.
Caulk into the overall countershaft groove.
10.Make sure of firmly caulking self-locking nut on the groove, after caulking.