- replace with new axle shaft seals, extension collar, self-locking nuts and lock washers;
- check the technical condition of the fork ball joint insert;
Pic. 6.32. Clutch release fork: 1 - clutch release bearing; 2 - ledges; 3 - fork support; A - lubrication points
- lubricate the ends of the fork at A with a thin layer of MOLYKOTE BR2 PLUS grease (pic. 6.32);
- install the clutch release bearing so that its protrusions 2 enter the fork tips;
- lightly lubricate the clutch release bearing guide bush with MOLYKOTE BR2 PLUS grease;
Attention! Do not lubricate the gearbox input shaft splines.
- reinstall the bearing with the clutch release fork;
- move the bearing on the sleeve several times;
Attention! Make sure there are pins for installing the gearbox. Be careful not to pinch the wiring harnesses when installing the transmission.
- fill the space between the edges of the seals with grease;
- connect the gearbox to the engine;
- reinstall the top bolts 1 (see fig. 6.30) and tighten them to 55 Nm;
- clean the 4 axis threads (see fig. 6.25) and lubricate it;
- reinstall the axle with the washer;
- tighten the axle to 50 Nm;
- install spacer 5;
- install bracket 3;
- tighten bolts 6 to 60 Nm;
- install the rubber cushion 7 of the gearbox support;
- «make money» nut 9 and bolts 8 pillows;
- center the position of the power unit until the final tightening of the support pad fasteners;
- tighten bolts 8 to 30 Nm and nut 9 to 65 Nm;
- install the battery support 10 and tighten the bolts 1 to 20 Nm;
Cable drive clutch
- install bushing 4 (see fig. 6.5) on the clutch release fork;
- lubricate the collar of the bushing 2 and the cylindrical end of the tip 1 of the cable sheath with grease;
- insert the sleeve 2 into the support 3 of the cable and then the tip 1 of the sheath into the sleeve;
- install the clutch in the retainer in place A;
Clutch hydraulic
- reinstall slave cylinder 1 (see fig. 6.26) clutch and tighten the mounting bolts to a torque of 20 Nm;
All drives
- tighten the bottom bolts 1 (see pic. 6.29) fixing the gearbox to the engine with a torque of 55 Nm;
- install sealing ring 1 (see fig. 6.28);
- install gear 6 of the speedometer drive;
- install extension 5 and tighten bolts 4 to 15 Nm;
- install support 3 of the speedometer drive gear and tighten bolt 2;
- set limiter 2 (see fig. 6.27) rocking the power unit and tighten bolt 3 to 35 Nm and bolt 1 to 50 Nm;
- complete the installation of the gearbox in the reverse order of removal;
- fill the gearbox with fresh oil of the recommended brand and check the level;
- adjust clutch drive.