Disassemble spring clamp loop on output shaft liking that

shown in figure.

Take down forth and fifth gear wheel with pressure machine.

Note: hold the lower end of shaft to prevent it falling.

Move first and second gear to first gear.

Disassemble third gear with pressure machine, and hold the

lower end of shaft to prevent it falling, at this time, disassemble

roller bearing, synchronous loop and second gear.

Disassemble clip spring with clamp spring pliers, and do not

hurt bearing surface of shaft.

Transmission—Disassemble assembly

 177 

Measure the round flop liking that shown in figure, its maxi-

mal allowed flop value is 0.03, if exceeding this value, it is

necessary to change the output shaft.

Check the axial clearance between the back surface of syn-

chronous loop and end surface of gear splines with clear-

ance gauge, its minimal value is 0.8mm, if the clearance is

less than this value, it is necessary to change the synchro-

nous loop.

Check the clearance between gear cover fork slot and fork

with clearance gauge, its maximal value is 0.35mm, if exceed-

ing this value, it is necessary to change fork.

Check the abrasion and damaged situation of output shaft,

and measure the exterior diameter of bearing platform with

micrometer, its minimal value is 33.985mm, if measured re-

sult is less than this value, it is necessary to change the out-

put shaft.

Assemble first gear and synchronous loop liking that shown

in figure.

Transmission—Disassemble assembly

 178 

Press first and second gear synchronizer assembly in input

shaft with pressure machine, its direction likes that shown in

figure.

Use new clip spring used for shaft to replace that one which

has been stretched.

Note: do not hurt the shaft surface.

Assemble synchronous ring, roller bearing and second gear.

Press third gear in output shaft with pressure machine liking

that shown in figure, its direction likes that shown in figure.

Use pressure machine to press forth and fifth gear in output

shaft with the method in figure, its direction likes that shown

in figure.

Transmission—Disassemble assembly

 179 

Press bearing in input shaft with pressure machine liking that

shown in figure.

Note: adjust to bearing inner ring and put it into position

Assemble roller bearing, third gear and third gear synchro-

nizer loop liking that shown in figure, and assemble synchro-

nizer assembly by the direction in figure.

Transmission—Disassemble assembly

 180