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ID
19
OPERATION
No.
ID
331-3:
Overhauli?zg
the gearbox
COZXY
Op.ID
331-3
171
7
To
fit
the
forks:
a)
Engage
the
locking
plugs
(81),
the
1st
and'2nd
speed
fork
shaft
(96),
fit
the
fork
(97)
on
the
shaft.
Put
the
control
lever
(79)
in
p osition
in
the
groove
of the
shaft
(96).
b)
Fit
the
3rd
and
4th
speed
fork
shaft
(99),
fit
the
catch
(80),
fit
the
fork
(100)
on the
shaft
(99).
Put
the
control
lever
(95)
in
position
in
the
groove
of
the
shaft
(99).
Tighten
the
screw
fixing
the
fork.
c)
With
the
shafts
(96)
and
(99)
in
the
neutral
position,
push
the
reverse
gear
shaft
(101)
towards
the
rear
of
the
cover.
Engage
the
fork
(102)
on
the
shaft
and
put
the
lever
(94)
in
position
in
the
groove
of
the
shaft.
4
Tighten
the
screws
fixing
the
forks
(97)
and
(102).
Lock
the
screws
with
iron
wire,
fitted
in
such
a way
to
avoid
any
rotationinthe
directionofunscrewing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
9
10
11
12
Fit
the
locking
balls
(74),
the
springs
(73)
and
the
screws
(72)
(copper
joint
under
the
head)
. . . . . . . . . . , . . . . . . . . . . .
Fit
the
distance
piece
(78)
and
the
shim
(77)
on
the
mandrel
(A)
(see
Pl.
56,
fig.
3).
Fit
the
ring
seal
(71)
on the
support
tube
(70)
and
fit
the
mandrel
(B)
in
the
support
tube.
Put
18 balls
(103)
in
the
tube
(70),
g reased
to
keep
them
in
position
(see
Pl.
56,
fig.
3).
The
shafts
of the
forks
being
in
the
neutral
position,
engage
the
assembly
of the
mandrel
(B)
and
the
tube
(70)
in
the
cover
of
the
gearbox,
pushing
the
mandrel
(A)
at the
same
time
with
the
tube
(70)
(see
Pl.
56,
fig.
3).
Fit
the
circlip
(69)
in the
groove
of
the
tube
(70),
between
the
distance
piece
(78)
and
the
shim
(77)
. . . . . . . . . . . . .
Check
the
calibration
of the
locking
lever
spring
(68):
under
a load
of
29 *
1.5
kg.
the
length
should
be
52
mm.
(fixture
for
calibrating
springs
2420-T,
see
Pl.6)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fit
the
spring
(68)
and
the
cup
(67)
on
the
locking
lever
(66)
(spring
compressor
1792-T,
see
P1.57,
fig.4).
Engage
the
locking
lever
in
the
support
tube
(7'0)
and
with
the
latter
push
out
the
mandrel
(B)
(see
Pl.
56,
fig.
4).
Fit
the
circlip
(65)
retaining
the
locking
lever.
Fit
the
sealing
cap
(83)
with
"Hermetic".
.
. . . . . . . . . . . . . . . . . . . . . . . .
To
adjust
the
shafts
controlling
the
forks
(see
PI.
47):
b)
With
a set
of
feeler
gauges,
measure
the
distance
"b"
between
the
thrust
face
on
the
gearbox
cover
and
the
circlip
(69).
4
Select
a shim
of
appropriate
thickness,
sold
by
our
Spare
Parts
Department,
in
order
to
obtain
a clearance
of
0.15
to
0.25
mm.
d)
Remove
the
circlip
(69)
the
shim
(77)
and
the
distance
piece
(78).
4
Screw
in
for
a few
threads,
the
threaded
sleeves
(75)
of
the
fork
shafts,
together
with
the
locknuts
(76).
TOOLS
9 mm
spanner
17 mm
spanner
and
box
spanner
Mandrel
1793-T
Fixture
2420-T
Spring
compressor
1792-T
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