Bearing Bracket, Disassembling And Assembling

Special tools and workshop equipment required 

• Extracting Tool : T40413 
• Press Plate :VW402 
• Press Piece - Rod :VW411 
• Puller - Transmission Gears - Thrust Piece :T10309/5 
• Press Piece - Bushing - 50mm Diameter :VW432 
• Gearbox Assembly Tool :T40213A 
• Press Piece - 28x100mm :VW421 
• Two-Arm Puller (Kukko 20/10) :VAS 251 001 

Disassembling

Shaft for the reverse gear intermediate sprocket, pressing out

-- Remove the circlip.

Fig 1: Press Out the Shaft for the Reverse Gear Intermediate Sprocket -1-

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-- Press out the shaft -1- using the following tools:

• Press Piece - Rod : VW411  -2-
• Adapter 9 of the Gearbox Assembly Tool :T40213A  -3-
• Press Plate : VW402  -4-

-- Remove the reverse gear intermediate sprocket, needle bearing and thrust washers.

Input shaft ball bearing, driving out

-- Remove the reverse gear intermediate sprocket.

Fig 2: Drive Out the Input Shaft Ball Bearing -1-

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-- Detach the bolts for the retaining plate and remove the retaining plate.

-- Tension the bearing bracket in a vise.

-- Drive out the ball bearing -1- using the Press Piece - Bushing - 50mm Diameter : VW432  -2-.

Output shaft ball bearing, driving out

-- Remove the circlip.

Fig 3: Drive Out the Output Shaft Ball Bearing -1-

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-- Tension the bearing bracket in a vise.

-- Drive out the ball bearing -1- using the Press Piece - Bushing - 50mm Diameter : VW432  .

Assembling

-- Warm the bearing bracket -3- in the area of the bearing seats -A arrows- using the hot air gun.

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-- Insert the output shaft ball bearing -1- and input shaft ball bearing -2- in the bearing bracket.

Conditions

• Pay attention to the installation position of the ball bearing: grooves -B arrows-.

-- Insert the retaining plate -2- for the input shaft ball bearing 1 and secure to the bearing bracket with bolts -3-.

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-- Install the locking ring -1-.

Conditions

• Circlip installation position: the smooth side faces the ball bearing and the bevel -arrow- faces the 1st gear assembly

-- Insert the reverse gear intermediate sprocket -1-, needle bearing -2- and the thrust washers -3- in the bearing bracket.

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-- When installing the shaft for the reverse gear intermediate sprocket -1-, place a feeler gauge -A- with the dimension 0.20 mm between the bearing bracket -2- and the thrust washer -3-.

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-- Push in the intermediate sprocket reverse gear shaft -1- with the Sleeve :VW421  all the way.

-- Insert the circlip.

The dimension -a- of the locking sleeves is determined by the corresponding thrust pieces 5 and 6 of the Extracting Tool : T40413  .

-- Press off the locking sleeves.

Fig 4: Retaining Sleeves, Removing and Installing

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1. Locking Sleeve for Gearshift Rail/Fork for Gear 1/3
2. Locking Sleeve for Gearshift Rail/Fork for Gear 2/Reverse Gear
3. Locking Sleeve for Gearshift Rail/Fork for Gear 4/6
4. Locking Sleeve for Gearshift Rail/Fork for Gear 5/7

-- Press out the locking sleeve -1- :

Fig 5: Press on the Locking Sleeve -1-

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• 2 -  Two-Arm Puller (Kukko 20/10) : VAS 251 001  or KUKKO 20-10
• 3 -  Puller - Transmission Gears - Thrust Piece :T10309/5 

-- Press in the new locking sleeves -C- and -D- with thrust piece 5 of the Extracting Tool : T40413  .

Fig 6: Press in the New Retaining Sleeves -A, B, C and D-

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1. Spindle 4 of the Extracting Tool : T40413 
2. Thrust Piece 5 of the Extracting Tool : T40413 
3. Bracket 3 of the Extracting Tool : T40413 

-- Press in the locking sleeves -A- and -B- only after assembling the gear set. Refer to Gear Set, Disassembling and Assembling  .