ZEST/BOLT

DRIVETRAIN-TA65 Star

4.7. L. LAY SHAFT ASSEMBLY:

1. Press cylinder roller bearing on lay shaft by

using drift part no. 2702 5809 2603.

2. Fit the circlip. It should snugly fit.

NOTE:

Circlips are available in different thicknesses.

2.25mm,2.3mm,2.35mm,2.4mm.

3. Place first gear (lay shaft) on lay shaft by

keeping dog teeth upward.

4. Install preselected circlip (

Circlip thickness

should be so selected that there is no axial

play of gear).

5. Place the double synchro pack fitted over the

first gear.

Fig. 67

6. Place engaging gear (1/2 speed) with circlip

races downwardand with slot on engaging

gear on corresponding lug on synchrocone

7. Place springs (3 nos.) plungers (3nos.) into the

hole in engaging gear (1/2 speed).

8. Place sleeve carrier and steel ball on it and

slide reverse gear/shifter sleeve (1/2 speed) on

it with fork slot in upward position.

Place the double synchro cone pack for

Second gear on the engaging gear.

10. Place 2nd gear with its dog teeth

downward.