ZEST BOLT Service Manual

DRIVETRAIN-TA65 Star 53 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. 9. Place the double synchro cone pack for Second gear on the engaging gear. 10. Place 2nd gear with its dog teeth downward.