ZESTBOLT SERVICE MANUAL

DRIVETRAIN C549 38 NOTE: Position the circlips with their openings at the front to facilitate fitting. 23.Apply sealant to the contact surfaces between the TRANSAXLE casing and the main and lay shaft rear bearings retaining plate. 24. Fit the main and lay shaft rear bearings retaining plate and secure it tightening the M8 bolt to torque 2.1 ~ 2.6 Kgm I. FIFTH GEAR - ASSEMBLY 1. Remove the 5th speed drive gear bush (1). 2. Fit the needle bearing (2) for the 5th speed drive gear. 3. Fit the 5th speed drive gear (3). 4. Fit the 5th speed synchronizer gear (4). 5. Fit the 5th speed engagement sliding sleeve hub (5). 6. Fit the 5th speed engagement sliding sleeve (5). 7. Place the synchronizer mountings (7) in their housings. 8. Fit the 5th speed control fork (8). 9. Fit the 5th speed synchronizer rollers and springs retaining flange (9). 10.Fit the 5th speed driven gear (10). 11.Tighten the new M20 ring nuts (11) for the main and lay shaft to a specified torque of 10 ~ 12.4Kgm 12.Tighten the M6 bolt (12) for the 5th speed control fork to the recommended torque of1.5~ 1.9 Kgm. 13.Lock the sleeve (1) in a vice fitted with protective plates;

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