Crankcase and covers
There should be no cracks on the crankcase, and wear on the surface of the bearing seats (see table. 5) or damage. The mating surfaces with the clutch housing and covers must also be free of damage that could cause axle misalignment and insufficient tightness causing oil leakage. Minor damage can be repaired with a velvet file. If parts are damaged or worn beyond the allowable limit, replace them with new ones.
Check up a condition of a forward cover, and also, whether its input shaft does not concern during rotation. If shaft and cover are misaligned, replace damaged parts. Check if the drain hole of the front cover is clogged and clean the drain plug.
Oil seals
There should be no damage or unevenness on the working edges, the permissible wear of the working edge in width is not more than 1 mm. Even with minor damage, replace them with new ones.
Shafts
On the working surfaces and splines of the output shaft, damage and excessive wear are not allowed (see table. 5). The flexible coupling flange must slide freely on the splines. The rolling surface of the needles at the front end of the input shaft and in the bore of the input shaft must not show any visible irregularities. The intermediate shaft must not be chipped or excessively worn teeth. The surface of the reverse gear shaft must be smooth and free from galling. Eliminate minor irregularities on the surfaces with a set of sanding papers with a grain size of 10-M40. If the shaft is severely damaged or deformed, replace it with a new one.
Gears
On the gears, damage or wear of the teeth is not allowed, exceeding the allowable lateral clearance in the mesh, specified in Table. 5. Pay special attention to the condition of the ends of the teeth on the rims of the synchronizers. The contact patch between the teeth of the gears in engagement should extend to the entire working surface, which should be smooth, with no visible signs of wear. Also, check the clearance between the gears (see table. 5).
Bearings
Must be in immaculate condition. Their radial clearance should not exceed 0.05 mm. When checking, press the inner ring against the outer ring with your fingers and turn one of them in both directions, while the rolling should be smooth. On the surface of the balls (rollers) and treadmills of the rings are not allowed to be damaged. Replace defective bearings with new ones.
Rods and forks
Deformation of the shift forks is not allowed. The rods should slide freely without significant play in the crankcase bores. Check up a condition of blocking crackers, springs and balls of clamps. Parts that show visible signs of seizing or wear should be replaced with new ones.
Hubs, couplings and synchronizer rings
Check for signs of seizing on the hubs of the gear shifting clutches, especially on the sliding surfaces of the clutches. Pay special attention to the condition of the ends of the coupling teeth. Excessive wear of the surface of the blocking rings is not allowed when they abut against the synchronizer sleeve. Faults that prevent free sliding, eliminate with a velvet file. Replace worn parts with new ones.
The dimensions of the main mating parts of the gearbox and the limits of permissible wear are given in Table. 5.