- Clean all the components of the gear-
box and gear selector assembly, and
additionally the crankshaft, using any
degreasing agent.
- Re-assemble the gearbox secondary
shaft, taking particular care to ensure
correct assembly of all the compo-
nents, in order to avoid malfunction
and seizing.
- Fit the gearbox assembly into the
right hand crankcase half, (the pri-
mary and secondary shafts should be
inserted meshed together at the same
time).
- First check the overall width of the
secondary shaft sub-assembly inclu-
ding the adjusting shims on each
side.
Overall width of secondary shaft:
MAX 87.700 mm.
MIN 87.350 mm.
(there are different thicknesses of
shim available to ensure that the
thickness is correct.)
- Next install the selector forks, the
selector drum and the washers, and
the selector fork studs. Lubricate the
surface of the gear mechanism with
AGIP gear 10W40.
- Check that the gearbox operates
correctly, by selecting the different
gears, and turning the selector drum
in both directions. If it seizes, check
once again that the components have
been correctly fitted. Leave the gear-
box with neutral selected, and confirm
that all the elements in the assembly
are able to rotate freely.
- Fit the crankshaft into the right hand
side crankcase half.
- Fit a new crankcase sealing gasket,
paying particular attention to the free
piece in the area of the admission
system.
- Heat up the left hand crankcase half
to approximately 60ºC, and close it
onto the right hand crankcase half.
Then fit the assembly securing studs,
after first ensuring that they are scru-
pulously clean.
- Crankcase joint securing screw tor-
que setting: 6Nm (0,6 mkg).
- Check that the crankshaft and the
gearbox shafts rotate freely after the
crankcase is completely closed.
12-6
2ª 6ª 4ª 3ª 5ª 1ª
Z-30 Z-22 Z-24 Z-27 Z-23 Z-34
- Check the axial play of the gearbox secondary shaft,
which should be between 0.2 and 0.4 mm.
- Using the special installation punch tool (special tool,
part reference number: 00H05400451), fit new seals on
the crankshaft, first applying AGIP Speed lubricant to
the lips.
- Refit the primary drive assembly.
- Refit the magneto - ignition system.
- Refit the cylinder, piston, and cylinder head assemblies.
- Remount the engine into the frame.
- Refill and bleed the cooling system, and the separate
engine lubricating system.
- Refill the gearbox-clutch side crankcase half with oil.
- Start up the engine and carry out a brief check of all its
functions, and check the correct operation of the gear-
box and the clutch.
