Castelletto gear lever 500/595 Abarth-Instructions

500 / 595 Abarth gear lever replacement bezel instructions

DISASSEMBLE THE GEAR SHIFT LEVER KNOB.
IF YOUR CAR MODEL WAS WITH ALUMINUM KNOB THE OPERATION WILL BE VERY DIFFICULT, WITH THE HIGH POSSIBILITY OF RUINING THE KNOB ITSELF.
THIS IS BECAUSE THE KNOB IS ORIGINALLY FIXED WITH STRONG FRENAFILETTI ADHESIVE.
( IN THIS REGARD WE HAVE BUILT SPECIAL TOOL TO AVOID PROBLEMS).

REMOVE THE UPPER ( WHICH SERVES AS THE HEADSET SUPPORT )
AND LOWER PLASTICS. WHICH BOTH COVER THE SHIFT LEVER SUPPORT.
DISCONNECT THE GEAR ENGAGEMENT ROPES AND UNSCREW THE 4 NUTS/BOLTS THAT HOLD THE SHIFT LEVER SUPPORT TURRET TO THE FRAME.

APPLY OUR BRACKET COMPLETE WITH LEVER.
FOR ATTACHMENT USE THE 2 ORIGINAL NUTS AND OUR BOLTS PROVIDED IN THE KIT.

the original bezel in versions after 2015 is fixed with 4 8 millimeter bolts.
In versions prior to that date the bolts are three,and in the upper left position
Instead of the bolt there is a stud, also 8 millimeters.
in this case for fastening use the tapered nut provided in our kit,and after having
tightened and secured our bezel,cut off the excess thread protruding from our tapered nut.
this operation will prevent interference with the gear selection head.

DECIDE FOR THE TYPE OF FORWARD-BACKWARD STROKE REDUCTION,OPTING BETWEEN THE ROPE ENGAGEMENT BALLS: 1 OR 2 SEE PHOTO #1

IN POSITION 1 THE STROKE WILL BE 79 MM
IN POSITION 2 THE STROKE WILL BE 62 MM

MAKING SURE THE GEARBOX IS IN THE NEUTRAL POSITION,MOVE THE LEVER TO THE MIDDLE POSITION ( FORWARD BACKWARD ) BY SHIFTING THE ADJUSTABLE SHEATH HOLDER MARKED WITH THE LETTERS FR.RE
TIGHTEN THE HOLDING SCREWS WITH 10 MM HEXAGON.

ALIGN THE SHEATH AS MUCH AS POSSIBLE WITH RESPECT TO THE BALL WHERE THE ROPE IS ATTACHED USING THE FIXING PLATE MARKED WITH CENT
TIGHTEN THE SEALING SCREWS WITH ALLEN HEAD DIAMETER 6 MM.SEE PHOTO NO.2

BRING THE LEVER TO THE CENTER RIGHT LEFT POSITION BY SHIFTING THE ADJUSTABLE SHEATH HOLDER MARKED WITH THE LETTERS 2° REG LAT TIGHTEN THE HOLDING SCREW WITH 13 MM HEXAGON SEE PHOTO NO.3

THE STROKE IS RECORDED BY US WITH THE RIGHT/LEFT ENGAGEMENT STROKE AT 50 MM. THIS IS THE OPTIMAL WORKING POSITION.
YOU CAN INCREASE THE STROKE BY FURTHER SCREWING THE HEAD ONTO THE PIN BRINGING THE ENGAGEMENT STROKE TO 55 MM.

DIFFERENTLY BY UNSCREWING THE HEAD YOU WILL HAVE A SHORTER STROKE.
DO NOT EXCEED THE LENGTH OF MM 28 FROM THE BEGINNING OF THE HEAD TO THE BEGINNING OF THE HEXAGON FIXING NUT. SEE PHOTO NO.4

ONCE YOU MAKE SURE THE LEVER IS IN THE CENTER POSITION IN THE HOLDER,
LOOSEN THE SELF-LOCKING NUT OF THE ANTAGONIST SPRING SUPPORT SYSTEM, MARKED WITH THE ELLIPTICAL LETTERS RM AND ALIGN THE CENTER OF IT WITH THE CENTER OF THE GEAR SELECTION PIN.SEE PHOTO #5

CHECK ALL GEAR COUPLINGS AND PROCEED WITH THE REASSEMBLY OF THE COVER PLASTICS.
NB:ALL JOINTS AND CONNECTIONS DO NOT REQUIRE PERIODIC LUBRICATION.