1ST/2ND Synchronizer

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.





Disassembly

NOTE: When dismantling the first/second gears' synchromesh unit, place output shaft assembly tool No. 87 92 103, or equivalent, over the gear wheels to keep the synchromesh together.





1. Cut off the tie strap and remove output shaft assembly tool from the synchromesh unit.





2. Lift out the second gear wheel and its bearing sleeve.
3. Lift out the synchromesh.
4. Remove the locking spring from the "beans".
- Lift out the sleeve and place the "beans" in a safe place.
5. Lift out and turn the synchromesh hub.
- Remove the locking spring on the bottom side.
6. Lift out the first gear's synchromesh from the gear wheels.
7. Check the condition of all parts as regards wear.
- Replace damaged or defective parts.
- Measure the wear on the trisected synchromeshes by installing them into their respective places.
- Measure with a feeler gauge in three places between the large baulk ring and the carriage wheel and calculate a mean value.
- New synchromesh 1.4-1.5 mm.
- If the mean value is less than 0.8 mm, the synchromesh should be changed.





Assembly
Lubricate all parts with engine oil suitable 10W30 before they are installed.
1. Assemble and install the first gear's synchromesh on the first gear wheels.





2. Place the synchromesh hub in the sleeve
- The sleeve should be placed with the fork groove facing downwards.

NOTE: The notches for the "beans" in the sleeve should face the notches for the "beans" in the synchromesh hub.

3. Place and install the three "beans".
- Install the locking spring clockwise.
- Turn carefully and then install the locking spring on the bottom side clockwise.

NOTE: The locking springs on both upper and bottom side should hook into the same "bean".





4. Place the sleeve (side with the fork groove downwards) and the synchromesh hub on the first gear's synchromesh.
- The notches in the synchromesh hub should install over the heels in the synchromesh.





5. Assemble and install the second gear's synchromesh on the second gear's gear wheels.
- Install the bearing sleeve in the second gear's gear wheel and install the entire unit in the sleeve and the synchromesh hub.
- The heels on the baulk ring should install in the notches in the synchromesh hub.





6. Hold down the gear wheels and change gears as a test.
7. Install the output assembly tool over the synchromesh unit so that it does not fall apart during the assembly.