Transmission Disassembly

1. Remove back-up light switch. Remove sealing bolt (sealing bolt has square hole). Remove all housing bolts. Access mainshaft bearing snap ring through sealing bolt opening. Spread snap ring, lift and remove cover. See Fig 1 and Fig 2 .
2. Using a chisel, cut lock nut (mainshaft, countershaft) lock tab. Pry tab up and remove nut from each shaft. Remove shift fork set bolt. Remove 5th gear components from mainshaft and countershaft. See Fig 1 and Fig 2 .
3. Remove all set bolts, springs and steel detent balls. Disassemble and remove strainer assembly. Remove all housing bolts. Lift and remove housing. See Fig 1 and Fig 2 .
   Fig 1: Exploded View Of Transmission (1 of 2)

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
   Fig 2: Legend For Exploded View Of Transmission (2 of 2)

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. Inspect reverse shift holder and shift fork. Measure clearance between 5th/reverse shift piece pin and reverse shift fork. See Fig 3 . Clearance for dimension "A" should be .002-.014" (.05-.35 mm). Clearance for dimension "B" should be .016-.032" (.40-.80 mm). Service limit for dimension "A" is .020" (.50 mm). Service limit for dimension "B" is .039" (1.0 mm). If clearance exceeds service limit, measure groove width of reverse shift fork. Width of groove (dimension "A") should be .278-.285" (7.05-7.25 mm). Width of groove (dimension "B") should be .291-.303" (7.40-7.70 mm). If grooves exceed specification, replace reverse shift holder.
5. Measure clearance between reverse idler gear and reverse shift fork. See Fig 5 . Clearance should be .020-.043" (.50-1.10 mm). Service limit is .067" (1.7 mm). If clearance exceeds service limit, measure end width of reverse shift fork. Width of end of reverse shift fork should be .551-.563" (14.00-14.30 mm). If width is greater than maximum, replace reverse shift holder.
6. Inspect change holder assembly. Measure clearance between change piece and select arm. See Fig 6 . Clearance should be .002-.014" (.05-.35 mm). Service limit is .020" (.50 mm). If clearance exceeds service limit, measure width of select arm. See Fig 6 . Thickness should be .465-.472" (11.8-12.0 mm). If thickness is less than specification, replace change holder. If width is within specification, replace change piece.
7. Measure clearance between change piece and shift arm. Clearance should be .004-.016" (.10-.40 mm). Service limit is .020" (.50 mm). See Fig 8 . If clearance exceeds service limit, measure width of shift arm. Width should be .504-.512" (12.8-13.0 mm). If width is less than specification, replace change holder. If width is within specification, replace change piece.
8. Measure clearance between shift fork shafts, 5th/reverse shift piece and shift piece. See Fig 10 . Clearance should be .008-.020" (.20-.50 mm). Service limit is .028" (.70 mm). If clearance exceeds service limit, measure width of shift piece. Width should be .469-.472" (11.9-12.0 mm). If width is less than specification, replace change holder. If width is within specification, replace 5th/reverse shift piece.
9. Measure clearance between shift piece and shift arm. Clearance should be .004-.016" (.10-.40 mm). Service limit is .024" (.60 mm). See Fig 12 . If clearance exceeds specification, replace change holder.
10. Remove reverse shift fork. Remove change holder assembly. Remove reverse idler gear and shaft. Remove mainshaft, countershaft and shift forks as one assembly. Remove secondary gear assembly. Disassemble remaining components. Ensure all components are inspected for wear or damage.