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Exploded View

Fig 1: Exploded View Of Mainshaft Components
G03660095Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

NOTE: Refer to the Exploded View as needed during this procedure.
  1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th and 5th/6th synchro hubs.
  2. Install the new angular ball bearing (A) using the special tool and a press. Note the direction of installation.
    Fig 2: Installing Angular Ball Bearing (A) Using Special Tool And Press
    G03660096Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Install the needle bearing (A) and 3rd gear (B) on the mainshaft (C).
    Fig 3: Identifying Needle Bearing (A), 3rd Gear (B) And Mainshaft (C)
    G03660097Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 3rd gear (C), then install the synchro spring (D).
    Fig 4: Identifying Synchro Assembly (A), Synchro Cone Fingers (B), 3rd Gear (C) And Synchro Spring (D)
    G03660098Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Install the 3rd/4th synchro hub (A) by aligning the outer synchro ring fingers (B) with the grooves in the 3rd/4th synchro hub (C).
    Fig 5: Identifying 3rd/4th Synchro Hub (A), Synchro Ring Fingers (B) And Synchro Hub Grooves (C)
    G03660099Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Install the 3rd/4th synchro hub (A) using the special tool.
    Fig 6: Installing 3rd/4th Synchro Hub (A) Using Special Tool
    G03660100Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) with the 3rd/4th synchro sleeve and hub. After installing, check the operation of the 3rd/ 4th synchro hub set.
    Fig 7: Installing 3rd/4th Synchro Sleeve (A) By Aligning Stops (B) With 3rd/4th Synchro Sleeve And Hub
    G03660101Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Install the synchro spring (A).
    Fig 8: Identifying Synchro Spring (A), Synchro Assembly (B), Synchro Ring Fingers (C) And Synchro Hub Grooves (D)
    G03660102Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Install the double cone synchro assembly (B) by aligning the outer synchro ring fingers (C) with the grooves in 3rd/4th synchro hub (D).
  10. Install 4th gear (A) by aligning the synchro cone fingers (B) with the holes in 4th gear (C).
    Fig 9: Installing 4th Gear (A) By Aligning Synchro Cone Fingers (B) With 4th Gear Holes (C)
    G03660103Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Install the needle bearings, distance collar, 5th gear, synchro ring, and synchro spring.
  12. Install the 5th/6th synchro hub (A) by aligning the outer synchro ring fingers (B) with the grooves in 5th/6th synchro hub (C).
    Fig 10: Installing 5th/6th Synchro Hub (A) By Aligning Outer Synchro Ring Fingers (B) With Synchro Hub Grooves (C)
    G03660104Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install the 5th/6th synchro hub (A) using the special tool.
    Fig 11: Installing 5th/6th Synchro Hub (A) Using Special Tool
    G03660105Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Install the 5th/6th synchro sleeve.
    Fig 12: Installing 5th/6th Synchro Sleeve
    G03660106Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Install the synchro spring and synchro ring.
  16. Install the distance collar, needle bearing, and 6th gear.
  17. Install the new angular ball bearing (A) using the special tool. Note the direction of installation.
    Fig 13: Installing Angular Ball Bearing (A) Using Special Tool
    G03660107Courtesy of AMERICAN HONDA MOTOR CO., INC.
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