Reassembly

NOTE:
- Use the correct thrust shim to assure the proper mainshaft thrust clearance.
- Select proper shim.
- Use the correct thrust shim to assure the proper super-low 2nd shaft thrust clearance.
- Select proper shim




1. Install the oil guide plate, mainshaft thrust shim and super-low 2nd shaft thrust shim.




2. Install the oil gutter and collect plates in the transmission housing.
3. Install the transfer shaft assembly and 2-4 selector rod.
4. Install the differential assembly in the clutch housing.




5. Put the bearing on the transfer shaft.




6. Install the spring washer with the angle against the clutch housing as shown.
Install the super-low 2nd shaft, countershaft assembly and mainshaft assembly in the clutch housing.




7. Install the super-low shift piece B and shift fork on the super-low shift fork shaft.
8. Assemble the super-low shift fork shaft assembly with the following parts, and install them on the super-low 2nd shaft.

NOTE: Note the installation direction of the synchro sleeve.




9. Install the following parts in the clutch housing:

NOTE:
- Align the lug on the end of the super-low 1st shaft with the groove in the clutch housing.
- Install the 62 mm lock washer with the dished end facing up.




10. Install the reverse shift holder assembly in the clutch housing.
11. Install the following parts on the mainshaft:
1. Reverse shift fork
2. 3rd/4th shift fork
3. 5th shift fork




12. Slide the 5th/reverse shift fork shaft down through each shift fork.

NOTE: Install the fork shaft with the detent hole facing the countershaft





13. Install the following parts on the countershaft in the order shown.
1. 1st/2nd shift fork
2. Super-low shift piece A
3. Super-low shift lever
14. Slide the 1st/2nd shift fork shaft through each shift piece and shift lever.

NOTE: Install the 1st/2nd shift fork shaft with the detent hole facing the mainshaft.

15. Install the super-low shift piece bar in the reverse shift holder assembly.




16. Install the reverse idler gear and idler gear shaft in the clutch housing.

NOTE: Install the idler shaft with the threads facing outside.




17. Apply sealant to the transmission mating surface of the clutch housing.

NOTE: This transmission uses no gaskets between the major housings; use Honda Sealant, (P/N 08718-0001). Assemble the housings within 20 minutes after applying the sealant and allow it to cure for at least 30 minutes after assembly before filling it with oil.




18. Install the 14 x 20 mm dowel pins.
19. Place the transmission housing over the clutch housing, being careful to line up the shafts.




20. Install the snapring to the countershaft ball bearing and sealing bolt.

NOTE: Apply sealant (P/N 08718-0001) to the threads of the 32 mm sealing bolt.




21. Torque the bolts in the sequence shown to: 25 N.m (2.5 kg-m, 18 lb-ft)




22. Install the following parts on the transmission housing.

NOTE: Apply Honda Sealant (P/N 08718-0001) to the threads of the super-low shift lever bolt.