Component Disassembly & Reassembly: MAINSHAFT: Reassembly

1. Using press and adapter, press mainshaft 3rd gear on mainshaft. See Figure .
2. Install thrust needle bearing and needle bearing on mainshaft. Using press and adapter, press mainshaft 4th gear and 4th clutch collar on mainshaft.
   NOTE: Replace 4th clutch collar if it can be installed on mainshaft by-hand.
3. Remove mainshaft from press. Ensure mainshaft 4th gear rotates freely on mainshaft.
4. Install 1st-4th clutch, gear collar, distance collar, thrust shim and snap ring on mainshaft.
   NOTE: DO NOT  install thrust needle bearing, needle bearings, mainshaft 1st gear and thrust needle bearing on mainshaft at this time.
5. Remove ball bearing for mainshaft from transaxle housing. Install ball bearing on mainshaft.
6. Install gear collar, thrust shim and 2nd clutch on mainshaft. See Figure . DO NOT  install thrust needle bearings, needle bearings and mainshaft 2nd gear at this time.
7. Install disc spring, distance collar, mainshaft reverse gear, ball bearing, washer and used lock nut on mainshaft. Ensure disc spring is installed with largest side against 2nd clutch. Tighten lock nut to 22 ft. lbs. (30 N.m).
8. Move 1st-4th clutch against 4th clutch collar. Using feeler gauge, measure mainshaft 4th gear clearance between gear collar and 1st-4th clutch guide. See Fig 1 .
9. Measure mainshaft 4th gear clearance in 3 different places. Use average reading as mainshaft 4th gear clearance. Mainshaft 4th gear clearance should be 0-.003" (0-.08 mm).
10. If .003" (.08 mm) feeler gauge can be installed, install different thickness 4th clutch collar and recheck clearance. Refer to the 4TH CLUTCH COLLAR SPECIFICATIONS  table.
11. Once correct mainshaft 4th gear clearance is obtained, disassemble mainshaft. Lubricate all components with ATF. Wrap splines of mainshaft with tape. Install NEW "O" rings on mainshaft. Reassemble mainshaft.

NOTE: Ensure thrust needle bearings are installed with unrolled edge of bearing retainer facing washer.

4TH CLUTCH COLLAR SPECIFICATIONS

Clutch Collar No.	Part Number	Thickness In. (mm)
1	90431-PY4-010	.381-.382 (9.67-9.70)
2	90432-PY4-010	.383-.384 (9.72-9.75)
3	90433-PY4-010	.385-.386 (9.77-9.80)
4	90434-PY4-010	.387-.388 (9.82-9.85)
5	90435-PY4-010	.389-.390 (9.87-9.90)
6	90436-PY4-010	.391-.392 (9.92-9.95)
7	90437-PY4-010	.393-.394 (9.97-10.00)

Fig 1: Removing & Installing Mainshaft (1 of 2)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 2: Removing & Installing Mainshaft (2 of 2)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 3: Checking Mainshaft 4th Gear Clearance

Courtesy of AMERICAN HONDA MOTOR CO., INC.