Exploded View

Fig 1: Exploded View Of Secondary Shaft Assembly With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

NOTE: Refer to the Exploded View as needed during the following procedure.

Remove the sealing rings (A), the 32 mm snap ring (B), then remove the 2nd clutch (C) and O-rings (D).

Fig 2: Locating Sealing Rings, 32 mm Snap Ring, 2nd Clutch And O-Rings
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the 37 x 49 x 3.4 mm thrust washer (E), the 37 x 50 x 2.5 mm thrust needle bearing (F), 1st gear (G), the 32 x 38 x 34 mm needle bearing (H), the 37 x 52 x 2 mm thrust washer (I), and the 38 x 54 x 3.5 mm thrust needle bearing (J).
Secure the idler gear (A) on the secondary shaft (B) in a bench vise with wood blocks, loosen the lock bolt (C), and remove it.
NOTE: After this procedure, remove wood chips that may be stuck to the gear.

Fig 3: Securing Idler Gear On Secondary Shaft In Bench Vise With Wood Blocks
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Place the idler gear (A) on press bases (B), and place a spacer (C) between the secondary shaft (D) and the press to prevent damaging the secondary shaft.

Fig 4: Locating Idler Gear, Press Bases, Spacer And Secondary Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the ball bearing (A), the 38 x 64 x 3.5 mm thrust needle bearing (B), 2nd gear (C), the 38 x 44 x 22.5 mm needle bearing (D), the 39 x 57 x 2.5 mm thrust needle bearing (E), the 2nd gear collar (F), the 2nd/5th clutch (G), the O-rings (H), the 5th gear collar (I), the 49 x 66 x 3 mm thrust needle bearing (J), 5th gear (K), the 45 x 50 x 25 mm needle bearing (L), the 49 x 66 x 3 mm thrust needle bearing (M), and the idler gear (N) using a press.

Fig 5: Identifying Secondary Shaft Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Inspect the bearings for galling and rough movement.
Check the shaft bearing surfaces for scoring and excessive wear, and check the shaft splines for excessive wear and damage.
Check the secondary shaft 2nd gear axial clearance and 5th gear axial clearance (see SECONDARY SHAFT 2ND GEAR AND 5TH GEAR AXIAL CLEARANCE INSPECTION ), and check the secondary shaft installation height (see SECONDARY SHAFT INSTALLATION HEIGHT INSPECTION/ADJUSTMENT ).