| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Transmission fluid | Capacity Use Honda MTF | Fluid change | 1.4 L (1.5 US qt, 1.2 Imp qt) | |
| Overhaul | 1.6 L (1.7 US qt, 1.4 Imp qt) | |||
| Mainshaft | End play | 0.11-0.18 mm (0.004-0.007 in.) | Adjust | |
| Diameter of bushing surface | 18.80-18.85 mm (0.740-0.741 in.) | 18.75 mm (0.738 in.) | ||
| Diameter of distance collar | 28.992-29.005 mm (1.1414-1.1419 in.) | 28.93 mm (1.139 in.) | ||
| Diameter of ball bearing contact area (clutch housing side) | 25.977-25.990 mm (1.0227-1.0232 in.) | 25.92 mm (1.020 in.) | ||
| Diameter of needle bearing contact area | 34.984-35.000 mm (1.3773-1.3780 in.) | 34.93 mm (1.375 in.) | ||
| Diameter of ball bearing contact area (transmission housing side) | 24.987-25.000 mm (0.9837-0.9843 in.) | 24.93 mm (0.981 in.) | ||
| Runout | 0.02 mm (0.0008 in.) max. | 0.05 mm (0.002 in.) | ||
| Mainshaft 3rd, 4th, 5th, and 6th gears | I.D. | 39.009-39.025 mm (1.5358-1.5364 in.) | 38.95 mm (1.533 in.) | |
| End play | 3rd | 0.06-0.21 mm (0.002-0.008 in.) | 0.30 mm (0.012 in.) | |
| 4th | 0.06-0.19 mm (0.002-0.007 in.) | 0.28 mm (0.011 in.) | ||
| 5th | 0.06-0.14 mm (0.002-0.006 in.) | 0.23 mm (0.009 in.) | ||
| 6th | 0.06-0.16 mm (0.002-0.006 in.) | 0.25 mm (0.010 in.) | ||
| Thickness | 3rd | 27.02-27.07 mm (1.064-1.066 in.) | 26.95 mm (1.061 in.) | |
| 4th | 25.52-25.57 mm (0.994-1.007 in.) | 25.45 mm (1.002 in.) | ||
| 5th | 22.42-22.47 mm (0.883-0.885 in.) | 22.35 mm (0.880 in.) | ||
| 6th | 23.92-23.97 mm (0.942-0.944 in.) | 23.85 mm (0.939 in.) | ||
| Countershaft | Diameter of needle bearing contact area (clutch housing side) | 34.000-34.015 mm (1.3386-1.3392 in.) | 33.95 mm (1.337 in.) | |
| Diameter of distance collar contact area | 38.987-39.000 mm (1.5349-1.5354 in.) | 38.94 mm (1.533 in.) | ||
| Diameter of ball bearing contact area (transmission housing side) | 26.020-26.033 mm (1.0244-1.0249 in.) | 25.97 mm (1.022 in.) | ||
| Runout | 0.02 mm (0.0008 in.) max. | 0.05 mm (0.002 in.) | ||
| 35 mm shim-to-bearing inner race clearance | 0.04-0.10 mm (0.0016-0.0039 in.) | Adjust | ||
| Countershaft 1st gear | I.D. | 48.509-48.525 mm (1.9098-1.9104 in.) | 48.58 mm (1.913 in.) | |
| End play | 0.06-0.21 mm (0.020-0.025 in.) | 0.25 mm (0.010 in.) | ||
| Thickness | 27.42-27.47 mm (0.902-0.904 in.) | ——— | ||
| Countershaft 2nd gear | I.D. | 48.509-48.525 mm (1.9098-1.9104 in.) | 48.52 mm (1.910 in.) | |
| End play | 0.06-0.14 mm (0.002-0.006 in.) | 0.23 mm (0.009 in.) | ||
| Thickness | 26.42-26.47 mm (1.040-1.042 in.) | ——— | ||
| Countershaft 1st gear distance collar | I.D. | 39.00-39.01 mm (1.5354-1.5358 in.) | 39.02 mm (1.536 in.) | |
| O.D. | 44.489-44.500 mm (1.7515-1.7520 in.) | 44.44 mm (1.750 in.) | ||
| Length | 21.53-21.58 mm (0.843-0.849 in.) | ——— | ||
| Countershaft 2nd gear distance collar | I.D. | 39.00-39.01 mm (1.5354-1.5358 in.) | 39.02 mm (1.536 in.) | |
| O.D. | 44.489-44.500 mm (1.7515-1.7520 in.) | 44.44 mm (1.750 in.) | ||
| Length | 26.53-26.56 mm (1.044-1.046 in.) | ——— | ||
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Mainshaft 4th and 5th gears distance collar | I.D. | 29.014-29.024 mm (1.1423-1.1427 in.) | 29.03 mm (1.143 in.) | |
| O.D. | 34.989-35.000 mm (1.3775-1.3780 in.) | 34.94 mm (1.376 in.) | ||
| Length
| A | 48.97-49.03 mm (1.9279-1.9303 in.) | ——— | |
| B | 22.53-22.56 mm (0.887-0.888 in.) | ——— | ||
| Mainshaft 6th gear distance collar | I.D. | 25.00-25.10 mm (0.984-0.988 in.) | 25.12 mm (0.989 in.) | |
| Length | 24.03-24.08 mm (0.946-0.948 in.) | ——— | ||
| Reverse idler gear | I.D. | 18.016-18.043 mm (0.7090-0.7104 in.) | 18.08 mm (0.712 in.) | |
| Gear-to-reverse gear shaft clearance | 0.032-0.077 mm (0.001-0.003 in.) | 0.14 mm (0.016 in.) | ||
| Synchro ring | Ring-to-gear clearance | Ring pushed against gear | 0.655-1.334 mm (0.026-0.053 in.) | 0.4 mm (0.016 in.) |
| 1st/2nd shift fork | Finger thickness | 6.7-6.9 mm (0.264-0.272 in.) | ——— | |
| Fork-to-synchro sleeve clearance | 0.35-0.65 mm (0.014-0.026 in.) | 1.0 mm (0.039 in.) | ||
| 3rd/4th, 5th/6th shift fork | Finger thickness | 7.4-7.6 mm (0.29-0.30 in.) | ——— | |
| Fork-to-synchro sleeve clearance | 0.35-0.65 mm (0.014-0.026 in.) | 1.0 mm (0.039 in.) | ||
| Reverse shift fork | Finger thickness | 14.7-14.9 mm (0.527-0.587 in.) | ——— | |
| Fork-to-reverse idler gear clearance | 0.20-0.60 mm (0.007-0.024 in.) | 1.2 mm (0.047 in.) | ||
| Shift arm | I.D. | 14.013-14.058 mm (0.5517-0.5535 in.) | ——— | |
| Shift piece diameter at contact area | 0.20-0.61 mm (0.008-0.024 in.) | 0.7 mm (0.028 in.) | ||
| Shift arm-to-shift lever clearance | 0.013-0.085 mm (0.0005-0.0033 in.) | ——— | ||
| Select lever | O.D. | 13.941-13.968 mm (0.5489-0.5499 in.) | ——— | |
| Shift arm cover clearance | 0.032-0.127 mm (0.0005-0.0033 in.) | ——— | ||
| Inter lock | O.D. | 13.941-13.968 mm (0.5489-0.5499 in.) | ——— | |
| Inter lock-to-select lever clearance | 0.032-0.136 mm (0.0013-0.0054 in.) | ——— | ||
| Shift piece | I.D. | 14.000-14.068 (0.5512-0.5539 in.) | ——— | |
| Shift piece-to-select lever clearance | 0.032-0.127 mm (0.0005-0.0050in.) | ——— | ||
| Shift fork diameter at contact area | 0.2-0.5 mm (0.008-0.020 in.) | ——— | ||
| M/T differential carrier | Pinion shaft contact area I.D. | 18.010-18.028 mm (0.7091-0.7098 in.) | ——— | |
| Carrier-to-pinion shaft clearance | 0.027-0.057 mm (0.0011-0.0022 in.) | 0.100 mm (0.004 in.) | ||
| Driveshaft contact area I.D. | 28.025-28.045 mm (1.1033-1.1041 in.) | ——— | ||
| M/T differential pinion gear | Backlash | 0.05-0.15 mm (0.002-0.006 in.) | ——— | |
| I.D. | 18.042-18.066 mm (0.7103-0.7113 in.) | ——— | ||
| Pinion gear-to-pinion shaft clearance | 0.059-0.095 mm (0.002-0.004 in.) | 0.150 mm (0.006 in.) | ||
| 80 mm shim | 80 mm shim-to-bearing outer race clearance in transmission housing | 0-0.10 mm (0-0.0039 in.) | Adjust |