Ring gear removal/shim replacement
Remove the distance collar.
Remove the dust guard plate bolt and remove the dust guard plate by turning it counterclockwise.
![](https://motoinstruction.ru/img/honda/9/116145.jpg)
Remove the case cover bolts and gear case cover.
![](https://motoinstruction.ru/img/honda/9/116146.jpg)
Remove the wave washer if it remains in the gear case.
If the ring gear stays in the cover, perform the following procedure.
![](https://motoinstruction.ru/img/honda/9/116147.jpg)
Support the cover horizontally with the ring gear facing down and press the gear out using the special tools and hydraulic press.
Tools:
- Oil seal driver 07965-MC70100
- Attachment, 72x75 mm 07746-0010600
Remove the ring gear from the gear case.
Remove the oil seal from the ring gear.
![](https://motoinstruction.ru/img/honda/9/116148.jpg)
Remove the ring gear bearing using the commercially available bearing puller.
![](https://motoinstruction.ru/img/honda/9/116149.jpg)
This bearing may not need to be replaced after removal. However, inspect the bearing for excessive play after removal.
Replace the ring gear shim.
![](https://motoinstruction.ru/img/honda/9/116150.jpg)
If the gear set, pinion bearing, ring gear bearing and/or gear case are replaced, install a 2.00 mm (0.079 in) thick shim (standard).
Ring gear installation
For the case bearing replacement and breather hole cleaning, see page 12-17.
![](https://motoinstruction.ru/img/honda/9/116151.jpg)
![](https://motoinstruction.ru/img/honda/9/116152.jpg)
If the ring gear assembly was loose against the cover (if it did not stay in the cover), do the following:
![](https://motoinstruction.ru/img/honda/9/116153.jpg)
Place the ring gear shim onto the ring gear.
Press the bearing onto the shaft.
Tools:
- Oil seal driver 07965-MC70100
- Attachment, 72 x 75 mm 07746-0010600
If the ring gear remained in the cover, do the following:
![](https://motoinstruction.ru/img/honda/9/116154.jpg)
Remove the case cover oil seal (see following page). Press the ring gear bearing into the cover using the special tools.
Tools:
- Driver 07749-0010000
- Bearing driver attachment 07GAD-SD40101
Install the shim onto the ring gear.
![](https://motoinstruction.ru/img/honda/9/116155.jpg)
Support the bearing inner race with the special tool, and press the ring gear into the bearing.
Tools: Oil seal driver 07965-MC70100.
Coat a new oil seal with grease and install it into the ring gear.
![](https://motoinstruction.ru/img/honda/9/116156.jpg)
Remove and discard the case cover oil seal.
![](https://motoinstruction.ru/img/honda/9/116157.jpg)
Install a new oil seal and apply grease to the seal lips.
Tools:
- Driver 07749-0010000
- Bearing driver attachment 07GAD-SD40101
Install the ring gear into the gear case cover.
![](https://motoinstruction.ru/img/honda/9/116158.jpg)
Measure the clearance between the ring gear and the ring gear stop pin with a feeler gauge.
Clearance: 0.30-0.60 mm (0.012-0.024 in).
Remove the ring gear if the clearance exceeds the service limit. Heat the gear case cover to approximately 80°C (176°F). Heat the case cover evenly and slowly to prevent warpage.
![](https://motoinstruction.ru/img/honda/9/116159.jpg)
Do not heat small areas individually. When the gear cover case is heated to the proper temperature, remove the stop pin by tapping the cover.
Always wear insulated gloves when handling the gear case cover.
Notice: Case cover warpage can occur if the cover is not heated properly.
Install a stop pin shim to obtain the correct clearance.
SHIM THICKNESS:
- A: 0.10 mm (0.004 in)
- B: 0.15 mm (0.006 in)
Install the shim and drive the stop pin into the case cover.
![](https://motoinstruction.ru/img/honda/9/116160.jpg)
Clean all sealing material off the mating surfaces of the gear case and cover.
Keep dust and dirt out of the gear case.
Be careful not to damage the mating surfaces.
Check the gear tooth contact pattern after the ring gear shim has been replaced (see next page).
![](https://motoinstruction.ru/img/honda/9/116161.jpg)
Gear tooth contact pattern check
![](https://motoinstruction.ru/img/honda/9/116162.jpg)
Apply a thin coat of Prussian Blue to the pinion gear teeth for a tooth contact pattern check.
Place the wave washer and ring gear into the gear case.
![](https://motoinstruction.ru/img/honda/9/116163.jpg)
Pack grease into the seal lip cavity of the case cover oil seal and install the gear case cover.
![](https://motoinstruction.ru/img/honda/9/116164.jpg)
Tighten the cover bolts in two or three steps until the cover evenly touches the gear case, then tighten the 8-mm bolts to the specified torque in a crisscross pattern in two or more steps.
Next tighten the 10-mm bolts to the specified torque.
Torque:
- 8-mm: 25 N·m (2.6 kgf·m, 19 lbf·ft)
- 10-mm: 62 N·m (6.3 kgf·m, 46 lbf·ft)
Remove the oil filler cap from the final gear case.
![](https://motoinstruction.ru/img/honda/9/116165.jpg)
Rotate the ring gear several times in the normal direction of rotation.
Check the gear tooth contact pattern through the oil filler hole.
The pattern is indicated by the Prussian Blue applied to the pinion.
Contact is normal if the Prussian Blue is transferred to the approximate center of each tooth and slightly towards the face.
If the pattern is not correct, remove and change the pinion shim.
Replace the pinion shim with a thicker one if the contact pattern is too high.
![](https://motoinstruction.ru/img/honda/9/116166.jpg)
Replace the pinion shim with a thinner one if the contact pattern is too low.
![](https://motoinstruction.ru/img/honda/9/116167.jpg)
The patterns will shift about 1.5-2.0 mm (0.06-0.08 in) when the thickness of the shim is changed by 0.1 mm (0.004 in).
Ring gear shims:
- A: 1.82 mm (0.072 in)
- B: 1.88 mm (0.074 in)
- C: 1.94 mm (0.076 in)
- D: 2.00 mm (0.079 in) — Standard
- E: 2.06 mm (0.081 in)
- F: 2.12 mm (0.083 in)
- G:2.18 mm (0.086 in)
For gear case assembly, see page 12-17.
Pinion gear removal/shim replacement
Place the final gear case in a vise with soft jaws.
![](https://motoinstruction.ru/img/honda/9/116168.jpg)
Assemble the pinion holder plate and collars and install them onto the gear case to avoid damaging the gear case.
Remove the pinion joint nut.
Tools:
- Pinion holder plate 07924-ME40010
- Collar set "С" 07924-ME40020
Remove the bolt and retainer lock tab.
![](https://motoinstruction.ru/img/honda/9/116169.jpg)
Remove the pinion retainer with the retainer wrench.
Tool: Retainer wrench 07910-4630100.
![](https://motoinstruction.ru/img/honda/9/116170.jpg)
Assemble the pinion puller set as shown.
Pull out the pinion assembly with the pinion puller.
Tools:
- Puller base 07HMC-MM8011A
- Puller shaft 07931-ME4010B and
- Special nut 07931-HB3020A
![](https://motoinstruction.ru/img/honda/9/116171.jpg)
Pull the bearing outer and inner races from the shaft with the bearing puller.
This bearing may not need to be replaced after removal. However, inspect the bearing for excessive play after removal.
![](https://motoinstruction.ru/img/honda/9/116172.jpg)
Remove the pinion shim.
If the gear set, pinion bearing, ring gear bearing and/or gear case are replaced, install a 2.00 mm (0.79 in) thick shim (standard) for initial reference.
![](https://motoinstruction.ru/img/honda/9/116173.jpg)
Pinion gear installation
![](https://motoinstruction.ru/img/honda/9/116174.jpg)
Install the pinion shim (see previous page) on the pinion gear.
Drive the pinion gear bearing onto the pinion gear using the special tool.
Tools:
- Driver, 40 mm i.D. 07746-0030100
- Attachment, 30 mm I.D. 07746-0030300
![](https://motoinstruction.ru/img/honda/9/116175.jpg)
Remove the О-ring and oil seal from the pinion retainer.
![](https://motoinstruction.ru/img/honda/9/116176.jpg)
Drive a new oil seal into the retainer using the special tools.
Tools:
- Driver 07749-0010000
- Attachment, 52x55 mm 07746-0010400
Pack grease into the seal lip cavity.
![](https://motoinstruction.ru/img/honda/9/116177.jpg)
Coat a new О-ring with grease and install it on the retainer.
![](https://motoinstruction.ru/img/honda/9/116178.jpg)
Place the gear case in a vise with soft jaws.
Drive the pinion assembly into the gear case until enough threads are visible to accept the pinion retainer to avoid damaging the gear case.
![](https://motoinstruction.ru/img/honda/9/116179.jpg)
Tools:
- Driver, 40 mm I.D. 07746-0030100
- Attachment, 30 mm I.D. 07746-0030300
Screw the pinion retainer in, pressing the pinion bearing in place, then tighten retainer to the specified torque.
Tool: Retainer wrench 07910-4630100.
Torque: 147 N·m (15.0 kgf·m, 108 lbf·ft).
![](https://motoinstruction.ru/img/honda/9/116180.jpg)
Install a lock tab, depending on the position of the pinion retainer grooves in relation to the lock tabs.
Install and tighten the lock tab bolt.
Torque: 10 N·m (1.0 kgf·m, 7 lbf·ft).
![](https://motoinstruction.ru/img/honda/9/116181.jpg)
The lock tab plate is available in the two types shown.
Install the pinion joint to the pinion gear shaft.
Apply locking agent to the threads of the pinion joint nut and screw in it by hand as far as it goes.
![](https://motoinstruction.ru/img/honda/9/116182.jpg)
Hold the pinion joint using the pinion holder plate and collars.
Tighten the pinion joint nut.
Tools:
- Pinion holder plate 07924-ME40010
- Collar set "С" 07924-ME40020
Torque: 108 N»m (11.0 kgf·m, 80 lbf·ft).
![](https://motoinstruction.ru/img/honda/9/116183.jpg)
Case bearing replacement
Remove the ring gear and pinion gear.
Heat the gear case to 80°C (176°F) evenly using heat gun.
![](https://motoinstruction.ru/img/honda/9/116184.jpg)
Tools:
- Bearing remover 07936-3710300
- Remover handle 07936-3710100
- Remover weight 07936-371020A or 07936-3710200
Always wear insulated gloves when handling the heated gear case.
Remove the oil seal and discard it.
![](https://motoinstruction.ru/img/honda/9/116185.jpg)
Drive a new oil seal into the gear case using the special tools.
Tools:
- Driver 07749-0010000
- Attachment, 52 x 55 mm 07746-0010400
![](https://motoinstruction.ru/img/honda/9/116186.jpg)
Drive a new ring gear bearing into the gear case using the special tools.
Tools:
- Driver 07749-0010000
- Attachment, 52x55 mm 07746-0010400
- Pilot, 35 mm 07746-0040800
![](https://motoinstruction.ru/img/honda/9/116187.jpg)
Breather hole cleaning
To avoid damaging the breather cap, remove it before blowing compressed air through the breather hole.
![](https://motoinstruction.ru/img/honda/9/116188.jpg)
Gear case assembly
Clean all sealing material off the mating surfaces of the gear case cover.
![](https://motoinstruction.ru/img/honda/9/116189.jpg)
Apply liquid sealant to the mating surface of the gear case and cover. Do not apply sealant around the dowel holes.
Install the ring gear and gear case cover with the wave washer.
Tighten the cover bolts in two or three steps until the cover evenly touches the gear case, then tighten the 8-mm bolts to the specified torque in a crisscross pattern in two or more steps.
Next, apply locking agent to the 10-mm bolt threads and tighten them to the specified torque.
Torque:
- 8-mm: 25 N·m (2.6 kgf·m, 19 lbf·ft)
- 10-mm: 62 N·m (6.3 kgf·m, 46 lbf·ft)
![](https://motoinstruction.ru/img/honda/9/116190.jpg)
Make sure the gear assembly rotates smoothly without binding.
![](https://motoinstruction.ru/img/honda/9/116191.jpg)
Measure the final gear assembly preload.
Preload: 0.2-0.4 N·m (2-4 kgf·m, 1.7-3.5 lbf·ft).
If the preload reading does not fall within the limit, disassemble the final gear and check the bearings for proper installation.
Install the dust guard plate by aligning the plate tabs with the case cover grooves and turn it clockwise to lock.
Tighten the guard plate bolt.
Torque: 10 N·m (1.0 kgf·m, 7 lbf·ft).
Install the distance collar with the polished side facing the gear case.
![](https://motoinstruction.ru/img/honda/9/116192.jpg)