Honda TRX450R Service Manual page 305

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER ('04 - '05)
Do not expand the
snap ring more than
necessary for
removal.
Remove the mainshaft, countershaft and left shift
fork as an assembly.
Remove the left shift fork from the C4 gear.
Disassemble the mainshaft and countershaft.
NOTE:
• Keep track of the disassembled parts (gears,
bushings, washers and rings) by sliding them
onto a tool or slipping them onto a piece of wire.
COUNTERSHAFT
MAINSHAFT
INSPECTION
Check the gear shifter groove, dogs, dog holes and
teeth for abnormal wear or damage.
Measure the I.D. of each gear.
SERVICE LIMITS: M4: 28.05 mm (1.104 in)
M5: 28.06 mm (1.105 in)
C1: 22.07 mm (0.869 in)
C2: 30.07 mm (1.184 in)
C3: 28.07 mm (1.105 in)
Check the bushings for abnormal wear or damage.
Measure the O.D. of each bushing.
SERVICE LIMITS: M4, M5: 27.94 mm (1.100 in)
C1: 21.94 mm (0.864 in)
C2: 29.94 mm (1.179 in)
C3: 27.94 mm (1.100 in)
Measure the I.D. of each bushing.
SERVICE LIMITS: M5: 25.06 mm (0.987 in)
C1: 19.06 mm (0.750 in)
C2: 27.06 mm (1.065 in)
C3: 25.06 mm (0.987 in)
Check the spline grooves and sliding surfaces of the
mainshaft and countershaft for abnormal wear or
damage.
Measure the O.D. of the mainshaft and counter-
shaft.
SERVICE LIMITS: at M5: 24.95 mm (0.982 in)
atC1: 18.94 mm (0.746 in)
at C2: 29.94 mm (1.061 in)
at C3: 24.94 mm (0.982 in)
15-14