Gear Shift Actuator

Sequential Manual Transmission
















REMOVAL
1. CONFIRM THAT GEAR IS IN N POSITION
2. REDUCE ACCUMULATOR PRESSURE
3. REMOVE SUSPENSION UPPER BRACE
Remove the 2 bolts, 2 nuts and suspension upper brace.
4. REMOVE AIR CLEANER CAP AND AIR HOSE ASSEMBLY, AIR FILTER AND AIR CLEANER CASE
5. REMOVE FRONT ENGINE UNDER COVER
6. REMOVE BATTERY BRACKET
a. Loosen the clamp nut, and remove the clamp, battery and tray.
b. Remove the 3 bolts and battery bracket.
7. DISCONNECT ENGINE WIRE FROM TRANSMISSION





a. Disconnect the 2 hose clamps and engine wire clamp.





b. Disconnect the 2 engine wire clamps.
c. Remove the bolt, and disconnect the engine wire.





8. DISCONNECT NEUTRAL START SWITCH CONNECTOR AND 2 BACK-UP LIGHT SWITCH CONNECTORS





9. DISCONNECT GSA CONNECTORS





10. DISCONNECT GSA CONNECTOR BRACKET
Remove the bolt and disconnect the GSA connector bracket.
11. DISCONNECT SET SYSTEM HOSES
a. Disconnect the SMT system return hose.





1) Hold the system return hose with the SST as shown in the illustration.
SST 09340-00010
2) Then disconnect the system return hose by pushing the SST downward until a click sound is heard.

HINT: Put force equally and horizontally against the system hose with the SST.

b. Disconnect the SMT system clutch hose and SMT system master hose.





HINT: The way of removing the 2 SMT system hoses is the same.

1) Hold the system clutch and master hoses with the SST as shown in the illustration.
SST 09340 00010
2) Then disconnect the system clutch and master hoses by pushing the SST upward until a click sound is heard.

HINT: Put force equally and horizontally against the system hose.





c. Disconnect the 3 SMT system hoses from the flexible hose bracket.
d. Remove the bolt and flexible hose bracket.
e. Remove the clamp A from the 2 SMT system hoses.
f. Disconnect the 2 SMT system hoses from the engine wire bracket.
g. Remove the bolt and engine wire bracket.
h. Disconnect the other SMT system hose from the clamp B.
12. REMOVE GSA ASSEMBLY FROM TRANSMISSION





a. Remove the GSA cover.





b. Install the actuator link fixing plate to the GSA.
Part the No.: Actuator link fixing plate: 33963-0W010





c. Remove the bolt.





d. Fix the actuator link fixing plate with protection tape in order for the fixing plate not to slip off.





e. Using SST, remove the neutral start switch from the transmission assembly.
SST 09817-16011





f. Remove the 4 bolts, shift and select lever shaft assembly and gasket from the transmission assembly.





g. Remove the bolt and nut, so that the fuel tank inlet pipe can move.

NOTICE: Open the fuel tiller opening lid beforehand, so that the tip of the fuel tank Inlet pipe will not deform the fuel filler opening lid.





h. Disconnect the connector clamp and input sensor connector.





i. Remove the 3 C bolts and stiffener plate.
j. Loosen the A bolt.

HINT: Do not separate the A bolt from the GSA assembly.

k. Remove the B bolt.

NOTICE: Because the B bolt IS tensed up by the release cylinder cable of the GSA assembly, hold the GSA assembly not to damage the bolt's thread when removing the B bolt.

l. Take out the GSA assembly from the transmission assembly.





m. Pulling the release cylinder cable while the GSA assembly is close to the clutch fork, separate the cable from the clutch fork.





HINT: Place the GSA assembly as shown in the illustration after the GSA assembly is removed.

n. Remove the protection tape and actuator link fixing plate.

REPLACEMENT
1. REPLACE 3 STROKE SENSORS (SELECT, CLUTCH AND SHIFT)





a. Disconnect the 3 stroke sensor connectors and 3 connector packings.

HINT: Place markings on each sub-wire before removing the subwires.

b. Disconnect the 2 sub-wires from the GSA connector bracket.

HINT: The way of replacing the 3 stroke sensors is the same.





c. Using a torx socket wrench (T25), remove the 2 torx bolts, sensor cover and stroke sensor.
d. Apply sequential M/T grease to a new stroke sensor and the piston ring in the GSA.
e. Using a torx socket wrench (T25), install the stroke sensor and sensor cover with the 2 torx bolts.
Torque: 2.2 Nm (22 kgf cm, 19 inch lbs.)
f. Install the 3 connector packings to each stroke sensor connector.
g. Connect the 3 stroke sensor connectors.
2. REPLACE SHIFT ACTUATOR LINK





a. Remove the shift actuator link from the GSA.
b. Apply sequential MIT grease to a new shift actuator link as shown in the illustration.
c. Install the shift actuator link to the GSA.

INSTALLATION
1. INSTALL GSA ASSEMBLY TO TRANSMISSION





a. Install actuator link fixing plate to the GSA assembly.
Part the No.: Actuator link fixing plate: 33963-0W010





b. Fix the actuator link fixing plate with protection tape in order for the fixing plate not to slip off.





c. Attach the A bolt to the GSA assembly.





d. Apply release hub grease to the release fork and clutch cable.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
e. Pay attention to combine the clutch cable and clutch fork.





f. Pulling the clutch fork, install the GSA assembly.





g. Temporarily tighten the A and B bolts.

NOTICE:
^ Because the B bolt is tensed up by the release cylinder cable of the GSA assembly, hold the GSA assembly not to damage the bolt's thread when install the B bolt.
^ Install the B bolt before the A bolt.

h. Install the stiffener plate bracket with the 3 C bolts.
Torque: 42 Nm (428 kgf-cm, 31 ft. lbs.)
i. Tighten the A and B bolts.
Torque: 42 Nm (428 kgf-cm, 31 ft. lbs.)





j. Attach the fuel tank inlet pipe, and install the bolt and nut. Torque:
Bolt: 27 Nm (275 kgf-cm, 20 ft. lbs.)
Nut: 8.5 Nm (87 kgf-cm, 75 inch lbs.)





k. Connect the connector clamp and input sensor connector.





l. Install the shift and select lever shaft assembly, gasket and 4 bolts to the transmission assembly.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)





m. Using SST, install the neutral start switch to the transmission assembly.
SST 09817-16011
Torque: 29 Nm (300 kgf cm, 22 ft. lbs.)
n. Remove the protection tape from the actuator link fixing plate.





o. Install the bolt.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
p. Remove the actuator link fixing plate from the GSA assembly.





q. Install the GSA cover as shown in the illustration.
2. CONNECT NEUTRAL START SWITCH CONNECTOR AND 2 BACK-UP LIGHT SWITCH CONNECTORS
3. CONNECT SMT SYSTEM HOSES





a. Install the engine wire bracket and bolt.
Torque: 8.3 Nm (85 kgf-cm, 73 inch lbs.)
b. Install the flexible hose bracket and bolt.
Torque: 19.6 Nm (200 kgf cm, 14 ft. lbs.)





c. Connect the SMT system hose to the clamp B.
d. Connect the 2 SMT system hoses to the engine wire bracket.
e. Install the clamp A to the 2 SMT system hoses.
f. Connect the 3 SMT system hoses to the flexible hose bracket.





g. Apply a light coat of sequential M/T fluid to the 3 new O-rings.
h. Install the 3 new O-rings.





i. Connect the 3 SMT system hoses by pushing the hoses downward until a click sound is heard.





4. INSTALL GSA CONNECTOR BRACKET
Install the connector bracket with the bolt.
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)





5. CONNECT GSA CONNECTORS
6. CONNECT ENGINE WIRE TO TRANSMISSION





a. Connect the 2 clamps.
b. Install the bolt and engine wire





c. Connect the 2 hose clamps and engine wire clamp.
7. INSTALL BATTERY BRACKET
a. Install the battery carrier with the 3 bolts.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
b. Install the battery tray and also the battery with the battery clamp.
8. INSTALL FRONT ENGINE UNDER COVER
9. CHECK SMT SYSTEM FLUID LEVEL
10. INSTALL AIR CLEANER CAP AND AIR HOSE ASSEMBLY, AIR FILTER AND AIR CLEANER CASE
11. INSTALL SUSPENSION UPPER BRACE
Install the suspension upper brace with the 2 bolts and 2 nuts.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.) for bolt
80 Nm (816 kgf-cm, 59 ft. lbs.) for nut
12. PERFORM INITIAL LEARNING OF SMT SYSTEM
13. CHECK FOR SMT FLUID LEAKS
14. CHECK ROAD TEST