Gear Shift Actuator: Installation

1. Install actuator link fixing plate to the GSA assembly.

   Part the No.:

   Actuator link fixing plate: 33963-0W010

   Fig 1: Installing Actuator Link Fixing Plate To GSA Assembly

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2. Fix the actuator link fixing plate with protection tape in order for the fixing plate not to slip off.
   Fig 2: Fixing Actuator Link Fixing Plate With Protection Tape

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3. Attach the A bolt to the GSA assembly.
   Fig 3: Attaching Bolt To GSA Assembly

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4. Apply release hub grease to the release fork and clutch cable.
   1. Sealant:Part No. 08887-01806, RELEASE HUB GREASE or equivalent 
5. Pay attention to combine the clutch cable and clutch fork.
   Fig 4: Releasing Hub Grease To Release Fork And Clutch Cable

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6. Pulling the clutch fork, install the GSA assembly.
   Fig 5: Pulling Clutch Fork

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7. Temporarily tighten the A and B bolts.
   NOTE:

   • 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.
8. Install the stiffener plate bracket with the 3 C bolts.
   1. Torque: 42 N.m (428 kgf.cm, 31 ft.lbf) 
9. Tighten the A and B bolts.
   1. Torque: 42 N.m (428 kgf.cm, 31 ft.lbf) 
   Fig 6: Tightening Bolts

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10. Attach the fuel tank inlet pipe, and install the bolt and nut.
    1. Torque: 
       1. Bolt: 27 N.m (275 kgf.cm, 20 ft.lbf) 
       2. Nut: 8.5 N.m (87 kgf.cm, 75 in..lbf) 
    Fig 7: Attaching Fuel Tank Inlet Pipe

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11. Connect the connector clamp and input sensor connector.
    Fig 8: Connecting Connector Clamp And Input Sensor Connector

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12. Install the shift and select lever shaft assembly, gasket and 4 bolts to the transmission assembly.
    1. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 
    Fig 9: Installing Shift And Select Lever Shaft Assembly, Gasket And Bolts

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13. Using SST, install the neutral start switch to the transmission assembly.

    SST 09817-16011

    1. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 
14. Remove the protection tape from the actuator link fixing plate.
    Fig 10: Installing Neutral Start Switch To Transmission Assembly

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15. Install the bolt.
    1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
16. Remove the actuator link fixing plate from the GSA assembly.
    Fig 11: Installing Bolt

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17. Install the GSA cover as shown in the illustration.

Fig 12: Installing GSA Cover

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1. Install the engine wire bracket and bolt.
   1. Torque: 8.3 N.m (85 kgf.cm, 73 in..lbf) 
2. Install the flexible hose bracket and bolt.
   1. Torque: 19.6 N.m (200 kgf.cm, 14 ft.lbf) 
3. Connect the SMT system hose to the clamp B.
4. Connect the 2 SMT system hoses to the engine wire bracket.
5. Install the clamp A to the 2 SMT system hoses.
6. Connect the 3 SMT system hoses to the flexible hose bracket.
   Fig 13: Installing Flexible Hose Bracket And Bolt

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   Fig 14: Connecting SMT System Hose To Clamp

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7. Apply a light coat of sequential M/T fluid to the 3 new O-rings.
8. Install the 3 new O-rings.
   Fig 15: Installing New O-Rings

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

Fig 16: Connecting SMT System Hoses By Pushing

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Install the connector bracket with the bolt.

1. Torque: 8 N.m (82 kgf.cm, 71 in..lbf) 

Fig 17: Installing Connector Bracket With Bolt

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1. Connect the 2 clamps.
2. Install the bolt and engine wire.
   Fig 19: Installing Bolt And Engine Wire

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3. Connect the 2 hose clamps and engine wire clamp.

1. Install the battery carrier with the 3 bolts.
   1. Torque: 24 N.m (245 kgf.cm, 18 ft.lbf) 
2. Install the battery tray and also the battery with the battery clamp.

Install the suspension upper brace with the 2 bolts and 2 nuts.

1. Torque: 
   1. 74 N.m (755 kgf.cm, 55 ft.lbf) for bolt 
   2. 80 N.m (816 kgf.cm, 59 ft.lbf) for nut