Overhaul
MT Gear Shift LeverDISASSEMBLY
1) Remove the spring pin from the slider.
2) Remove the slider and spring.
3) Cut off the band clip.
4) Remove the reverse check cable from the cable plate.
5) Remove the reverse check cable from the gear shift assembly.
6) Remove the holder and spring.
7) Disassemble the lock wire.
NOTE:
Do not reuse the lock wire.
8) Remove the boss from the rod.
9) Remove the rod from lever.
10) Separate the rod and inner boot.
11) Remove the snap ring from the stay.
12) Separate the gear shift lever and the stay.
13) Remove the O-ring and bushing from the gear shift lever.
14) Remove the spring pin, and then remove the bushing and snap ring.
15) Remove the bushing and spacer from the boss.
16) Remove the bushing and cushion rubber from the stay.
ASSEMBLY
NOTE:
^ Clean all the parts before assembly.
^ Apply NIGTIGHT LYW No. 2 grease or equivalent to each part.
1) Mount the bushing and cushion rubber to the stay.
2) Install the bushing and spacer to boss.
3) Install the snap ring to gear shift lever and install the bushing.
NOTE:
Apply grease to the bushing.
4) Apply grease to the bushing and O-ring, and then install to gear shift lever.
5) Apply sufficient grease into boss, and then install the gear shift lever to the stay.
6) Install the washer and snap ring.
7) Insert the gear shift lever and rod into boot hole.
8) Install the rod.
9) Install the boss to the rod.
10) Install a new lock wire.
NOTE:
^ Install the lock wire to the stay groove.
^ Bend the extra wire to the same direction of lock wire winding.
11) Install the holder.
12) Insert the reverse check cable into the boot hole.
13) Insert the reverse check cable into the gear shift assembly, and fix in place with a band clip.
NOTE:
^ Cut the excess band clip.
^ Make sure that the reverse check cable is inserted into the gearshift lever with no gaps.
14) Install the seat cushion and spring.
15) Use the spring pin to secure the end of the slider and reverse check cable.
NOTE:
Apply grease to the moving part of slider.
16) With the cable pulled (the slider is lowered), adjust the distance between the edge of cable plate and the reverse check cable to 84 mm (3.31 in), and tighten the lock nut.
17) Secure the reverse check cable to the stay clip.
NOTE:
Install the reverse check cable on top of the stay.
INSPECTION
1) Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. If necessary, correct or replace faulty parts. Compare the removed parts with new parts to judge if there are damages or not.
2) Check the swing torque of rod linked with the gear shift lever.
If the torque exceeds the specifications, replace the bushing or retighten nuts.
