Installation

CLUTCH UNIT (for R155F):

INSTALLATION

1. INSTALL INPUT SHAFT BEARING





(a) Using SST and a hammer, install the input shaft bearing.
SST: 09304-30012
HINT: After assembling the input shaft bearing to the hub, make sure that it rotates smoothly.

(b) Install 4 new bolts.
Torque: 27 Nm (270 kgf-cm, 20 ft-lbf)






(c) Mark each bolt with paint as shown in the illustration.
(d) Retighten each bolt by 90°.
(e) Check that the mark on each bolt is at a 90° angle from its original position.






2. INSPECT INPUT SHAFT BEARING
(a) Turn the bearing by hand while applying force in the rotation direction.
If the bearing is stuck or difficult to turn, replace the input shaft bearing.
HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.





3. INSTALL CLUTCH DISC ASSEMBLY
(a) Insert SST into the clutch disc assembly, then insert them into the flywheel sub-assembly.
SST: 09301-00210
NOTE: Take care not to insert clutch disc assembly in the wrong orientation.





4. INSTALL CLUTCH COVER ASSEMBLY
(a) Align the matchmarks on the clutch cover assembly and flywheel sub-assembly.
(b) Tighten the 6 bolts, in the order shown in the illustration, starting with the bolt located near the knock pin on the top.
Torque: 19 Nm (195 kgf-cm, 14 ft-lbf)
HINT:
- Following the order in the illustration, uniformly tighten the bolts.
- Move SST up and down, right and left gently after checking that the disc is in the center, and tighten the bolts.





5. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
(a) Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment:
0.5 mm (0.020 in.)
If the alignment is not as specified, adjust the diaphragm spring tip alignment using SST.
SST: 09333-00013
6. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support onto the transaxle assembly.
Torque: 47 Nm (479 kgf-cm, 35 ft-lbf)
7. INSTALL RELEASE BEARING HUB CLIP






8. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Apply release hub grease to the release fork and release bearing assembly contact surfaces, release fork and push rod contact surface and release fork pivot point.
Sealant:
Part No. 08887-01806, RELEASE HUB GREASE or equivalent
(b) Install the release fork onto the release bearing assembly.
9. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
(a) Apply clutch spline grease to the input shaft spline.
Sealant:
Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent
(b) Install the bearing onto the release fork, and then install them onto the transaxle assembly.
NOTE: After installation, move the fork forward and backward to check that the release bearing slides smoothly.

10. INSTALL CLUTCH RELEASE FORK BOOT
11. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY