CLUTCH UNIT REMOVAL/INSTALLATION [F35M-R]

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Caution

•  When newly replacing the clutch cover or the clutch disc, replace the clutch cover and the clutch disc as a set.

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

2.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

3.  Remove the front wheels and tires. (See GENERAL PROCEDURES (FRONT AND REAR AXLES).)

4.  Remove the fresh-air duct and air cleaner component as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

5.  Remove the fitting bolts of the EGR pipe (intake manifold side) using the procedure indicated in the figure. (See EGR PIPE REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

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6.  Suspend the EGR pipe (intake manifold side) with a cable in place out of the way

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7.  Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [F35M-R].)

8.  Remove the manual transaxle.

9.  Remove in the order indicated in the table.

10.  Install in the reverse order of removal.

11.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT [F35M-R].)

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1	Clutch release collar (See CLUTCH RELEASE COLLAR INSPECTION [F35M-R].)
2	Boot
3	Clutch release fork
4	Clutch cover (See Clutch Cover and Disc Removal Note.) (See Clutch Cover Installation Note.)
5	Clutch disc (See Clutch Cover and Disc Removal Note.) (See Clutch Disc Installation Note.)
6	Pilot bearing (See Pilot Bearing Removal Note.) (See Pilot Bearing Installation Note.)
7	Flywheel (See Flywheel Removal Note.) (See Flywheel Installation Note.)

Clutch Cover and Disc Removal Note

1.  Install the SSTs.

2.  Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.

3.  Remove the clutch cover and disc.

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Pilot Bearing Removal Note

Note

•  The pilot bearing does not need to be removed unless you are replacing it.

1.  Use the SST to remove the pilot bearing.

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Flywheel Removal Note

1.  Hold the flywheel using the SST.

2.  Remove the lockbolts evenly and gradually in a crisscross pattern.

3.  Remove the flywheel.

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4.  Inspect for oil leakage from the crankshaft rear oil seal.

•  If there is any malfunction, replace the crankshaft rear oil seal. (See REAR OIL SEAL REPLACEMENT [MZR 1.3, MZR 1.5].)

Flywheel Installation Note

Caution

•  Clean the crankshaft threads before tightening the bolts.The threads may be damaged if the bolts are tightened with any old sealant remaining.

1.  Clean the crankshaft thread holes before installing the new flywheel lockbolts.

2.  Install the flywheel to the crankshaft.

3.  Hand-tighten the flywheel lockbolts.

4.  Install the SST to the flywheel.

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5.  Gradually tighten the flywheel lockbolts in a crisscross pattern.

Pilot Bearing Installation Note

1.  Install the pilot bearing using the SSTs.

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2.  As shown in the figure, press-fit the pilot bearing to the position which is 0—0.4 mm {0.00—0.015 in} from the crankshaft end.

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Clutch Disc Installation Note

1.  Clean the splines of the clutch disc and primary shaft gear with a brush.

2.  Apply a small amount of molybdenum grease to the splines.

3.  Hold the clutch disc position using the SST.

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Clutch Cover Installation Note

1.  Install the SSTs.

2.  Tighten the bolts in Min. 2 stages.

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(1)  Temporarily tighten the bolts in the order shown in the figure

(2)  Tighten the bolts completely in the order shown in the figure and install the clutch cover

Tightening torque

18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}