CLUTCH PEDAL REMOVAL/INSTALLATION [F35M-R]

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Caution

•  Fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is spilled, wipe it off immediately.

•  If clutch system-related hydraulic parts are removed, supply brake fluid, bleed air, and inspect for fluid leakage after the installation.

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

2.  Remove the battery clamp and battery box and battery. (L.H.D.) (See BATTERY REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

3.  Remove in the order indicated in the table.

4.  Plug the clutch pipe after removing it to avoid leakage.

5.  Install in the reverse order of removal.

6.  Fully depress the clutch pedal, and verify that the engine starts.

L.H.D.

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1	Reserve hose (See Reserve Hose Removal Note.) (See Reserve Hose Installation Note.)
2	Clutch pipe (See Clutch Pipe Removal Note.) (See Clutch Pipe Installation Note.)
3	Clutch pedal position switch connector
4	Clutch pedal position switch (See Clutch Pedal Position Switch Installation Note.)
5	Clutch pedal component (See Clutch Pedal Position Switch Installation Note.)
6	Pedal pad

R.H.D.

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1	Reserve hose (See Reserve Hose Removal Note.) (See Reserve Hose Installation Note.)
2	Clutch pipe (See Clutch Pipe Removal Note.) (See Clutch Pipe Installation Note.)
3	Clutch pedal position switch connector
4	Starter interlock switch connector (General (R.H.D.) specs)
5	Clutch pedal position switch (See Clutch Pedal Position Switch Installation Note.)
6	Starter interlock switch (General (R.H.D.) specs) (See Starter Interlock Switch Removal Note.) (See Starter Interlock Switch Installation Note.)
7	Clutch pedal component (See Clutch Pedal Position Switch Installation Note.)
8	Pedal pad

Reserve Hose Removal Note

1.  Move the clip upward.

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2.  Disconnect the reserve hose.

Clutch Pipe Removal Note

Caution

•  When disconnecting the clutch pipe, the seal ring installed to the end of the clutch pipe connector may fall off or remain on the clutch pedal component clutch master cylinder side. If the clutch pipe is assembled with the seal ring not installed, it may cause fluid leakage from the clutch pipe connector or the clutch may not operate normally. When disconnecting the clutch pipe, remove the seal ring and clutch pipe connector as a single unit.

1.  Pull the clutch master cylinder clip to the position shown in the figure and pull out the clutch pipe connector straight to detach it.

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2.  Verify that the seal ring is removed together with the clutch pipe connector.

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Starter Interlock Switch Removal Note

1.  Detach hook B in the direction of the arrow shown in the figure.

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2.  Remove the starter interlock switch by sliding the switch in the direction of the arrow

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Clutch Pedal Component Installation Note

1.  Add the clutch fluid, bleed the air, and inspect for leakage after the installation. (See CLUTCH FLUID AIR BLEEDING/REPLACEMENT [F35M-R].)

2.  After installing the clutch pedal, inspect the clutch pedal. (See CLUTCH PEDAL INSPECTION [F35M-R].)

Starter Interlock Switch Installation Note

Caution

•  The starter interlock switch may not operate normally if the rod is pushed in. Do not push in the rod when installing the starter interlock switch.

1.  Insert the new starter interlock switch.

(1)  Insert hook A of the starter interlock switch into the bracket hole.

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(2)  While pressing the starter interlock switch against the bracket, slide the switch until hook B is locked in the direction of the arrow shown in the figure.

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2.  Fully depress the clutch pedal, and verify that a click sound from the starter interlock switch is heard.

Clutch Pedal Position Switch Installation Note

1.  Insert the new clutch pedal position switch into hole of the pedal bracket until the switch stops.

2.  Rotate the clutch pedal position switch 45° clockwise.

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3.  Verify that the clutch pedal position switch is locked securely.

Clutch Pipe Installation Note

1.  Verify that the seal ring is assembled to the clutch pipe so that the ends of the seal ring and the clutch pipe overlap each other.

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Caution

•  Verify that there is no chipping or damage to the seal ring of the clutch pipe connector.

•  Replace the damaged seal ring with a new one.

2.  Return the clutch master cylinder clip to the position shown in the figure.

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3.  Insert the clutch pipe connector straight.

4.  Pull the clutch pipe to verify that it does not come off, and reinsert it completely.

Reserve Hose Installation Note

1.  Connect the reserve hose until a click is heard.

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2.  Verify that the reserve hose is securely installed by pulling it, and reinsert into the reserve tank.