CLUTCH UNIT REMOVAL/INSTALLATION [F35M-R, G35M-R, G66M-R, A26M-R]

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1.  Remove in the order indicated in the table.

2.  Install in the reverse order of removal.

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1
Clutch release cylinder
(See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [F35M-R, G35M-R, G66M-R, A26M-R].)
2
Manual transaxle
(See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R].)
(See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G35M-R].)
(See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G66M-R].)
(See MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26M-R].)
3
Clutch release collar
(See CLUTCH RELEASE COLLAR INSPECTION [F35M-R, G35M-R, G66M-R, A26M-R].)
4
Boot
5
Clutch release fork
(See Clutch Release Fork Removal Note.)
6
Clutch cover
(See Clutch Cover and Disc Removal Note.)
(See Clutch Cover Installation Note.)
7
Clutch disc
(See Clutch Cover and Disc Removal Note.)
(See Clutch Disc Installation Note.)
8
Pilot bearing
(See Pilot Bearing Removal Note.)
(See Pilot Bearing Installation Note.)
9
Flywheel
(See Flywheel Removal Note.)
(See Flywheel Installation Note.)


Clutch Release Fork Removal Note

1.  Remove the fork supporter before disassembling the release fork.

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Clutch Cover and Disc Removal Note

Caution
•  When replacing components, always replace as a complete set. (A26M-R)
•  Due to the automatic adjustment function of clutch cover, if the old cover assembly is reused, it must be reinstalled together with its original clutch disc. (A26M-R)

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 bolts evenly and gradually in a crisscross pattern.

3.  Remove the flywheel.

Except MZR-CD (RF Turbo)

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MZR-CD (RF Turbo)

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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 [ZJ, ZY, Z6].)
(See REAR OIL SEAL REPLACEMENT [LF, L3].)
(See REAR OIL SEAL REPLACEMENT [L3 Turbo].)
(See REAR OIL SEAL REPLACEMENT [MZR-CD (RF Turbo)].)


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 lock bolts.

2.  Install the flywheel to the crankshaft.

3.  Hand-tighten the flywheel lock bolts.

4.  Install the SST to the flywheel.

Except MZR-CD (RF Turbo)

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MZR-CD (RF Turbo)

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5.  Gradually tighten the flywheel lock bolts in a crisscross pattern.

Tightening torque
ZJ, ZY, Z6: 96.1—103.0 N·m {9.8—10.5 kgf·m, 70.9—75.9 ft·lbf}
LF, L3: 108—116 N·m {11.1—11.8 kgf·m, 79.7—85.5 ft·lbf}
L3 Turbo, MZR-CD (RF Turbo): 151.3—161.1 N·m {15.5—16.4 kgf·m, 111.6—118.8 ft·lbf}


Pilot Bearing Installation Note

1.  Use the SSTs to install the pilot bearing (ZJ, ZY, Z6, MZR-CD (RF Turbo)).

Install the pilot bearing using the corresponding 20mm {0.79 in} side of a Snap-on brand millimeter size bushing driver set A160M adapter A160M7 (20-22 mm {0.79-0.86 in})(LF, L3, L3Turbo).

ZJ, ZY, Z6, MZR-CD (RF Turbo)

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LF, L3, L3 Turbo

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Substitution
•  A160M7 (20 mm {0.79 in})
Outer diameter: 21 mm {0.83 in}
Inner diameter: 19 mm {0.75 in}
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Clutch Disc Installation Note

1.  Hold the clutch disc position using the SST.

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Clutch Cover Installation Note

1.  Install the SSTs.

2.  Tighten the bolts evenly and gradually in a crisscross pattern.

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Tightening torque
ZJ, ZY, Z6: 17.6—26.5 N·m {1.8—2.7 kgf·m, 13.0—19.6 ft·lbf}
LF, L3, L3 Turbo, MZR-CD (RF Turbo): 25—33 N·m {2.6—3.4 kgf·m, 18.5—24.4 ft·lbf}