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.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

3.  Remove the following parts:

(1)  Battery and battery tray (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)
(2)  Fresh-air duct and the air cleaner as a single unit (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
(3)  Front tires (See GENERAL PROCEDURES (SUSPENSION).)
(4)  Splash shield (See SPLASH SHIELD REMOVAL/INSTALLATION.)
(5)  Aerodynamic under cover No.2 (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)
(6)  EGR pipe (intake manifold side)(European (L.H.D. U.K.) specs.)(See EGR PIPE REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

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

5.  Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R].)

6.  Remove in the order indicated in the table.

7.  Install in the reverse order removal.

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

Note
•  If the transaxle is overhauled and installed to the vehicle, perform the "INSPECTION AFTER TRANSAXLE INSTALLATION" and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [F35M-R].)
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1
Boot
2
Clutch release collar
3
Clutch release fork
(See Clutch Release Fork Removal Note.)
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
Plate
8
Flywheel
(See Flywheel Removal Note.)
(See Flywheel Installation Note.)


Clutch Release Fork Removal Note

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

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Clutch Cover and Disc Removal Note

1.  Install the SSTs.

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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.


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.

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

3.  Remove the flywheel.


Flywheel Installation Note

1.  Clean the crankshaft thread holes.

2.  Install the flywheel to the crankshaft.

3.  Hand-tighten the new flywheel lock bolts.

4.  Install the SST to the flywheel.

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

Tightening torque
97—103 N·m {9.9—10 kgf·m, 72—75 ft·lbf}


Pilot Bearing Installation Note

1.  Use the SSTs to install the pilot bearing.

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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—0.01 in} from the crankshaft end.

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Clutch Disc Installation Note

1.  Clean the splines of the clutch disc and the main drive gear with a brush.

2.  Spread a thin layer of clutch grease on the splines.

3.  Hold the clutch disc position using the SST.

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Clutch Cover Installation Note

1.  Install the SSTs.

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2.  Tighten the bolts in Min. 2 stages.

3.  Tighten partially with a crisscross pattern.

4.  Fully tighten to specified torque with a crisscross pattern.

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