CLUTCH UNIT REMOVAL/INSTALLATION

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CLUTCH UNIT REMOVAL/INSTALLATION

B3E051016000W01

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

.

1 | Clutch release cylinder (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION.)
2 | Manual transaxle (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R].) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G35M-R].)
3 | Clutch release collar (See CLUTCH RELEASE COLLAR INSPECTION.)
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.

## 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.

## 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.

## Pilot Bearing Installation Note

1. Use the SSTs to install the pilot bearing.

ZJ, Z6

LF

## 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.

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, Z6].)
  (See REAR OIL SEAL REPLACEMENT [LF].)

## Flywheel Installation Note

1. Install the flywheel to the crankshaft.

2. When reusing the bolts, clean threads and hole, then apply locking compound to the threads.

  Note

  • No locking compound is needed when using new bolts.

3. Hand-tighten the flywheel lock bolts.

4. Install the SST to the flywheel.

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

  Tightening torque
  ZJ, Z6: 96.1-103.0 N·m
  {9.8-10.5 kgf·m, 70.9-75.9 ft·lbf}
  LF: 108-116 N·m
  {11.1-11.8 kgf·m, 79.7-85.5 ft·lbf}

## Clutch Disc Installation Note

1. Hold the clutch disc position using the SST.

## Clutch Cover Installation Note

1. Install the SSTs.

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

  Tightening torque
  ZJ, Z6: 17.6-26.5 N·m
  {1.8-2.7 kgf·m, 13.0-19.6 ft·lbf}
  LF: 25.0-33.0 N·m
  {2.6-3.4 kgf·m, 18.5-24.4 ft·lbf}