Download Mazda RX7 1993 Workshop Manual

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    RX-7 FD – Part 7 – Installing Koyo Radiator I decided to swap the old stock RX-7 FD radiator for a Koyo radiator to increase the cooling. The stock radiator is very thin and has end tanks made of plastic, …

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One comment on “Download Mazda RX7 1993 Workshop Manual”

  • Resurfacing the flywheel on a Mazda RX-7, or any vehicle for that matter, involves several key components and steps. The flywheel is a crucial part of the manual transmission system, as it plays a vital role in the engagement of the clutch and overall engine performance. Here’s a breakdown of the main components and the process involved in resurfacing:

    ### Main Components

    1. **Flywheel**: The primary component that needs resurfacing. It is a heavy, circular metal disc that helps to smooth out the power delivery from the engine to the transmission.

    2. **Clutch Plate**: While not directly resurfaced, the clutch plate’s condition should be checked, as a worn clutch can affect how the flywheel works. A new clutch plate may be necessary if the old one is worn unevenly.

    3. **Pressure Plate**: Similar to the clutch plate, ensure that the pressure plate is in good condition. Any warping or damage can lead to engagement issues.

    4. **Alignment Tool**: This tool helps in aligning the clutch and flywheel during reassembly.

    5. **Torque Wrench**: Used to ensure that the flywheel bolts are tightened to the manufacturer’s specifications.

    6. **Resurfacing Equipment**: A flywheel grinder or resurfacing machine is typically used for the actual resurfacing process.

    ### Resurfacing Process

    1. **Removal**: Start by removing the transmission from the vehicle to access the flywheel. This typically involves disconnecting various components, including the driveshaft, shifter linkage, and any electrical connections.

    2. **Inspection**: Once the flywheel is removed, inspect it for cracks, warping, or excessive wear. It’s important to assess whether it can be resurfaced or needs to be replaced.

    3. **Resurfacing**: Use a flywheel resurfacing machine to grind the surface of the flywheel. This process removes any imperfections, such as grooves or heat spots, ensuring a flat and smooth surface for optimal clutch engagement. The machinist will usually remove a specific amount of material to ensure uniformity.

    4. **Cleaning**: After resurfacing, clean the flywheel thoroughly to remove any debris or dust that may have accumulated during the machining process.

    5. **Reinstallation**: Reinstall the flywheel onto the crankshaft. Ensure that it is aligned properly and use a torque wrench to tighten the flywheel bolts to the specified torque settings.

    6. **Reassemble**: Reinstall the clutch assembly, pressure plate, and transmission, following the reverse order of the disassembly process.

    7. **Testing**: After everything is reassembled, it’s a good practice to test the clutch engagement and overall performance to ensure the resurfacing has resolved any issues.

    ### Conclusion

    Resurfacing the flywheel is a critical maintenance task that can significantly affect the performance of the Mazda RX-7’s manual transmission. Proper tools and techniques must be employed to ensure the flywheel’s longevity and functionality. Always refer to the vehicle’s service manual for specific instructions, torque specifications, and other details pertinent to the specific model year.

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