Finally, got the car up and running again (due a rusted freeze plug in front iron) after sitting since last October. Now, I need to move on to project # 2. Back in April 2021, I installed a newly rebuilt transmission, Exedy clutch kit, rear main seal & o-ring, newly resurfaced flywheel and new clutch hydraulics. I picked up the flywheel on Ebay and had it sitting in my basement storage area for several years. It developed some surface rust, so after searching around, I took it to a machine shop to be resurfaced. The machine shop that I usually had dealt with had closed down due to the owner's retirement. So, I took it to a machine shop that I've never used before. Told the guy that it was a recessed type flywheel and he said no problem. When I picked it up from a relatively young guy who did the work, he indicated that there a small pit in the friction surface that he wasn't able to get out. I asked him: "How much material did you take off?" He said: "Oh, I don't know." I told him that he needed to remove from the bosses the same same amount that he removed from the friction surface. He said that he did. I had a bad feeling since that exchange.

So, I installed new flywheel, clutch and transmission. First test drive, and clutch starts to engage at only a couple inches off the floor. Thought the hydraulics needed to be re-bled, but no change. So, I came to the conclusion that the machine shop fu˘ked up my flywheel. I've been doing this type of work for a long time now and this isn't the first time that a machine shop fu˘ked up something on me. Always beware when taking something into a machine shop.

I need to get this clutch problem fixed. My options are:

1. Reinstall my original flywheel. This would be my cheapest option. My original flywheel has a small ridge where is seats at the seal. This is the only thing that concerns me about the original flywheel. Non-turbo S5 flywheels seem to be hard to get. Atkins used to sell used resurfaced flywheels, but now they don't have any left. Appears that new ones are no longer available from Mazda, but I maybe wrong.

2. Installing aftermarket flywheel. I don't want super light, so I've been looking at the Bönez Light Steel Flywheel - 86-91 Non-Turbo from RX7.com (Rotary Performance | FC Flywheel). So, this would be more expensive since I'd need to buy both the counterweight and flywheel. I usually tend to keep my car's as stock as possible. I would reuse my Exedy clutch setup. I was wondering if anybody has either used this Bonez flywheel or if anybody has any comments?

 

Whats the issue? Clutch engaged too soon in the pedal throw or too late? Is it slipping or anything? You're probably just not used to the new clutch.

 

Clutch engages just barely off the floor. Maybe about 2", if even that. Way too soon.

 

Sounds like you just need to adjust the clutch pedal

 

Sounds like you're not used to the new clutch. I believe my 3 puck was the same way.

 

I'll take a look at it, but I don't know if that would give me a couple more inches of pedal travel. I've owned this '90 GXL since new and after installing several clutches during its lifetime have never had to adjust the pedal. Stock clutch always engaged at about the midway position or slightly higher.

 

option 3, measure the step on the original flywheel, and have the new one cut to the same spec.
actually is it possible to measure that without taking things apart?