How to: replace your clutch - Yamaha R6 Forum: YZF-R6 Forums
LinkBack Thread Tools Display Modes
post #1 of 6 (permalink) Old 08-11-2003, 03:47 PM Thread Starter
I eat my R6
Join Date: Mar 2003
Location: Plano, TX
Posts: 831
How to: replace your clutch

This is a really easy project. I would say it would take the average guy 4 hours to do with no distractions. This procedure is detailed in the R6 enginge manual for the Pre 03 R6 starting on page 45 in the pdf file on this site. So download it first and print it out. I have also attached an image that shows the actual inside of the clutches.

Pay close attention to how the clutch cable connects to the shift linkage and how it goes back together. This will save lots of time on the reinstall. It is also detailed in the manual. This is on page 47 of the manual.

Take pictures if you can. This helped me greatly!

Tools needed
Philips screw driver to remove fairings
small flat head
5 mm allen wrench
10 mm socket and wrench
Inch pound or small foot pound torque wrench

Parts needed:
New gastet for clutch cover
8 friction plates
7 steel plates
6 new clutch springs
4 quarts of motorcycle oil (I use Yama Lube)
A new "E" clip if you bend or lose yours. Buy one just in case.

Bolt specs
Bolts holding the clutch cover on = 8.7 ft/lbs
5mm allen head

Bolts holding on the pressure plate=5.8 ft/lbs
10mm hex

Put new clutches in a pan of motor oil and cover with a lid. I got dirt in oil while taking the bike apart and could not use the oil in the pan.

Start a timer for 30 minutes. That is the amout of time the clutches need to soak for the Barnett carbon clutches. Read the instructions with your kit.

Remove right side lower fairing

Drain engine oil

Remove the 5mm allen bolts holding on the clutch cover

Manuever the cover off and then remove the clutch linkage. Take your time and really watch how it is supposed to be. The correct position is in the manual. Don't lose your "E" clip unless you bought a new one.

Remove the 6 "10mm " bolts holding on the pressure plate. The clutch springs are behind these bolts.

Slide out the 8 clutches and 7 metal plates.

Look to see if the clutches have been soaking for 30 mintes. If not drink beer until time has been reached.

Slide in new clutches. There will be two green clutches in your pack. (at least in my kit) I had to start and end with a green clutch. The green side went so it was facing either the engine case or the clutch cover.

Alternate clutch plate, and then metal plate. You will end with a green clutch facing toward you.

Put on the pressure plate. Read page 54 of the manual for the exact procedure. Make sure the punch marks in the pressure plate and the pull lever are aligned. I missed this and had to start over.

Put new springs over stock bolts and thighten to 5.8 ft/lbs.

Reconnect the clutch linkage.

Put on the clutch cover and tighten the allen bolts to 8.7 ft/lbs

Check the clutch lever and see if the clutch disengages. If you changed springs, mine as well, the lever should feal much stiffer. You will also need to adjust the slack in the clutch cable up by the lever.

Fill with oil and put another beer in the freezer.

Put on your helemt and go for a short ride around the block to test it out. Do not go fast until you are sure you did it right.

Put on your fairings. Drink your ice cold beer to a job well done!

I am not responsible if you mess up your motor or trans. Let me know if you have questions or if I missed a step.

Last edited by yoda; 03-30-2007 at 01:31 PM.
dj1298 is offline  
Sponsored Links
post #2 of 6 (permalink) Old 09-20-2007, 07:38 PM
My R6 eats me.
Join Date: Sep 2007
Posts: 1
Re: How to: replace your clutch

Thanks for the good write up, i will be replacing my clutch with the ebc kit. How do you access the pdf file on the forum?
2004R6silver is offline  
post #3 of 6 (permalink) Old 09-26-2007, 03:28 PM
I eat my R6
Join Date: Nov 2006
Location: NYC
Posts: 197
Bike: 06 R6, 08 CBR1000rr
Send a message via AIM to mike1023
Re: How to: replace your clutch

funny i got the Barnett kit and i did not have 2 green ones they were all like redish pink
mike1023 is offline  
post #4 of 6 (permalink) Old 10-01-2007, 07:40 AM
My R6 eats me.
Join Date: Aug 2007
Posts: 29
Re: How to: replace your clutch

whats the average price for a clutch kit
slutstang is offline  
post #5 of 6 (permalink) Old 10-02-2007, 01:31 PM
I eat my R6
Join Date: Nov 2006
Location: NYC
Posts: 197
Bike: 06 R6, 08 CBR1000rr
Send a message via AIM to mike1023
Re: How to: replace your clutch

mike1023 is offline  
post #6 of 6 (permalink) Old 11-04-2007, 06:49 PM
get at me dog
simalac's Avatar
Join Date: Nov 2007
Location: fayettevile
Posts: 1
Bike: R6
Re: How to: replace your clutch

i paid about 130 for mine

COLOR=DarkRed]hated by many, love by few, respected by all!!! RR[/COLOR]
simalac is offline  
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Yamaha R6 Forum: YZF-R6 Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Similar Threads
Thread Thread Starter Forum Replies Last Post
clutch noise 2002 r6 cakemonster General Discussions 10 07-03-2011 08:25 PM
R6 Clutch Replacement Tech. Questions QuickStudy Garage / Mechanical Help 7 08-09-2006 11:55 AM
06' R6 exhaust? R6RidnRuff General Discussions 29 11-06-2005 09:44 PM
hard to replace clutch? 7and6 Garage / Mechanical Help 6 10-12-2005 09:02 AM
R6 Clutch Replacement Tech. Questions QuickStudy Garage / Mechanical Help 0 08-20-2004 07:34 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome