How to: replace your clutch : Yamaha R6 : R6 Forum

» Insurance
» Sponsors
» Yamaha YZF R6 Prices
Go Back   Yamaha R6 Forum: YZF-R6 Forums > R6 Related Discussion > How To's...

Thread Tools Display Modes
Old 08-11-2003, 02:47 PM   #1
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 12:31 PM.
dj1298 is offline   Reply With Quote
Sponsored Links
Old 09-20-2007, 06:38 PM   #2
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   Reply With Quote
Old 09-26-2007, 02:28 PM   #3
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   Reply With Quote
Old 10-01-2007, 06:40 AM   #4
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   Reply With Quote
Old 10-02-2007, 12:31 PM   #5
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   Reply With Quote
Old 11-04-2007, 05:49 PM   #6
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   Reply With Quote
Sponsored Links

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not 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

Forum Jump

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

Powered by vBadvanced CMPS v3.2.2

All times are GMT -7. The time now is 01:56 AM.

Powered by vBulletin® Copyright ©2000 - 2015, Jelsoft Enterprises Ltd.
Motorcycle News, Videos and Reviews
Honda Grom Forum Harley Davidson Forum Honda 600RR Forum Kawasaki Forum Yamaha R6 Forum Yamaha FZ-09 Forum
1199 Panigale Forum Honda Africa Twin Forum Roadglide Forum Honda CBR1000 Forum Vulcan Forum Yamaha R1 Forum Yamaha R3 Forum
Ducati Monster Forum Harley Forums Honda CBR250R Forum ZX10R Forum Star Raider Forum Yamaha Viking Forum
Suzuki GSXR Forum V-Rod Forums Honda Shadow Forum Kawasaki Motorcycle Forum Star Warrior Forum KTM Duke 390 Forum
SV650 Forum BMW S1000RR Forum Honda Fury Forum Kawasaki Versys Forum Drag Racing Forum Ducati 899 Panigale Forum
Suzuki V-Strom BMW K1600 Triumph Forum Victory Forums Sportbikes BMW NineT Forum
Volusia Forum BMW F800 Forum Triumph 675 Forum MV Agusta Forum HD Street Forum Suzuki GW250 Forum
Yamaha Motorcycles Victory Gunner Forum Victory Charger Forum Honda Vultus Forum HD LiveWire Forum Ninja H2 Forum
BMW Scrambler Forum Ducati Scrambler Forum Kawasaki Ninja 250SL Forum is an independent Yamaha enthusiast website. Content on is generated by its users and is not in any way affiliated with Yamaha Motor Corporation, U.S.A.