2002 Yamaha R6 Install Clutch

Many of the problems associated with a 2002 Yamaha R6's clutch happen because of an improperly adjusted clutch cable or by overfilling the engine with oil. The plates and springs within the clutch are also susceptible to wear, causing the clutch to slip regardless of any adjustments made to the cable. Extreme riding conditions, such as those found on a racetrack, can put further stress on the clutch and cause the metal clutch basket to warp. While the task of removing and installing the clutch is straightforward, a familiarity with the R6's engine is a must.

Tools Used

Tools
Swingarm lift
Phillips screwdriver
4 and 5 mm Allen wrenches
Oil catch pan
10, 17 and 22 mm sockets
Socket wrench
Torque wrench
10 mm combination wrench
Vernier caliper
Yamaha clutch holder tool
Flat screwdriver
Eight fiber friction plates
Seven steel clutch plates
Three quarts, 10W-30 SE or SF-Grade engine oil
Two thrust washers
Clutch basket collar
Clutch basket
Clutch boss
Lock washer
Six Clutch springs
Clutch cover gasket

Install Clutch

• Mount the R6 on a swing arm lift to support it in an upright position. Remove the lower fairing and the right fairing panel, using a Phillips screwdriver or a 4 mm Allen wrench.

• Place an oil catch pan below the engine. Unscrew the oil drain plug from the bottom of the engine crankcase, using a 17 mm socket and a socket wrench. Allow the oil to drain until the flow of oil reduces to a slow drip. Screw the drain plug into the crankcase by hand, then tighten it to 18 foot-pound with a torque wrench.

• Loosen the lower clutch cable lock nut, found near the clutch release lever on the bottom of the clutch cover at the right side of the engine, using a 10 mm combination wrench. Pull the cable out of the clutch release lever by hand. Remove the clutch cover and gasket from the engine to reveal the clutch assembly, using a 5 mm Allen wrench.

• Remove the clutch springs and spring bolts from the outer clutch pressure plate, using a 10 mm socket. Pull the outer clutch pressure plate out of the clutch assembly by hand. Measure the clutch springs, using a vernier caliper. Replace the springs as a set, if any of the springs' total length is not equal to 2.165 inches, or 55 mm.

• Pull the clutch plates out from the clutch assembly by hand. Separate all eight fiber friction plates from the seven steel clutch plates. Measure the thickness of the fiber plates. Replace the friction plates as a set, if any of the plates' are less than 0.114 inches, or 2.9 mm thick. Lay the steel plates on a level, smooth work area to check for warpage. Replace the steel plates as a set, if any of the plates are warped in any way.

• Bend the folded lock washer tab away from the clutch boss nut, located at the center of the clutch assembly, using a flat-head screwdriver. Hold the outer clutch basket steady with a Yamaha clutch holder tool and unscrew the clutch boss nut, using a 22 mm socket. Pull the clutch boss, lock washer and thrust washer out of the clutch basket by hand. Grasp the clutch basket and pull it from the engine crankshaft by hand. Slip the thrust washer and collar off the crankshaft. Skip this step, if you are only replacing the clutch plates and springs.

• Slide a new clutch basket collar, followed by a new thrust washer and the clutch basket onto the crankshaft. Slide a second thrust washer, followed by the clutch boss and a new lock washer, into place within the clutch basket. Hold the clutch basket steady and screw a new clutch boss nut onto the end of the crankshaft. Tighten the nut to 51 foot-pounds. Bend the lock washer tab up and against the side of the clutch boss nut. Skip this step, if you are only replacing the clutch plates and springs.

• Soak the new fiber friction plates and steel clutch plates in 10W-30 SE or SF-Grade engine oil for 10 minutes. Arrange the clutch plates in a stack, starting with a fiber friction plate followed by a steel clutch plate, until all 15 plates have been arranged in an alternating pattern. Slip the plates into the clutch basket, then place the outer pressure plate over the clutch plates. Insert the new clutch springs into the pressure-plate spring wells. Screw the spring bolts into place and tighten the bolts to 5.8 foot-pounds.

• Reinstall the clutch cover and a new gasket. Slip the clutch cable into the clutch release lever and tighten the lower cable lock nut.

• Fill the engine with 2.6 quarts of engine oil, through the filler neck built into the top of the clutch cover.

• Reinstall the lower fairing and the right fairing panel. Remove the swing-arm lift and lower the R6 onto its kickstand.

Tips & Warnings

• Take used oil to your nearest Yamaha service center or an auto parts retailer for responsible disposal or recycling. Store used engine oil in a sealed container to prevent accidental exposure to children or animals, if the oil cannot be disposed of immediately.