How to Change the Clutch on a 2005 Yamaha R6
- 1). Remove the right side and lower fairings from your R6, using a 5 mm Allen wrench to unscrew the fairing's bolts. Remove the plastic pop rivets from the front of the side fairings and the bottom of the lower fairings. Use the tip of a screwdriver to depress the center of the rivets, then pull the rivets out of the fairing panel.
- 2). Place your R6 on a rear swingarm stand to support it in an upright position. Start the motor and let it warm up for at least three minutes, or until the temperature gauge on the speedometer assembly indicates an engine temperature of 150 degrees. Stop the motor and let it cool for another 10 minutes.
- 3). Unscrew the drain plug from the bottom of the motor, using a 17 mm socket attached to a socket wrench. Drain the motor's oil into an oil pan, then screw the drain plug into place. Tighten the plug to 31 foot-pounds using your 17 mm socket attached to a torque wrench.
- 4). Follow the hose on the bottom right side of your R6's radiator to the water pump on the right side of the motor, just below the large round clutch cover. Unscrew the drain bolt from the bottom edge of the water pump, using a 10 mm socket and a socket wrench, and drain your R6's coolant into a large container. Screw the drain bolt into place and tighten it to 7.2 foot-pounds, using your 10 mm socket attached to a torque wrench.
- 5). Unhook the clutch cable from the clutch arm, positioned on the bottom of the round clutch cover. Unscrew the bolts from the clutch cover, using a 5 mm Allen wrench. Pull the clutch cover and its gasket away from the motor to reveal your R6's clutch assembly.
- 6). Unscrew the clutch spring bolts from the face of the clutch assembly, using a 14 mm socket and a socket wrench. Pull the clutch springs, the pressure plate and push rod out of the clutch assembly by hand. Reach into the clutch assembly and remove the friction and clutch plates from the clutch assembly.
- 7). Straighten the bent tabs on the clutch boss nut's lock washer, located in the center of the clutch assembly, using a flat screwdriver. Hold the clutch assembly steady with a Yamaha universal clutch holder, then unscrew the clutch boss nut and its lock washer with a 22 mm socket and a socket wrench. Grasp the sides of the clutch assembly with both hands and pull it off the motor. Slide the thrust plate, hidden behind the clutch assembly, off the clutch shaft.
- 8). Slide a new thrust washer onto the clutch shaft, placing the washer's grooved face away from the motor. Slide the new clutch assembly onto the clutch shaft, followed by the clutch boss nut lock washer. Hold the clutch assembly steady with your universal clutch holder and tighten the clutch boss nut to 51 foot-pounds, using your 22 mm socket attached to a torque wrench. Bend the tabs of the new lock washer against the sides of the clutch boss nut with a flat screwdriver.
- 9). Coat the new friction and clutch plates with fresh 10W30 motor oil. Place the clutch and friction plates into the clutch assembly in the following order: .09-inch clutch plate, purple friction plate, .08-inch clutch plate, purple plate, .08-inch clutch plate, brown friction plate, .08-inch clutch plate, brown friction plate, .08-inch clutch plate, brown friction plate, .08-inch clutch plate, brown friction plate, .08-inch clutch plate, brown friction plate, .08 inch-clutch plate and the last brown friction plate.
- 10
Insert the push rod into the back of the new pressure plate. Align the mark on the edge of the pressure plate with the corresponding mark on the side of the clutch assembly. Place the pressure plate over the clutch discs and onto the clutch housing. Push the clutch springs into the depressions in the pressure plates outer face. Screw the clutch spring bolts into place and tighten them to 5.8 foot-pounds, using your 14 mm socket attached to a torque wrench. - 11
Reinstall the clutch cover and its gasket onto the motor, using a 5 mm Allen wrench. Tighten the cover's bolts to 5 foot-pounds with a torque wrench. Reattach the clutch cable to the clutch arm on the bottom of the cover. - 12
Refill the motor with 2.5 quarts of 10W30 motor oil through the filler neck on the top of the clutch cover. Remove the cap from the right side of the radiator. Fill the radiator with 2.25 quarts of ethylene glycol anti-freeze coolant. Screw the cap into place. - 13
Reinstall the right side and lower fairings onto your R6, using a 5 mm Allen wrench. Remove the rear swingarm stand and lower your R6 onto its kick stand.