2000-2002 Yamaha YZF-R6 clutch replacement

[@Luke03R6]

This video is four years as I’ve watched it and it’s helped massively thank you 🙏

[@819Snowman]

I’m running a 99-02 r6 in my sprint car and this video is one of many helping in my rebuild process. Thanks

[@GldVWisRR]

Your video helped a bunch. Everything went smoothly replacing the clutch on my 00' R6. Only to have it go blah because of the clutch cable fraying by the lever. So new cable is on the way. Not a hard job to do on these. Your video gave me a heads up on what I'm doing. Thanks.

[@reggylippens6259]

i love this video so much it helped me number of times putting my clutch back togheter every time i have too look how the baffle edge goes in else i screwed it up al lot thank you

[@tyclairep3744]

I love the video!! Its going to help me get my clutch replaced ❤❤

[@leroyrodriguez8933]

you should do a video on how to replace a detent spring

[@javierr1blue]

I just got a 2001 R6 let me told you I"m enjoying every single video thank you. Are you in Texas ?

[@brandon508]

Thanks for the video bro Been very helpful rebuilding R6 for my son Like to see a DIY for breaks

[@WillowsWorldofDIY]

Thanks! It's always good to hear that my videos helped someone. I can do a video on breaks, what exactly do you need me to show you?(Replacing break pads, steel braided break lines, replacing master cylinders, replacing calipers, replacing break rotors, bleeding the breaks)? Good luck on your R6 rebuild! Thanks for watching!

[@brandon508]

Willow’s World of DIY i asked Yamaha shop to rebuild carbs and they told me it’s a long process and had to use a machine to recalibrate and $700 to fix! Wow

[@brandon508]

Breaks replacing pads front and back

[@WillowsWorldofDIY]

Wow! That's ridiculous! I'm out of town right now but I can do a R6 break video for you in 2-3 weeks.

[@brandon508]

Willow’s World of DIY after instilling he carb you don’t have to synchronize the carb?

[@mchammerp]

i want to see a front sprocket and rear sprocket + chain install, im from canada, and soon to be doing the job on my 2002 R6C

[@saleentrixx]

Awesome video thanks for the help just clean that garage

[@WillowsWorldofDIY]

😂 I definitely do need to clean and get rid of some stuff!

[@johngrimes3117]

GREAT vid, man! LOTS of help!!!! TY!

[@jasonbrown1237]

On the clutch “fork”/ cable attachment point I only assume you need to pull the slack out of the fork until the 2 dots line up then install your cable.? I hope I’m right because that’s what I did and it seems to work okish

[@seymaseyma2366]

teşekkür ederim 2000 model yamaha r6 sahibiyim . işime yaradı türkiyeden selamlar i.m turgue

[@robdixon6862]

Bro. Love your videos. Appreciate you bro. About to do a Carb clean on 02. Might reach out to you if I get in trouble.... :)

[@dirtydean1]

Great video. Thanks

[@billblass5961]

Great video, thank you!

[@chrisirving8390]

Thanks bra great video

[@chrismarshall6376]

Was going to try upgrading my r6 came across this video and you mentioned racing camshafts what brand are in you're bike? And was wondering what power number you got out of if?

[@WillowsWorldofDIY]

Hi chris, I put GYTR racing camshafts in my R6, unfortunately I think GYTR stopped selling camshafts for late model R6's back in 2008 but I could be wrong about that. I also lapped in the cams with fine lapping compound to loosen it up just a little bit for faster spin up and quicker rpm's, plus i slotted the cam sprockets to allow for more timing adjustment. I also put a thinner head gasket and ported the heads a little bit. I dynode my bike at PPIR in Colorado which is at 5,361ft in elevation and I was running sunoco U4 race fuel, My R6 made 118hp at the rear wheel. I thought that was really good hp numbers at that time because my friends Honda 954 was on the dyno before me and only dynode at 119hp and weighted more than my R6. But then Roger Hayden's factory Kawasaki Zx-6 went on the dyno after me and put up a whopping 136hp. I think I gained about 20hp at the rear wheel over the stock hp numbers with all the work I did to my R6. I hope this is helpful. Thanks for watching!

[@chrismarshall6376]

@@WillowsWorldofDIY thanks I don't think they make them because I've been looking for any brand that makes any of them and have had 0 luck.

[@dannyhernandez7737]

Do use any kinda of sealer when replacing the gaskets to the sator cover and clutch cover or do you just put the gaskets on help please i have a 2003 r1???

[@WillowsWorldofDIY]

It really depends on the condition of the matings surface. If the mating surface is smooth and in good condition then I just use the gasket but, if the mating surface has any damage and isn't completely flat then I use YamaBond 5 amzn.to/33BDhS8 on both sides of the gasket to seal it. I hope this is helpful. Thanks for watching!

[@Dirtyol12valve]

What are common problems with the 02 r6? Mine has 32k miles and is perfect.

[@WillowsWorldofDIY]

The 00-02 R6 is a great motorcycle. I'm not sure if these are common problems but here are some of the problems that I have had. At about 15k I started having shifting problems and the transmission would jump out of gear into a false neutral. I had to replace 2nd gear due to spider cracks and because the shift dogs were rounded. I also inspected and replaced the shift drum and shift forks because they showed signs of excessive wear. Besides that the only thing that I have had to replace is the cam chain tensioner. I'm sure these repairs depend on how hard the motorcycle has been ridden, I used to race my R6 and that's most likely the reason for the repairs that I had to do. I hope this is helpful. Thanks for watching!

[@Dirtyol12valve]

Willow’s World of DIY thank you for taking the time to reply. Mine shifts great. Little clunk between each gear and more so 1st to 2nd but seems fairly normal as all bikes I’ve ridden had a nice thud shifting. Seems everyone says 2nd gear is an issue. Mine doesn’t slip or Pop out under WOT all the way to redline so I’m good. I don’t know prior history though on it. I bought it with 29k miles. Ever heard of cylinder liners cracking ?

[@MrJpdr15]

@@WillowsWorldofDIY wow... im having the same problems 😭😭😭 at 31km but i did push the bike alot!

[@dirtydean1]

on the yamaha forum i read that the YR6 had a problem with the gearbox. it should break the 2nd or 3rd gear. what do you know about that. I have a Y yzf thundercat, similar engine

[@WillowsWorldofDIY]

I had spider cracking on my 2nd gear but I haven't seen that on any other R6 that I have worked on. The main problem that I have seen with the R6 transmissions is the engagement dogs on the gears get rounded over time and won't engage under heavy load (full throttle). I sent my transmission to R&D Race Transmissions and had them under cut and harden the engagement dogs on every gear. It really improved the shifting, I never miss shifts and don't have anymore problems with it popping out of gear. I hope this is helpful. Thanks for watching!

[@dirtydean1]

@@WillowsWorldofDIY Thanks. True. Seems to me i have that problem on my Yyzf thundercat. Thanks

[@brownchawklet]

Great video man! Just one quick question. I'm about to change my clutch this weekend and I was wondering if you had to drain the oil before removing the clutch case? Just did an oil change a couple of months ago and I don't feel like buying new oil again... xD (Same bike as yours btw).

[@WillowsWorldofDIY]

You don't have to drain the oil to replace the clutch but, I recommend changing the oil when you install new clutch plates because any debris from the old clutch will be in the old oil. I hope this is helpful. Thanks for watching!

[@MythicalBuilds]

So my old clutch came out in your order but the manual looked up shows the clutch pack starting with a friction disc being 8 friction discs and only 7 steel plates...kinda curious why there is so much different info on different things. Mine is an 02 btw

[@WillowsWorldofDIY]

There is 8 friction plates, 7 steel plates 1.9mm - 2.1mm and 1steel drive plate 2.2mm - 2.4mm. The service manual that I use shows the clutch installation is exactly the way I installed the clutch in this video. This is the link to the service manual that I use runthacity.com/wp-content/upl... what you are looking for is on page 4-46. I hope this is helpful. Thanks for watching!

[@MythicalBuilds]

@@WillowsWorldofDIY got an error code on that website.

[@WillowsWorldofDIY]

Sorry about that. The link for the 99-02 service manual is in the description of this video. Please give that a try and see if it works. Page 4-46 shows a diagram on how it should be installed.

[@MythicalBuilds]

@@WillowsWorldofDIY ok thanks. this is the manual i had seen that confused me because it shows it starting off with a fiber plate and ending with a fiber plate but looking above i see the steel plate so i'm thinking that the clutch pack i ordered didn't come with that thicker plate. unfortunately i don't have the tool to measure to know for 100% certainty. the whole reason i pulled the clutches because my grab zone was soo small that it made me think the plates were worn down or broken but turns out they were brand new. finding parts and info on these gen 1 R6s is more difficult than i thought it would be haha

[@MythicalBuilds]

@@WillowsWorldofDIY also trying to figure out if i have to replace the whole water pump cover housing or not because what i believe is the return line, is leaking as if the elbow isn't tight enough or something. its seeping out and unfortunately i haven't had any luck in finding the part that isn't used and not knowing the real condition or if i can just fix my issue without rigging it... sorry for throwing this all at you. this is my first bike is a long long time and first time ever owning a Yamaha and some things have been quite a bit different than past projects

[@joshuajune9757]

When I shift my bike in 2nd gear it pops back in neutral can your clutch do that or

[@WillowsWorldofDIY]

It's most likely a problem with transmission, when the dogs on 2nd gear get rounded it will pop back into neutral under acceleration. You will need to replace 2nd gear and inspect 1st gear for excessive wear where the 2nd gear dogs in gauge 1st gear. This is a common problem with the R6. I hope this is helpful. Thanks for watching!

[@shinobisensei4027]

Hi! Can you make a clutch cable replacement, and adjustment at the bottom video?:D

[@WillowsWorldofDIY]

I can make a clutch replacement and adjustment video but unfortunately I won't be able to film it till the end of July. Please let me know if you still want me to film it in July.

[@shinobisensei4027]

Yes sir ! It would be good :)

[@jbath39]

Hi I need your advice I have a 2000 R6 I changed the clutch cable along with new levers...does the arrow and dot on the clutch arm have to line up when the cable is not attached? I try to put it in gear and the bike jumps and stalls out

[@WillowsWorldofDIY]

The arrow and the dot on the clutch arm need to line up when you start to get tension on the clutch arm before you hook up the cable and the arrow and dot should be close to same that position with the clutch Cable hooked up. I hope this is helpful. Thanks for watching!

[@jbath39]

@@WillowsWorldofDIY okay while lining up the arrow and mark while the bike be in neutral...

[@tommyv22222]

I have a 99 r6 i bought that has been setting for 5 years. Ive got it all up and going but there is a fine line between 1st neutral and second no slipping and it clutch less shifts fine through the rest of the gears as it warms up it almost goes away but occasionally I have to hold up while I’m shifting at first when cold to keep it in gear if i give it just the least amount of gas its fine it stays in but if I don’t give it gas it will come out sometimes. Does this sound familiar to you as far as the dogs go because i have no slipping but I’m not to sure if i have the clutch cable adjusted right. Do you think its possible the oil went bad it looks brand new and doesn’t smell burnt so I’m not sure. I plan on changing the oil i just didn’t know if this could be part of it? Also one other thing I haven’t heard you mention inn your videos but do you have a whirring noise or friction noise when your rolling in gear with the clutch not engaged? As soon as i pull the clutch in it goes silent but upon release i can hear it again through all gears. Swww i know that is a lot but if you get the time I would definitely appreciate your advice. Oh and thank you for all the informative videos your awesome

[@WillowsWorldofDIY]

It's hard to diagnose without see the Motorcycle in person. Based on the information that you have told me I think it sounds like you have a problem with the shift drum and/or the shift forks. From what you said It doesn't sound like the gear dogs are the problem. I think it's the shift drum and/or shift forks because the gear dogs aren't fully engaging when the motor is cold and as the motor heats up the metal in the transmission expand and it works fine. Also I think the whirring or grinding noise is probably coming from the transmission and could be because the shift forks are worn out and is causing some friction where it rides on the transmission gears. Unfortunately the shift drum and shift forks have to be removed to inspect them for excessive wear. It doesn't sound like the clutch cable is the problem because it would happen in every gear. The clutch cable should have a small amount of slack when it's adjusted correctly in its resting position, make sure that you have 1-2mm of space between the clutch lever and the clutch lever perch. I hope this is helpful. Thanks for watching!

[@tommyv22222]

@@WillowsWorldofDIY thank you sir I appreciate it! For some reason I didn’t notice but i was low on oil so i added and it feels a lot better setting still going through gears. Snowing right now so in due time. Oh I have heard a few answers to this but to inspect the forks and drum do i split the case ? Or is that for replacement of 2nd and 6 th dogs? I thought you said you had to but i think i heard someone else maybe in a forum say no. But anyways thanks keep up the good vides

[@WillowsWorldofDIY]

No, you don't have to split the cases to get the transmission, shift forks and shift drum out. You will need to pull the clutch and clutch basket out to gain access to the transmission, shit forks and shift drum. Thanks Tommy! I hope this is helpful.

[@tommyv22222]

@@WillowsWorldofDIY thanks i appreciate it!!

[@miroslavbotkaru5298]

Thank you. Good job!

[@mikehaha385]

Those hot spots are because it was slipping against the friction plates correct?

[@WillowsWorldofDIY]

Yes that is correct.

[@b106dom1]

Hi buddy I’ve got a 99 with a problem that sounds like it’s coming from the front sprocket ⚙️ shaft do you think it could be the bearings if yes how do you change it? Can it be done without pulling the engine out? Tia

[@WillowsWorldofDIY]

It's hard to say without seeing it in person, there's a lot of noises that could come from the transmission. There is 2 bearings on the drive axle assembly (front sprocket axle) and 2 bearings on the main axle assembly. The bearings on the main axle assembly can be replaced without pulling the motor, but to replacing the bearings on the drive axle assembly you will have to pull the motor and split the upper and lower cases to remove the bearings. I posted a link to the service manual in the description of this video, the transmission section starts on page 4-83. I would start by taking off the chain and try moving the drive axle to feel for any slop or tight spots in the bearings. I hope this is helpful. Thanks for watching!

[@b106dom1]

@@WillowsWorldofDIY thanks for your reply buddy I have just replaced the back brake pads yesterday and when I put the wheel and chain back on the adjust it I did notice the chain got extremely tight when I spun the wheel so just had to leave it a little slack than I would expect. So looking like I need to get it to a garage lol cheers buddy

[@WillowsWorldofDIY]

It could be a tight spot on the chain and that can wear out the bearings over time. I would put a new chain on it and see if it gets better before you start pulling the motor and split the cases.

[@b106dom1]

@@WillowsWorldofDIY I’ve replaced the chain just a few months back so I’m guessing it’s the bearings that are the main problem. It’s a pain in the ass and a bigger pain to my wallet lol but if it’s gotta be done. Cheers buddy at least now after watching your video I know how to change my clutch. Top man

[@shinobisensei4027]

Can you help me? I Just want to ask you, after i put back together, mine clutch feels like i pull nothing, its very easy to pull in the clutch lever, but i think it not works well, but i do everything like you, what am i failed?

[@WillowsWorldofDIY]

Hi Shinobi Sensei. Did you line up the indication marks on the clutch case and the clutch case lever arm when you installed the clutch case cover? Those 2 marks need to line up when the case is fully installed and tension is on the clutch case lever arm.

[@shinobisensei4027]

@@WillowsWorldofDIY i tried to line up this two things , but when im turning the lever arm, its always a little further, or little before the dot line :/

[@WillowsWorldofDIY]

Set it a little before the dot. When the clutch cable is connected the marks should be close to lining up. I hope this helps.

[@shinobisensei4027]

@@WillowsWorldofDIY yes thank you so much

[@shinobisensei4027]

@@WillowsWorldofDIY Finally works, thanks :DD

[@danigutten]

Hello! I have a problem with my r6 it May be the clutch. When i change to gear and release clutch nothing happens. What do you think? And btw where can i buy quality fairing coat sets?

[@WillowsWorldofDIY]

I'm really not sure without see the motorcycle in person. Does the transmission feel like it's shifting through all the gears? or is it stuck in neutral a false neutral? If the transmission is shifting properly then I would look at the clutch. I usually get race parts from Sportbiketrackgear.com and they sell race fairings/bodywork. I hope this is helpful. Thanks for watching!

[@stephenwaterman770]

Do you have to drain oil

[@WillowsWorldofDIY]

You don't have to drain the oil to replace the clutch but, I recommend changing the oil when you install new clutch plates because any debris from the old clutch will be in the old oil. I hope this is helpful. Thanks for watching!

[@dirtydean1]

Do you change clutch plate gasket every time?

[@WillowsWorldofDIY]

If I'm working on a customers bike then I always replace the gasket, but on my personal bike I inspect the gasket and if it looks good then I will reuse it and I haven't had any problems with it leaking. I hope this is helpful. Thanks for watching!

[@kickersixx9014]

I've got the frigging 2nd gear issue, how do I fix it

[@WillowsWorldofDIY]

You're going to have to pull out the clutch and clutch basket to get access to the Transmission so you can get the gears out. I have a link to the service manual in the description of this video, it will show you diagram. I hope this is helpful. Thanks for watching!

[@kickersixx9014]

@@WillowsWorldofDIY soo can it be done without having to split my engine case apart ? I just want to replace 2 with either the 03 5 dog gear or at least get the new one undercut but everyone says I have to split the whole motor casing to access the gears, can I really just pull them out from removing the clutch basket?

[@WillowsWorldofDIY]

You definitely do NOT need to split the cases to replace 2nd gear. You don't even need to pull the Engine out of the frame. I have repaired multiple R6 transmissions, the first time I did this repair I removed the engine from the frame but I was also doing other work to the head and cams. After repairing the transmission with the Engine out I realized that I could fix the Transmission with the engine in the frame and I have been doing it that way ever since. You will have to remove the shift shaft cover and the drive sprocket on the left hand side of the motor and the oil pan on the bottom of the motor as well as the clutch and clutch basket on the right side of the motor. Then you will have access to the drive axle assembly, you have to use 2 6MM bolts and screw them into main axle assembly bearing housing, it shows you in the service manual exactly where you need to install the 2 6mm bolts on page 4-89. screw the 2 bolts in till they hit the case and then it will press the main axle bearing assembly housing out as you tighten the bolts. once that's done you have to remove the shift forks and shift drum, then the main axle shaft assembly will pull right straight out of the right side of the engine. then you can remove the drive axle assembly on the left side of the motor where the drive sprocket goes. The Service manual really needed you will find the Transmission section on page 4-83 through 4-91. I hope this is helpful. Let me know If you have any more questions.

[@kickersixx9014]

@@WillowsWorldofDIY you're the r6 God brother! I will keep you posted on how it goes sounds similar to my yz90 transmission I grew up wrenching on so hopefully it goes off without any issues, I did the clutch after watching your KZbin video and it went awesome not much different from the old Harleys I'm used to working on, but the little things like the thicker back plate and the dot on the clutch basket to line up is what made it go smoothly for sure thanks for being awesome man!! Maybe I'll make a video of the project lol, do you got a website for merch ? I'd like to help support the channel anyway I can bro

[@WillowsWorldofDIY]

Lol! Thanks bro! It sounds like you have experience wrenching on motorcycles so I think you can get it done. It definitely takes some time and patience, it's a little tricky putting it back together, just hard to reach getting the shift forks lined up to get them back on but its definitely doable so don't give up. I have been wanting to make a video on this repair, I just haven't had any problems with my R6 transmission since I installed a the new gears. I sent the gears to R&D race transmission and had them under cut and hardened. I don't have a website yet, but you can leave me a tip with the super thanks button on my videos. I really appreciate the love and support. keep me posted, I will try and help if you have any problems.

[@deongreyvenstein9818]

Hi can u do cables

[@WillowsWorldofDIY]

Clutch Cable? Throttle cables? How to adjust them? or replace? Can you be more specific?

[@deongreyvenstein9818]

@@WillowsWorldofDIY I mean carburetors needles and seats Yamaha r6 yzf 2000

[@deongreyvenstein9818]

@@WillowsWorldofDIY my bike is over fuel

[@WillowsWorldofDIY]

@@deongreyvenstein9818 so do you want to know how lean out the Carburetor? or rejet the Carburetors and replace the needles? Is your R6 jetted for your elevation?

[@deongreyvenstein9818]

@@WillowsWorldofDIY hello do u mean about jetted for your elevation do u have pic to show me

[@titosgervacio]

How’s it going. I have a 2001 Yamaha R6, I purchased it from an auction. The motorcycle turns on and stays on however, when I hit the first gear it stalls automatically. Do you know what might be the problem? . Thanks for your help

[@WillowsWorldofDIY]

Does the motorcycle move forward when you put it in gear before it stalls? If so its probably a problem with the clutch not disengaging and could be a simple clutch cable adjustment. If adjusting it doesn't help it could be a problem with the clutch or the transmission. Does it make any noises when you put it in gear?

[@marshelglidden1734]

I'd definitely look at your kickstand sensor and clutch sensor. If your short those auto kill switches and it's still stalling, then look at the clutch.

[@titosgervacio]

@@WillowsWorldofDIY It cuts off as soon as you put in gear .

[@titosgervacio]

@@marshelglidden1734 Yea I had a question about that. So the kickstand sensors is cut off completely. I got the bike as it came from an auction. Would I need to replace that kickstand cable

[@WillowsWorldofDIY]

I agree with Marshel, I think it's the kickstand sensor. You can install a piece of wire or just connect the two kickstand sensor wires together to bypass the kickstand sensor. I bypassed that sensor on my race bike and it worked just fine. If it works then you can decide if you want to replace the cable and sensor or leave it bypassed. I hope this is helpful. Thanks for watching!

[@nicholasanthony5289]

I just replaced my clutch plates but now my clutch won't engage

[@RdubstudiosCharlotte]

what clips are you using in the bodywork? Enjoyed your video, looking to replace my clutch soon and this is a nice start to see what's inside. :)

[@WillowsWorldofDIY]

I use Dzus 1/4 turn fasteners. I posted a Link in the description of this video. Good luck with your clutch replacement. Thanks for watching!

[@eabkzoolyfe138]

My won’t go past 2nd gear help

[@WillowsWorldofDIY]

If your motorcycle won't shift up past 2nd gear it's most likely a problem with your shift drum and shift forks. These parts wear out over time and will affect the gear shifting in the transmission. I have replaced the shift drum & forks in my R6 and in a couple friends motorcycles as well. You don't have to pull the motor for this repair but you will have to remove the clutch and clutch basket to get to the transmission where the shift drum & forks are located. I posted a link to the service manual that I use in the description of this video, the transmission section is on page 4-89 and it will tell you how to check the shift drum & forks. I hope this is helpful. thanks for watching!

[@eabkzoolyfe138]

Willow’s World of DIY thanks for the advice I needed that 😅 an I have a r6 to great bikes just having that one little problem

[@googlelimp9834]

hey man quick one sorry dont the oil dump? because my oil is new lol so if can save it e grate haha

[@WillowsWorldofDIY]

I don't recommend installing a new clutch with used oil, even if its only slightly used the oil it can have debris from the old clutch and the oil can get brunt if the old clutch was slipping and overheating the oil. I hope this is helpful. Thanks for watching!

[@googlelimp9834]

@@WillowsWorldofDIY no only the cable lead I changed.

[@googlelimp9834]

what company clutch kit you using??

[@WillowsWorldofDIY]

I use the Barnett performance clutch kit, there’s a link in the description of this video. I hope this is helpful. Thanks for watching!

[@googlelimp9834]

@@WillowsWorldofDIY Yeah sorry i did look it up thanks for the Info your American company so its more expensive over here but thanks