The following is a write up and information on installing a Yoyodyne slipper clutch on an '03 R6. Thanks to TJ over at Rider's Discount for hooking me up on a new one. And an honorable mention to Pat/Chidadog for trying to get me hooked up on a used one. Was actually successful, but timing just didn't work as I had already bought a new one.
Anyway, there was already a write up on the install which I found on another forum, so credit goes to that individual (XFBO at R6messagenet.com) who did the original write up. I also put two YouTube videos at the bottom of this write up that are of an install done on a CBR600. Very similar install, biggest difference was probably the fact that the CBR has some judder springs that the R6 does not. The install is actually pretty straight forward, first time for me doing a clutch and everything appears to be successful. Should be a treat to race with a slipper as compared to the current non-slipper. The biggest tip I would give is to have an impact on hand... if you don't have one, go to Sears or somoewhere and getcha one - makes it MUCH easier to get the main nut off.
Yoyo Slipper Clutch Install for the ‘03+ R6
Parts the Yoyo kit replaces:
- Pressure plate
- Clutch boss (new piece is a 2 part design)
- Nut and tabbed washer
- 6 bolts/buckets that hold the PP to the CB.
Uninstall
1- Place
bike on rear stand. (sidestand will work too)
2- Unscrew and remove clutch cover bolts.
3- Loosen clutch cable and detach it from the little arm that’s attached to the cover.
4- This little arm needs to be rotated counterclockwise (looking downward) and face rearward to make removal of cover easier.
5- Either remove (may make things easier) or pull some slack in the hose that runs from the radiator to the water pump.
6- With a screwdriver try to knock the cover loose…… carefully! (Tip- I actually found it easier to use a long solid rod snaking it through near the shock and tapping it with a mallet on one of the tabs.)
7- Once the side cover is removed, you can now loosen all six bolts and remove the pressure plate.
8- Now take out all friction AND clutch plates, trying to keep things in the same order/direction. This might be a good time to inspect them; I found TWO friction plates cracked.
Note: The last two friction plates are different from the others, don’t mix them up. Also the FINAL plate is a clutch plate (which is .25MM thicker than the rest of the clutch plates) place this one on the side, you won’t be using it. One final note about the clutch plates, take notice to how you put them back in, each plate has a rounded/smooth side and the other is brushed and has a sharp corner (just like a washer). These plates MUST face the same direction, either inwards or outwards but they must be the same.
9- Before loosening the center nut (30mm) there is a tab that must be bent up, find it, and then pry it up with a screwdriver.
10- If you have a clutch holder tool great, if not, an impact wrench will work.
11- Remove clutch boss.
Reinstall
12- Sit new clutch boss on table.
13- Make sure all six loose bearings are in place in their pockets.
14- Place the geared sprocket looking thing in place being careful not to knock any of the bearing loose.
15- Temporarily place two compression springs two new spring buckets & two new screws (opposite ends of each other) and tighten them up snug to keep these two parts tight. (This keeps the bearings from falling out of their pockets as you’re putting it in place inside the motor. You’ll see what I’m talking about once you get going)
16- Make sure the thrust plate in place on the spline, mine was stuck to the back of the clutch boss.
17- Place this new Yoyo clutch boss in position inside the motor.
18- Place the conical or cupped washer in next, you want the cone facing inwards.
19- Next is the star like washer, be sure the legs fit into their proper place.
20- Now place a dab of Loctite on the threads and finally screw the nut (30mm) in place hand tight.
21- Again if you have the clutch holder tool great but some of us aren’t that lucky so I just used the impact wrench again. Be sure to give it a good couple of zaps cuz just when I thought she was on tight, I marked the spline and nut and gave it another zap and she still tightened up a bit. (be sure check torq setting on Yoyo instructions)
22- You can now remove those two compression springs.
23- Onto the plates, as mentioned above, the last plate that came out of the motor is the thickest clutch plate, do NOT reinstall this clutch plate.
24- You want to start with one of the two friction plates I told you is different from the rest. If you look carefully at the tabs on all eight friction plates you will see only two tabs are NOT flared, another words they are thinner than the other six plates. These two thinner friction plates go in first.
Note: Friction plates and clutch plates ALWAYS alternate, at no time should either be side x side.
25- Remember to install the clutch plates in the SAME direction.
26- Now put the new pressure plate into place, put all six compression springs, buckets and screws in. Tighten in crisscross pattern. (be sure check torq setting on Yoyo instructions)
27- Reinstall cover and clutch cable.
Edited by user Saturday, September 24, 2011 12:10:43 PM(UTC)
| Reason: Not specified
