Fixing the 2000 YZF426 Clutch

[JohnLorenz]

The YZF426 is notorious for its grabby clutch and chattering. This has caused many of the 2000 baskets to explode. Yamaha has warrantied the clutches for Original owners, but for us that are not, there is a fix and it takes about one hour to transform the beast into a mild manor no more on / off clutch. Here is what needs to be done

Parts Needed from 2001 yzf426
1: 5JG-16321-00-00 PLATE, FRICTION
2: 5JG-16383-00-00 SPRING, CLUTCH BOSS
3: 5JG-16384-00-00 PLATE, SEAT
4: 93511-32027-00 Ball Bearing (Push Rod Assembly)
5: 5JG-16357-10-00 ROD, PUSH 2
6: 5JG-15453-00-00 Clutch Cover Gasket

To Install the new plates you need to remove the the clutch cover, remove the springs and slide the entire clutch out.

Note Item "3: 5JG-16384-00-00 PLATE, SEAT" is concaved and has stamped on it "Out Side" meaning this has to be facing out away from Engine.

Place item 3: 5JG-16384-00-00 into the basket, followed by item 2: 5JG-16383-00-00 SPRING, CLUTCH BOSS, then Item 1: 5JG-16321-00-00 PLATE, FRICTION.

Place all plates back into the basket (8 Total) assemble and go riding. The diff is Night and Day.

[Rockey]

Sorry, Im a little confused w/ all the part codes and terms, can you help me out a bit?

[JohnLorenz]

Those are the parts ya need

[cowboyona426]

I'm updating this post because it is missing one of the required parts. Below is a complete parts list with the correct part numbers.

5JG-16321-00-00 PLATE, FRICTION
5JG-16383-00-00 SPRING, CLUTCH BOSS
5JG-16384-00-00 PLATE, SEAT
93511-32027-00 BEARING, BALL (PUSH ROD ASSY.)
5JG-16356-00-00 ROD, PUSH 1
5JG-16357-10-00 ROD, PUSH 2
5JG-15453-00-00 GASKET, CLUTCH COVER

And here's the directions I wrote up a while back, hope this helps everyone.

1. Drain the oil from the engine and the frame.
2. Pull the clutch cover- removing the rear brake will make it easier to get all the clutch cover bolts out. Because all the bolts are different lengths, leave them in the holes in the cover when you pull the cover. Pull the cover off evenly and you shouldn't have any problems with tearing the gasket, so you can reuse it.
3. Remove the pressure plate. The short pushrod will probably stick to the pressure plate, FYI.
4. Pull out all the clutch plates. Remember to keep them in order! I used two picks to help me get all the plates out.
5. Pull the long pushrod from the center of the shaft the clutch hub is mounted on.
6. Pour some clean oil in the clutch cover, and soak the new plate in the oil for 5-10 minutes.
7. Install the flat base plate.
8. Install the spring plate- make sure the side marked "OUT" faces toward the outside of the engine.
9. Install the new clutch plate.
10. Install all the old plates, taking out the innermost plate. I dipped each plate in the oil before installing them to help use some of it up.
11. Install the new long pushrod in the tranny shaft- make sure the end with the tapered end goes to the inside of the motor.
12. Install the short pushrod with the ball bearing inside.
13. Install the pressure plate.
14. Install the clutch cover- make sure you dump the oil out first!

That's it! It is a really simple mod. Some people have been installing the 01 clutch arm too- I didn't. If you do, it is supposed to move the engagement point of the clutch farther from the bars. Also, you will have to readjust the freeplay in the lever, because installing the 01 parts creates a lot of slack in the cable.
I'm not sure how much all the parts cost, because I managed to score them all for free from moto2000 (from ThumperTalk)- thank you moto2000! I don't have the number for the 01 clutch arm, but your dealer should be able to find it easy enough. If anyone has any questions, feel free to ask.