01 Clutch Fix

[cowboyona426]

Just wanted to let you guys know that I rode the 426 for the first time today since doing the 01 clutch fix- this mod is definitely worth it! No more squeal, just hook up and go. Two things I noticed though- (1) the clutch pull seems stiffer, even with the longer 00 arm still installed, and (2) the engagement seems to be closer to the bars than before. This is a very easy mod to do.

Here are the needed parts:
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.)
5BE-16356-00-00 ROD, PUSH 1
5JG-16357-10-00 ROD, PUSH 2
5JG-15453-00-00 GASKET, CLUTCH COVER
Note: You only need the clutch cover gasket if you tear yours removing the cover. If you don't tear the gasket, you don't need to replace it.

Here's the steps:

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 at the lever after doing this mod, because installing the new 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 TT member moto2000- 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.

[Fastest1]

Cowboy, I thought the arm was supposed to be from a 98-99 Yzf? Isnt the 2000-2001 arm the same? Is it that much stiffer? Are you sure you reassembled everything correctly?

[cowboyona426]

The 2000 arm is the long one- it is quite a bit longer than the 01 arm. I'm starting to thing that I may not have got the push lever in all the way or something, because this just doesn't seem right. I know the pushrod is installed right, so the only thing that might be wrong is the push lever isn't in all the way or something. Any suggestions?