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'00 to '01 clutch upgrade issues

By GixRider,
in YZ400F/426F/450F/450FX

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GixRider

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I'm trying to solve some issues with the 00 to 01 conversion. Almost everything from clutch lever to basket is new. ASV lever w/adjuster, new cable, new oem pressure plate, new tusk clutch pack, new boss & seat for 01, and new PE billet basket. When I first put the whole kit in, I had the cable adjuster on the engine side and adjust on the ASV lever almost maxed out to take up all the slack. Its about the only way I could get the clutch to free up when the lever is pulled in. That works fine until I go ride tight single track, then it heats up and pulling in the lever doesn't fully disengage the clutch. What am I missing or did I screw up during the install? I shouldn't have to keep both the lever and the cable adjusted to the max. Should I upgrade the clutch rod to the 01 spec? Does that give me more throw?

Parts:

21 BALL 93511-32027-00

22 ROD, PUSH 2 5JG-16357-10-00

Also, does anybody know the difference between the 00 and 01 clutch springs?

I'll take a wild guess but I think Gray has all the answers... (as usual)

Thanks!

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GixRider

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well now that I'm home and looking at my manual, it appears the '00 has 8 clutch plates while the '01 has 8 plates plus the 1 smaller plate.

I'll order the rod and ball since it's only $14 or so from the TT OEM store and report back.

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00YZ426FMRCD

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I'm trying to solve some issues with the 00 to 01 conversion. Almost everything from clutch lever to basket is new. ASV lever w/adjuster, new cable, new oem pressure plate, new tusk clutch pack, new boss & seat for 01, and new PE billet basket. When I first put the whole kit in, I had the cable adjuster on the engine side and adjust on the ASV lever almost maxed out to take up all the slack. Its about the only way I could get the clutch to free up when the lever is pulled in. That works fine until I go ride tight single track, then it heats up and pulling in the lever doesn't fully disengage the clutch. What am I missing or did I screw up during the install? I shouldn't have to keep both the lever and the cable adjusted to the max. Should I upgrade the clutch rod to the 01 spec? Does that give me more throw?

Parts:

21 BALL 93511-32027-00

22 ROD, PUSH 2 5JG-16357-10-00

Also, does anybody know the difference between the 00 and 01 clutch springs?

I'll take a wild guess but I think Gray has all the answers... (as usual)

Thanks!

I just performed the 01 Clutch Mod (with the help of 642MX) about 3 months ago. The 00 and 01 clutch springs are different part #'s but they looked the same. I went ahead and replaced the 00 clutch springs with the 01 clutch springs but probably didn't need to. All you need is the parts noted below:

01 Clutch Mod https://www.thumpertalk.com/forum/showthread.php?t=461631

It looks like you went with some after market parts so not sure how things will match/mate up. I did not replace anything other than what is listed in the link above. My boss/clutch basket was ok and I didn't have to purchase parts 21 & 22 you mention above. (My 2000 didn't even have part 21) It could be possible that if you did replace the boss/basket that you may need them.

I had the same issue after putting in the 01 Mod as you describe but with some adjustments at the lever and primarily at the case, got things to where the clutch worked fine with the proper free play. I would honestly put this Mod even above the 450 Cam mod. Fortunately I have done both. I would recommend to anyone considering this mod to go with all OEM Yamie parts. Just my .02

- RCD

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00YZ426FMRCD

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Without digging into it further, I wonder if there is a greater number of plates in the '01 stack up. If so, you will likely need the '01 rod and ball also. If that's the case, I'll have to update the post listing the required parts.

There are actually the same # of plates. Both the 00 & 01 have 8 Clutch plates and 9-Friction plates. On the 01, Part # 12 is a friction plate that has a different part # (Can't remember if it is really different or not. With a different Part # it almost has to be)

The main difference is the addition of parts 13 and 14 from the 01 which are the Spring, clutch boss and the plate seat parts. The addition of these 2 is what really makes the mod work. Everything else providing that your springs basket/boss is in good shape will work fine.

The article below is to the T on what you need.

https://www.thumpertalk.com/forum/showthread.php?t=461631

- RCD

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grayracer513

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On the 01, Part # 12 is a friction plate that has a different part # (Can't remember if it is really different or not. With a different Part # it almost has to be)
The innermost friction plate, #12 in the illustration, is different in that the inside diameter is larger in order to accommodate the the boss spring and the spring seat plate. These parts won't fit inside the standard plates.

I'm still interested to know if the '01 pushrod and ball combo addresses the issue here at all, because it is an upgrade, even if it's the same length.

On digging up the original post on this mod from 2003, I see that the poster included the entire push rod assembly, including the short push rod, item 17 in the parts illustration. (one each of the following):

93511-32027-00 BEARING, BALL (PUSH ROD ASSY.)

5JG-16356-00-00 ROD, PUSH 1 (short, outer)

5JG-16357-10-00 ROD, PUSH 2 (long, inner)

Apparently, it's not strictly necessary, but I'm thinking that the inner rod and ball may not work with the older outer rod. My apologies for having not included this in the original parts list :crazy: The use of the later rod assembly is optional.

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642MX

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On the 01, Part # 12 is a friction plate that has a different part # (Can't remember if it is really different or not. With a different Part # it almost has to be)

Its different from the rest. Part 12 has a larger inside diameter to clear the spring boss and seat plate.

There is no need for the 01 ball or push rod.

00YZ426FMRCD is correct about the cable adjustment. We had to adjust the cable by the actuator arm to make it work right. You can get enough adjustment from the lever end to make it work.

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00YZ426FMRCD

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I'm still interested to know if the '01 pushrod and ball combo addresses the issue here at all, because it is an upgrade, even if it's the same length.

It might. Again the difference here regarding the original problem and post from GIX is that not all stock parts were used. I am confident if all stock OEM parts are used and the basket/boss is OEM,the pushrod and ball combo is not needed...

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GixRider

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Well I can't imagine having both the clutch lever and case adjuster maxed out could be associated with just a different brand clutch pack & basket. I'm guessing that's an inch of adjustment between the two ends of the cable.

Anyways, after looking at the fiche... I'm skeptical the rod2 and ball will fit without buying the rod1 part.

Thanks for all your input guys.

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cowboyona426

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If you're going to replace the clutch pack while going through this, then just order an 01 clutch pack- it should have the correct setup you'll need. If your clutch is OK, then you need the innermost plate from the 01, plus the spring plate and the spring boss. You need to adjust the cable down on the engine BEFORE adjusting at the lever.

The new pushrod setup is not necessary, but if you decide to do it you'll need all three parts- both rods and the ball. The long pushrod is shorter in the 01 setup, and the short rod (the little T-shaped deal that the longer rod slides into) has a longer neck on it to accomodate the ball bearing. Read my original post on this, and if you are still confused post here or shoot me a PM and I'll try and help you out.

I just want to mention- I wasn't the first person to try this or come up with the idea, I was just the first one to write a thorough how-to post on the subject.

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SXP

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I noticed you added the ASV levers at the same time. When I added the ASV levers to my stock 99 WR400 (no clutch mods or anything) I immediately noticed that I didn't have enough adjustment to take in the cable slack. I called ASV and complained and they said I needed a barrel extender that fits on the end of the ASV barrel on the ASV perch. They gave it to me free and all has been well since. Try hooking everthing up with the stock lever and perch to see if this takes care of the problem. If it does, that's the problem. Something to consider before you tear all your hair out.

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sam250

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If you're going to replace the clutch pack while going through this, then just order an 01 clutch pack- it should have the correct setup you'll need. If your clutch is OK, then you need the innermost plate from the 01, plus the spring plate and the spring boss. You need to adjust the cable down on the engine BEFORE adjusting at the lever.

The new pushrod setup is not necessary, but if you decide to do it you'll need all three parts- both rods and the ball. The long pushrod is shorter in the 01 setup, and the short rod (the little T-shaped deal that the longer rod slides into) has a longer neck on it to accomodate the ball bearing. Read my original post on this, and if you are still confused post here or shoot me a PM and I'll try and help you out.

I just want to mention- I wasn't the first person to try this or come up with the idea, I was just the first one to write a thorough how-to post on the subject.

Hi! I'm having the same issue and thinking the 426 I just purchased as an 01 is actually an 00. When I tried to change the clutch, I noticed the ball, seat plate and boss spring were missing and the difference in the last friction plate. Ordered those and now found out that the boss was cracked. ? So now I ordered the new boss and both pushrods just in case. Hopefully I'll be riding on Saturday.

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GixRider

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FYI, I ordered the new push rod and ball from an '01 but it is the same overall length as just the '00 push rod. The parts drop in fine but it doesn't help my situation. ASV said they'd send me a barrel adapter but it's been a couple weeks and I'm still waiting.

In the meantime, I may just use the 00 push rod with the 01 ball. In theory, this will work since the clutch arm(?) will be further out and use up more of the cable, giving me more adjustment capability(currently maxed on both ends)

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