So I swapped 99 600 motor that I bought in my 97 600 recently and have been having trouble getting the clutch to work properly. I have figured out (with the help of my trusty service manual) that the stack of plates is 5mm taller then that of the previous years (total stack height 45.585mm). So with the plates stacked 45.585mm like the manual says the last drive plate sits so that 1/2 of its thickness is sticking out of the basket. I have not put it back together to see if it works yet because it seems strange to me that the last plate will stick out like that.
So for anyone that has done the clutch on a 99 600, did your last plate stick slightly out of the basket?
I have compared the 99 and 97 clutch baskets by measuring (I have both) and comparing parts numbers and everything I find seems to show that they are the exact same. I'm hoping that someone can confirm this for me before I try and assemble it again. Thanks
5mm Taller is ALOT!
You either have too many plates or something is not assembled correctly.
Have you backed off on the pushrod adjuster to allow the entire clutch assy to become fully seated in the basket? According to my info 97-00 clutches are the SAME so perhaps your problem lies elsewhere?
5mm Taller is ALOT!
You either have too many plates or something is not assembled correctly.
Have you backed off on the pushrod adjuster to allow the entire clutch assy to become fully seated in the basket? According to my info 97-00 clutches are the SAME so perhaps your problem lies elsewhere?
In the back of the manual there is a section that is called "1999 model updates". In the clutch section it shows the stack of dry plates with a weight of 5kg on top of it should be 45.585mm tall while the main clutch section of the manual shows the stack as being 40.368mm, thats a difference of about 5mm. After comparing all of the clutch parts I found that the driven plates for the 97 600 are 1.6mm while the driven plates of the 99 600 are 2.3mm to get the difference in stack heights. So I ordered the correct plates for the 99 600.
Before I found this out I was using the 97 plates with the 40.368mm overall height and I adjusted both ends of the cable and the nut on the bottom exactly as the manual instructed. My problem is that my clutch is not dis-engaging, everything feels normal at the lever and the pressure plate is moving in and out. So I am assuming (because it is the only difference that I can find through all of my cross-referencing) that the 5mm difference in stack height is causing it to not disengage. The thing is that the stack of the plates is 45.585mm like that manual says but the inside of the basket (with the clutch sleeve hub in it) only measure 44.something. Leaving the last drive plate not completely in the basket.
I cross referenced 3 aftermarket clutck kits and ALL 3 stated the 97-00/600's were the SAME.
But...5mm is a considerable difference and would certainly foul your clutch set-up.
If the baskets are the same that would mean there is something else being overlooked. NO???
I cross referenced 3 aftermarket clutck kits and ALL 3 stated the 97-00/600's were the SAME.
But...5mm is a considerable difference and would certainly foul your clutch set-up.
If the baskets are the same that would mean there is something else being overlooked. NO???
According to the manual the clutch plates for the 99 600 are part # 21451-31E20 which are 2.3mm thick. When I ordered them from Ron Ayers I had them double check that I was ordering the correct plates for the 99 600 and they are correct. I am trying to figure out what is being over looked. I checked the part numbers on all the parts for the 99 and 97 on Ron Ayers fiche and they seem to be all of the same part numbers except for those plates. I have physically compared all of the parts from my previous 97 600 motor and those of the clutch that came in my 99 600 motor that I purchased and they all appear to be the same. I am hoping someone that has done a clutch on a 99 600 will see this and be able to at least tell me how the plates fit into the basket/if mine are obviously wrong.
The 750 uses an extra plate or two and i'm wondering of one/both these bikes had the wrong clutch in it to begin with?
The 99 motor having the wrong clutch to begin with has been a concern of mine too. I got the motor a little while back, got it in my bike, and fired it up without any problems but the clutch has not been right at all. I know that 97 600 clutch was good, I changed it a couple times myself and put over 40,000 miles on the motor myself. When the clutch from the 99 did not work I figured no big deal and tossed my clutch from my 97 motor in (it was fairly new still and as far as I could tell at that point in time everything was identical on them) and it still did not work. Since then I have done all kinds of swapping around, comparing and cross-referencing getting myself to the point I am at now... still lost.
The conclusion I have come to a few times now is that maybe the 99 had a deeper basket, but I cannot find anything anywhere that tells me that any of the 600 srad motors had anything but the same basket. I know that everything on the left side of the bike (cable and adjustments) is correct, I know that the basket moves in and out like it should be when you pull the clutch, something just is not lining up correctly. It makes sense to me that things would not be lining up properly if the stacks are 5mm difference in heights, thought that would solve it, but now the plates don't fit in the basket properly.
The service maual or the microfiche will tell you the order of assembly if thats at all in question?
You can measure the basket depths but i doubt they differ?
Its hard, without having it in front of me to figure it out.
This interent diagnostics is a be-atch you know!
Sometimes when you see it, it all clicks in place.
Sorry i can't be of more help here.
The service maual or the microfiche will tell you the order of assembly if thats at all in question?
You can measure the basket depths but i doubt they differ?
Its hard, without having it in front of me to figure it out.
This interent diagnostics is a be-atch you know!
Sometimes when you see it, it all clicks in place.
Sorry i can't be of more help here.
Yeah, I've used the manual for the assembly order every time I have re-assembled it trying to figure this out and am very confident that that is all correct. I have measured both baskets and many of the other parts with digital calipers and they are all the same. I appreciate you trying to help, I am very lost with this. The ideal situation would be if someone could measure the basket out of their 99 that they know that clutch works on, but I doubt I will find anyone with their 99 clutch apart that can measure it for me.
Linear Mode
