Hello I have a 1978 DT250 I'm restoring. I need to replace the clutch arm that actuates the push rod because the part where the cable attatches is all beat up. In the manual it says to just loosen the lock screw by the front sproket and it should pull right out. Well mine isn't. It stops about half way  when trying to pull it out. Does anyone have any experience with this? Thanks. 

I don't think it will come out unless you remove the pushrod first? 

 

It might come out if you rotate it about 180 degrees...  look at the new one and see if there is a way to get past the "step".

Thoughts…I finished my 78DT400 a couple months ago so already forgotten stuff! Be sure you remove the adjusting screw completely as it locks into a groove on the lever mechanism. After that should pull out. Maybe your getting caught on the seal or something. Check the shop manual too. Amazing how they help and have pictures too!

edit…the bottom of the lever could be getting caught on the pushrod as Mark T suggested. Mine was a complete tear down and rebuild by the manual. Check that manual for sure before you tear into the right side for that pushrod. I’m not home or I’d look in my manual.

So I took off the right case cover off and just removed the bolts and springs. After that I pulled up on the clutch arm and it slid out. When it slid out, the clutch plates moved out a bit so yeah the push rod wasn't allowing the arm to be removed. Pretty easy and relieved I didn't have to go deeper and remove the push arm. Thanks yall. 

Yamaha don't normally make it that difficult. Just screw right out & turn it back away heaps & should lift out.

So I got the bike put back together but now it won't shift into 2nd gear. 1st no problem. Neutral no problem. That's all it will do though. 

Is this with engine stationary or are you turning the shafts while trying to shift?  It's normal for it not to want to shift unless you rotate shaft to allow dogs to align. 

I'm guessing misalignment of the teeth of the change arm & other thingy. Common mistake. Teeth must be centraly aligned.
www.partzilla.com/catalog/yamaha/motorcy...t250e/shift-cam-fork
www.partzilla.com/catalog/yamaha/motorcy...8/dt250e/shift-shaft