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TOPIC: Hard Clutch will not disengage 68 DT1

Hard Clutch will not disengage 68 DT1 16 Jun 2017 17:42 #1

  • bart.ives
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Just got my 68 DT1 250 running, but the clutch just is not functioning. Clutch is a hard pull and feels like it is not pushing the clutch plates free. Installed brand new clutch actuator, with cover off the actuator works great, no cable bind, and moves well in and out. Pulled the push rod and it looks good and straight, some minor wear signs, but nothing that would stop it from pushing the clutch plates free. Clutch springs measure 33.44mm on average, book states that they should be 36.5mm. Adjusted clutch at cover so that it just touches and backed off 1/4 turn. I did not measure the friction plates, but they looked fine to me. The clutch was not working when I got the bike, same hard pull as now, just thought it was the actuator. The ball bearing would not come out from the left side, but was there when I replaced the friction plates, et.al. I did not pull the clutch basket just filed down the notches till smooth. Is it possible that a thrust washer is actually blocking the push rod from pushing on the ball bearing and disengaging the clutch when the clutch lever is pulled? Any help is greatly appreciated?

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Last Edit: by bart.ives.

Hard Clutch will not disengage 68 DT1 16 Jun 2017 18:26 #2

  • Giancarlo124
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So you didn't pull the clutch plates out? Is it possible they are stuck together from sitting a long time
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The Oil burners: 1973 DT-250, 1966 YM-1 305, 1966 YSD3, 09' jsw TDi

Hard Clutch will not disengage 68 DT1 16 Jun 2017 18:33 #3

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I did pull the clutch plates out. They looked okay to me and were not stuck together in any significant way. Put them back according to the parts diagram, same way they came out. Just did not measure them for wear, they did not look shiny or worn. Cleaned them up with a little Marvel Mystery Oil.

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Hard Clutch will not disengage 68 DT1 16 Jun 2017 21:19 #4

  • 1971DT250
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If it was bound up when you got it I suggest you take the clutch plates out and reassemble everything else and then see if the pressure plate moves outward when you pull the lever. Someone may have installed the wrong plates or in the wrong order. There are some minor differences between the steel plates and also there may be some differences between '68 and later years. The '68 gurus on the forum could chime in.

If the wrong plates or spacers were used or the wrong number of plates installed then the pressure plate may be hitting the case cover. Also deep combing in the basket fingers would make it hard but you said you filed them smooth.
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The hours spent riding my Enduros is not deducted from my life span.

Hard Clutch will not disengage 68 DT1 17 Jun 2017 03:44 #5

  • KennyandtheJets
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i once had to pull my clutch off to adjust my gear selectors... put it all back together and left out the ball bearing = no clutch ... but it felt free and loose
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When in doubt, power out !

Hard Clutch will not disengage 68 DT1 17 Jun 2017 04:11 #6

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Same thing just happened to me on my 1979 dt250. I drained and swapped oil 3 times to no avail. Then i totally cleaned the plates, drained oil for a few hours and put in some yamalube. worked for a day, then same issue.

What seems to have done the trick is i revved my engine and then engaged the clutch and the had enough force to separate the plates. Had to do that once or twice and now all is good.

I realise that may not be 100% helpful... but it's all i got.
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Hard Clutch will not disengage 68 DT1 17 Jun 2017 05:43 #7

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Unusual problem so attacking it from the 'hard pull' point of view!!. How about pulling the clutch cover again & eyeballing that the pressure plate is actualy lifting. If it doesn't & the lever goes hard i wonder if someone has either spaced up the springs to the point of coil binding [unlikely] or fitted way too heavy springs [unlikely] or pull the plates out & make sure the center revolves as it should [also unlikely tight]. mushroom headed rod missing [unlikely]. Well 'that' didn't help sorry. Apart from something not right over the other side in the lifter worm thingy. Should have a ball in there but slightly marked at the end so it wont fall out--well not a new lifter anyway. clutch rod has a big ball bearing the other end that the mushroom rod sits up to, plus of course the main rod coming right through to the ball from the left
www.partzilla.com/parts/search/Yamaha/Mo...T1/CLUTCH/parts.html
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Hard Clutch will not disengage 68 DT1 17 Jun 2017 08:43 #8

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Okay, so I pulled the right side cover. The actuator moved the clutch plate out quite a good distance, so I believe no problem there. A couple of pictures of the friction plates and spacers are attached, the stains on the spacers are not rough but smooth so I did not think that would be an issue. However, both the outer clutch basket and the inner clutch basket are locked together, without the clutch disk in place I thought the inner one should spin freely? Is that correct or not? I apologize as this is the first clutch I have worked on and am not quite sure of the total norms.

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Hard Clutch will not disengage 68 DT1 17 Jun 2017 09:08 #9

  • MarkT
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The clutch hubs should spin freely and independently of each other with the plates removed.. (Technically outer basket spins on bushing but of course is stopped by crank gear.) Inner hub is splined to trans and will spin if trans in neutral.

What you are describing could be what RT325 described in a recent post on Cmattina's bike... or someone "pinched" the washer or thrust bearing under the center bushing when assembling. Very easy to do... washer/bearing can slide down instead of riding over the spacer where it belongs.

You'll have to remove the center nut and pull the center hub and outer hub to check.
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1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250

Hard Clutch will not disengage 68 DT1 17 Jun 2017 09:49 #10

  • ASCO
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With all the clutch discs removed the clutch hub (boss) must spin freely without any
rubbing or bind against the basket..

That is secondary to the hard pull. Mine is hard pull too and needs inspection.

asco
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