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Makotosun

Clutch lever stiff on DT and RT engines

  • type one
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Clutch lever stiff on DT and RT engines was created by type one

Hi All

i have 2 bikes i occasionally use for classic events and the clutch lever pull on both requires super human strength to pull in and engage the gears …
…..
both have new clutch plates and metal rings ….

have I over tightened the springs?

whilst I can ride them it would be much better if they weren’t as stiff !!

thanks
T1
DT1's mainly -
x4 1968 US (survivor, shiny resto, MX frame mods & early project)
1968 AUS
1969 Early B front yard ripper
1969 B scabby track bike
1969 B MX project
73 CT3 project
'77 z750 hard tail chop ......
BMW GSA 2018
26 Jul 2021 21:56 #1

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Replied by RT325 on topic Clutch lever stiff on DT and RT engines

Chances are its split the nylon part of the actuator or lifter whatever ya call it. When it splits it just gets spread & tightens & resists being operated. There are optiong & the type out of RD350 & numerous others are 4 start rather than 3 start & work great but needs alterations to fit it as a complete inner & outer unit. Also saw a brass part to replace the nylon even though the nylon part isn't removable but someones managed it & produced the brass option with instruction on how to fit it to the middle bit. Someone will find a link for that soon i guess.
27 Jul 2021 00:36 #2

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Replied by Gr8uncleal on topic Clutch lever stiff on DT and RT engines

I know that you're quite experienced with these bikes, so I'm apprehensive about giving advice! Notwithstanding that, my first ports of call would be the cable (is it new, original, good aftermarket?) and the mechanism inside the left crankcase cover - the nylon inserts are known to crack.
27 Jul 2021 00:36 #3

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Replied by type one on topic Clutch lever stiff on DT and RT engines

Thanks guys …. I don’t think it’s the obvious candidates tbh … I think it maybe something more fundamental…

appreciate the suggestions and will revisit … thank you!
T1

  Thanks guys …. I don’t think it’s the obvious candidates tbh … I think it maybe something more fundamental…

appreciate the suggestions and will revisit … thank you!
T1

  Thanks guys …. I don’t think it’s the obvious candidates tbh … I think it maybe something more fundamental…

appreciate the suggestions and will revisit … thank you!
T1

  Thanks guys …. I don’t think it’s the obvious candidates tbh … I think it maybe something more fundamental…

appreciate the suggestions and will revisit … thank you!
T1

 
DT1's mainly -
x4 1968 US (survivor, shiny resto, MX frame mods & early project)
1968 AUS
1969 Early B front yard ripper
1969 B scabby track bike
1969 B MX project
73 CT3 project
'77 z750 hard tail chop ......
BMW GSA 2018
27 Jul 2021 01:53 #4

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Replied by Bigdog302 on topic Clutch lever stiff on DT and RT engines


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Replied by Gr8uncleal on topic Clutch lever stiff on DT and RT engines

Thanks for posting Bigdog. 

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"Type one" and any other UK buyers, if you go direct to KDI (see banner/link on the right of the screen), then you should avoid paying the 20% VAT that ebay are now obliged to charge us.
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27 Jul 2021 04:48 #6

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Replied by RT325 on topic Clutch lever stiff on DT and RT engines

Yeah hope it is something simple. I've got a bad habit of jumping in the wrong end like recondition the motor & find it only ran out of petrol haha.
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27 Jul 2021 05:05 #7

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Replied by turbodan on topic Clutch lever stiff on DT and RT engines

You can't really over tighten the pressure plate springs.  If the clutch stack height is wrong you can run into coil bind though. 

I've got the RT1/RT2/RT3/MX360 springs in my DT360 and the clutch pull is fairly light with a pleasant feel.  Nice thing about the 74 360 is that Yamaha simplified and improved the clutch release mechanism.  The older bikes have that problematic helical actuator.  For my Kawasaki Bighorn I was able to use a ball bearing item from a Suzuki Katana which worked much better, though it did require some modification of the side cover.  I don't know if that part would be compatible with the Yamaha but it would be worth looking into.
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27 Jul 2021 17:33 #8

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Replied by MarkT on topic Clutch lever stiff on DT and RT engines

Careful...  what's meant is snug down the spring screws until they stop and as long as they are original you can't screw them down too far.

You can over tighten them though...  then they go "snap".  Not fun.

Probably the actuator.  Or possible someone installed heavy springs.
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
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27 Jul 2021 19:11 #9

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Replied by JGersh on topic Clutch lever stiff on DT and RT engines

Here’s what a split nylon actuator looks like.  If this is the problem then replace with the KDI brass actuator as previously noted. 

 
2 - ‘68 DT1
‘70 RT1
‘70 CT1-B
2 - ‘70 HT-1’s
‘12 Triumph Scrambler
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27 Jul 2021 20:28 #10

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