I have a real mystery here. (I will provide pictures and hope they will post)

This is supposedly a virgin motor with just the covers pulled and injection pump removed.  Clutch pack is all intact.

The correct length 7.19" clutch push-rod WAS sticking out from the seal.  But when I pushed it in further to bottom up against the clutch pack ball-bearing & push crown - it went in PAST the seal - what's up with that?  

Measuring, I would need a rod about 9" in length to protrude out from the seal to bottom into the clutch push-screw mechanism in that LH cover - and that's not right.I have a real mystery here. (I will provide pictures and hope they will post)

This is supposedly a virgin motor with just the covers pulled and injection pump removed.  Clutch pack is all intact.

The correct length 7.19" clutch push-rod WAS sticking out from the seal.  But when I pushed it in further to bottom up against the clutch pack ball-bearing & push crown - it went in PAST the seal - what's up with that?  

Measuring, I would need a rod about 9" in length to protrude out from the seal to bottom into the clutch push-screw mechanism in that LH cover - and that's not right.

Help - I'm not hallucinating.
  

Help - I'm not hallucinating.
 

You need to post pictures to a 3rd party site like Imgur and link them here. 

There are two pushrods and a ball, you only mentioned the long pushrod.  What about the short one and the ball?

Thanks for the note back, MarkT. 

I'll hafta work on the picture posting - one was out of the service manual showing a cross-section of the system.
 
And granted, I haven't ever been into a Yamaha 250 engine like this, but everything I have been able to look at shows only this one long 7.19" pushrod - which goes up against the ball and this captive T-ended short pushrod (174-16356-00) within the clutch pack.

That's why I'm so baffled.

You said the clutch pack was "intact".  Have you actually pulled off the clutch pressure plate to verify the ball and short pushrod are there?   And if they are, how do you know they are correct?

P.S.  I'm not sure what the length of the long or short pushrod should be...  someone may have posted it here at one time but it's not a common "spec" so wondering where you got that dimension?

Well, I was told it had not been pulled before and was going with that - and wanted to throw this out for advice before I took on the clutch disassembly that I was hoping to avoid... but appears I'm gonna hafta do that to figure this out.  I can't believe that captive T-ended part would be missing - but we've all seen stranger things I guess.

I had measured my pushrod to be this 7.19" and a fellow on Ebay with a new NOS one for sale was kind enough to confirm his also was 7 3/16" long.  Its part no. is 183-16357-00

BTW - if you have any advice or caution you can give me before remove this clutch pack, etc.... I'd appreciate it.

Not sure if the year is right but the layout is the same. Note ball #13 is a big one 5/16 i think & same size as the mushroom piece so only goes in from mushroom end.
www.partzilla.com/catalog/yamaha/motorcycle/1970/dt1c/clutch
I see they draw the long pushrod #20 in two pieces, kind of, [but its one piece].

Just remove the screws around the pressure plate evenly.  Take plate off.  That's as far as you need to go to get to pushrod and ball. 

When reinstalling plate, just snug the screws down all the way.  They don't need to be that tight and can break/strip pretty easy.

 

Ah, thanks guys. Yeah, I actually don't have to completely 'take the clutch apart' - just pull off the cover as you say that will give you access to this 'mushroom piece' & ball'.
Will let you know what I find - it's good to know that this piece (if missing) is 'obtainable' too.

Yep, cover then pressure plate with screws & springs. Look closely at the 5mm screw threads as i have a handful of overstressed spring screws where there is obvious stretching of the thread at the base where thread ends against the screw solid part. Just becomes a problem if the break off in there that's all.

Well, whadaya know.  The T-rod end and ball were both missing when I pulled the cover off.

Why in the world that would be is a mystery to me - but just goes to show.Well, whadaya know.  The T-rod end and ball were both missing when I pulled the cover off.

Why in the world that would be is a mystery to me - but just goes to show.

Fortunately, I have found both pieces on Ebay and they are 'in the mail'.

Thanks for the notes back on all this.... 

Fortunately, I have found both pieces on Ebay and they are 'in the mail'.

Thanks for the notes back on all this....