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Cant get clutch cover off

  • wolfhound87
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Cant get clutch cover off was created by wolfhound87

Trying to get clutch cover off my dt 250 kick starter wont return and want to take a look all bolts out but when i try to take the side cover off it wants to take the kick starter shaft with it feels like the kick starter spring is what im pulling against is there something else i have to loosen to get it to come free i quit for now before i break something
16 May 2022 19:50 #1

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Replied by Tom P on topic Cant get clutch cover off

Some of them have a #3 Phillips screw under the autolube cover that holds the case on as well. When I was doing work on mine I accidentally knocked the kick-start spring off the stud when I pulled the case off, and didn't notice it. After I reassembled it and filled it up with oil, I noticed the kick-start spring was loose, so I had to drain the oil back out remove the cover, then pull it down with some wire and a needle nose.
16 May 2022 19:58 #2

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Replied by RT325 on topic Cant get clutch cover off

Welcome if you're new. DT250 means "74 & later. Here's a link to a partzilla view for a "74 & can look at the rest of the motor from that page i hope.
www.partzilla.com/catalog/yamaha/motorcy.../dt250a/kick-starter
If your is "73 DT3 then go for this link below.
www.partzilla.com/catalog/yamaha/motorcycle/1973/dt3/starter
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16 May 2022 20:55 #3

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  • wolfhound87
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Replied by wolfhound87 on topic Cant get clutch cover off

Got the clutch cover off but kick shaft came with it it was seized in the case i have another problem now kick starter will not return fully it will return only halfway from a full kick all the way to the foot peg i cant do half kicks like where you pick your spot where the compression is without picking the kick starter up myself is there a way to add preload to the spring? i tried but the ratcheting gear on the shaft would turn and lose the tension i looked for timing dots on the gears dont see any i can index the kick starter to far forward and it will return fully but will travel to far and hit the case anyone on here know the proper way to do this?
20 May 2022 21:02 #4

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Replied by RT325 on topic Cant get clutch cover off

 Assuming its "74 or so i think the spring is preloaded in the tin can. But once in action it probably doesn't end up on the tab in the can next time you pull the shaft. So--if i'm understanding the system--can you get the slot of the shaft into it a half turn back & turn it to wind up to where it should start turning from. I know what i mean--not sure anyone else does lol. I'll leave it at that & see what transpires.
Last edit: 20 May 2022 21:19 by RT325.
20 May 2022 21:16 #5

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