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Makotosun

DT2 Clutch Release

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Replied by AirborneSilva on topic DT2 Clutch Release

You are going to need to remove the push lever assembly from the side casing, the plastic worm gear is pressed on, as will the new brass one be. Mine was cracked in two places so it wasn't difficult to remove it. You could probably carefully use a dremel and cut it off, being careful not to damage anything. But be sure to mark it's position prior, can't stress that enough.
2023 Tenere T7
1976 DT400C
1975 DT400
1981 DT175H
1972 DT2 250
1980 GT80
1972 JT2
29 Nov 2022 09:21 #21

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  • phrog44
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Replied by phrog44 on topic DT2 Clutch Release

i think i may be screwed.  The worm gear was frozen into the case.  When I tried to move the push lever assembly, it just slipped at the shaft, losing any indication of the placement of the worm gear.  I was able to eventually get the worm gear out after the push lever was completely removed but, I have no way to know how the new gear has to be placed on the shaft.  Is there any way to find the orientation of the original installation?
29 Nov 2022 12:12 #22

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Replied by AirborneSilva on topic DT2 Clutch Release

The only way I can think of is slip the new worm gear in where it belongs then on the other side of the side case you might be able to match up the push lever assembly in it's proper orientation and possibly make the marks on push lever assembly, hope all that made sense...
2023 Tenere T7
1976 DT400C
1975 DT400
1981 DT175H
1972 DT2 250
1980 GT80
1972 JT2
29 Nov 2022 12:31 #23

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Replied by phrog44 on topic DT2 Clutch Release

Yes, that makes sense.  I'll try that.
29 Nov 2022 12:43 #24

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Replied by AirborneSilva on topic DT2 Clutch Release

Good luck brother!
2023 Tenere T7
1976 DT400C
1975 DT400
1981 DT175H
1972 DT2 250
1980 GT80
1972 JT2
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29 Nov 2022 12:43 #25

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Replied by Sneezles61 on topic DT2 Clutch Release

KDI sent a paper the shows you where to align things… just read it a couple of times.. look carefully..
Sneezles61
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29 Nov 2022 13:30 #26

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Replied by phrog44 on topic DT2 Clutch Release

Is there something attached that i am missing, or, is this something i can expect to receive from KDI?
29 Nov 2022 15:52 #27

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Replied by AirborneSilva on topic DT2 Clutch Release

The only thing/part you will get from KDI is the worm gear itself.
2023 Tenere T7
1976 DT400C
1975 DT400
1981 DT175H
1972 DT2 250
1980 GT80
1972 JT2
29 Nov 2022 16:14 #28

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Replied by MarkT on topic DT2 Clutch Release

Sounds to me like Sneezles got an instruction sheet with his... so you should too.
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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29 Nov 2022 16:36 #29

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Replied by Sneezles61 on topic DT2 Clutch Release

And believe me…. I need all the help I can get!
If I knew how to post a picture of that, I would do just that..
Sneezles61
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29 Nov 2022 17:01 #30

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