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This is what I used on my DT2, works great but you'll need a vice to install it and go slow when installing, also use plenty of lubrication.

Worm gear actuator

Welcome from NZ. Your DT looks a hell of a lot better than mine lol. Mine goes better than it looks though. The split clutch actuator won't have been caused by anything you've done & like been split for some years. Makes operating the clutch hard on the lever as its forcing the split open & tighter. I'm using an RD400 type in my 360 but don't have any pics of fitting it. Makes for a nice clutch & is a 4 start spiral instead of 3. Think the outer on that is nylon & the actuator is steel. Bit of fiddling & machining to fit it in. The actuator I used is basically the same as the XS type I believe. The outer nylon spiral but has a steel covering to keep it good. On the other hand if you can replace yours without emptying your back account then I guess that's the easiest option. I'll see if I can find a pic of a typical XS type.

 from near Salisbury, UK.

I believe that KDI might make good repro clutch actuators - see their link on the right of this page.

As well as wanted adverts on this forum, fleabay, Partzilla and CMSNL can be your friends for parts (others will post other suppliers).

As many parts were shared between models, and other parts fitted, even though they weren't meant for that model, it is very important to familiarise yourself with what a part looks like. I use CMSNL, this forum and the internet in general to see what part I need looks like, and CMSNL and Partzilla to see which other models used that part. Many parts are (accidentally) listed incorrectly, so do a very wide search (eg "Yamaha speedo").

Hey there. Inherited a 1971 dt1F 250. Was previously in poor shape and had a friend do a sort of basic resto on it. Don’t have too much cash to go buying NOS oem parts so it doesn’t look show room but the point is to make it roadworthy as a part time commuter. 

a question I have after searching forum. The worm gear clutch actuator that is nylon is cracked (thanks to me) and I see options for the xs version or the brass ones on eBay. 
my question is- after installing a new spring on the actuator arm, everything seems to function ok so do I even need the worm gear?
i’ve been searching for a new clutch (mine is slipping) and gonna give some eBay stuff a go unless someone chimes in to tell me otherwise. 

Wiring diagram- newer model manuals have great wiring diagrams. Does anyone have something similar for this model? 

thanks and have enjoyed lurking for a long time

This I'm going to have to eat humble pie there. Just looked up a seal & say 8.8 ID so in theory it should roll through the seal, or good magnet stick as seal will be a bit under size ID to grip the rod. Now I don't know what I'm talking about. Rod must be 9mm if seal is 8.8 I'm guessing. Ignore me lol. I see it steps down into the actuator.

www.partzilla.com/catalog/yamaha/motorcycle/1970/r5/clutch

has badges too!

I rebuilt my R5 which was missing the ball between the pressure plate lifter and the rod. I ended up putting a 5/16 ball I had in as a placeholder and ordered genuine Yamaha because the one I had had a bit of surface rust and is probably a POS from a dresser slide or something that works with crap steel 

Question: will ball roll past new rod seal on clutch actuator side, or will I have to remove and reinstall seal?  I put in a new seal so prefer to not mess with it but can if I must. Let me know and thank you. 

sounds pretty bad ass without baffles which are on order. 

Here's a link to the brass worm gear on KDI...

Clutch actuator worm gear

Clutch cable not throttle i'm sure you mean't, no worries. The actuator on those does split then you lose half the useful movement. Easy to check just turn it out to inspect & grease it while its out. Otherwise if it feels like its possitive & lifting the clutch then yep ya might have to 'go in'. Just been in my 360 clutch as it happens.
Sorry haha, typing too slow & above beat me to it. Thats good.

So, last Thursday I ordered the brass clutch actuator from KDI… holy OMG.. it showed up today!! A bit of looking and a very handy vice… it is installed… new cable… put it together and it is alot easier to pull! So, I put on the “ newer” fuel tank… a bit of monkeying around… and time fer a ride around the neighborhood, halfway around… the spark arrestor/screen gizmo shoots off… man was that a very snappy sounding exhaust! I’m saying, it would make my ears rap! My neighbor was following… he saw it fly out. Did I say it was quite hot? A little further and it was stumbling…. Got it home. The petcock was the culprit.. it would trickle in the on position.. flow well in reserve. So a bit of messing and using compressed air.. I dislodged a hunk of gunk… new fuel filter… then company over.. well, tomorrow I’ll go for a ride… close to home until I feel I’ve got the bugs worked out… it’s so close now!
Sneezles61 

It’s raining here today. Replacing the clutch cable… my how that cover is caked in dirt… I find that the cover has been welded. Sure seems fine so I won’t worry about looking for a cover. And I took the actuator apart to clean the grime… and as many of you have found, it’s in need of replacing. I’ll head over to KDI and get one coming.
I’m not in any big rush to get the old grey mule out of the garage. It’ll take what it takes and every part I find bad back to good order.. It’s plain old fun tinkering with it.
Sneezles61