Author Topic: DT200r clutch issue  (Read 180 times)

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Offline Lucky

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DT200r clutch issue
« on: April 28, 2019, 10:12:48 AM »
Hi all.

First time posting.
I have acquired a 91 DT200r that has been sitting for at least 12 months. After I drained and added new fuel it starts and runs perfectly other than a small coolant leak, seized rear brake calliper and a the clutch won?t disengage.
I have removed the clutch cover to see what?s going on. When I pull the lever there is no movement at all in the basket. I have seen after sitting for some time the plates can stick together. Does this sound right or could I have another problem?
Thanks Lucky 

Offline rosey250

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Re: DT200r clutch issue
« Reply #1 on: April 28, 2019, 10:25:22 AM »
Yeah they definitely stick after sitting! Give it an oil change and try bump starting and running along in gear till it warms up a bit and then try it.
 ? Lucky ? eh ? Then the clutch will be fine 😜
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Offline Lucky

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Re: DT200r clutch issue
« Reply #2 on: April 28, 2019, 02:41:55 PM »
I?ll give that ago. Will it be the same just sitting on a stand?
I don?t have anywhere nearby to ride.

Offline enduras_wr200

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Re: DT200r clutch issue
« Reply #3 on: April 29, 2019, 03:59:29 AM »
   Hi there mate! If there is no movement at all I would say it's a matter of fine tuning of the clutch, or the ball between the actuating rods is missing or badly squashed! If I remember correctly and assuming it's a 3ET,3CJ or 2YY DT, then when you pull the lever the pressure plate should be driven outward, pushed by the rods. the first is actuated by the lever, it pushes a ball which pushes the second rod, the one that is bolted on the pressure plate and can take fine tuning. Sorry, my english is not the best, check a parts list diagram and you'll get what I mean!



   Cheers, Fanis

Offline Lucky

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Re: DT200r clutch issue
« Reply #4 on: April 29, 2019, 05:17:08 PM »
This afternoon I put it back together to try Rosey?s idea. I had the bike running for about half an hour but still won?t disengage. The adjusting screw and Nat wiggle slightly but that?s it.
I guess I?ll have to pull it down again and check out the rods and ball.

Offline Glenngt750

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Re: DT200r clutch issue
« Reply #5 on: April 29, 2019, 05:52:01 PM »
Why not take the time to disassemble the clutch basket? Take and measure the plates and springs. See if they are, indeed, stuck together.
From:Edmonton, AB. Canada. Bike(s): 1990 Yamaha DT200R, 2006 Honda GL1800A, 1977 Suzuki GT750, 1985 Honda VF750FF, 1987 Honda VFR700F2.

Offline Lucky

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Re: DT200r clutch issue
« Reply #6 on: April 29, 2019, 06:53:19 PM »
Yeah. I will do that along the way

Offline fred99999au

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Re: DT200r clutch issue
« Reply #7 on: April 29, 2019, 08:16:08 PM »
You should be able to see a minute amount of movement in the pressure plate as the clutch lever is pulled. Perhaps a PO has disassembled it and lost the ball? Or have adjusted incorrectly.

Offline Lucky

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Re: DT200r clutch issue
« Reply #8 on: April 29, 2019, 10:22:36 PM »
Yeah Fred,

That?s what I am leaning towards. I am trying to track down a manual Ian I can re adjust correctly before I go removing everything.