200x clutch help needed

**f76** · 04-30-2015, 07:22 PM

I recently purchased a real nice shape 85 200x. Needed just a few small things which I knew going into it. One thing was a clutch cable, which promptly snapped after I got home with it. I put on a replacement clutch cable however the clutch arm is very easy to move. I can move it with fingers easily. If you pull the clutch lever it won't even pull it back, just stays pulled. I adjusted my cable both ways with no luck. Took it for a drive and the clutch would engage at the near end of the lever travel length. It was at the point where I would pull the lever and it would barely engage the clutch enough to be "engaged" but if I gave it throttle it would creep ahead. I couldn't pull the clutch arm forward anymore either.

Is this a symptom of new clutch springs needed? New clutch discs? I have the right side case half off already and figured I would ask before I start removing the clutch pack and such.
Thanks in advance.

Picture of the machine because we all like pictures!

**Dirtcrasher** · 04-30-2015, 08:24 PM

This is a symptom of something being assembled wrong.

Even worn springs don't pull in like butter and do nothing.

Get a free online manual and take the right cover off and see whats up. Something could be broke, missing or in the wrong place.

**f76** · 05-01-2015, 03:15 PM

Have the cover off and nothing appears out of place or broken. Clutch springs are all over 38mm, well over service limit of 34.7mm. Unfortunately I don't have the spanner lock nut socket so I can't take the clutch or oil filter off and measure the discs. It has the proper number of discs (5) and plates (4). I'm at a loss with this. Yesterday when I took it out for a spin the clutch wouldn't slip and held strong. I could spin the wheels around corners on gravel with big junk pro tires. Yet when I pulled the clutch it would barely disengage at the end of the ride and I could feel it still trying to engage. If I gave it throttle with the clutch pulled it would slowly creep forward, yet I couldn't move the clutch arm forward anymore.

**yaegerb** · 05-01-2015, 04:08 PM

Originally Posted by f76

I recently purchased a real nice shape 85 200x. Needed just a few small things which I knew going into it. One thing was a clutch cable, which promptly snapped after I got home with it. I put on a replacement clutch cable however the clutch arm is very easy to move. I can move it with fingers easily. If you pull the clutch lever it won't even pull it back, just stays pulled. I adjusted my cable both ways with no luck. Took it for a drive and the clutch would engage at the near end of the lever travel length. It was at the point where I would pull the lever and it would barely engage the clutch enough to be "engaged" but if I gave it throttle it would creep ahead. I couldn't pull the clutch arm forward anymore either.

Is this a symptom of new clutch springs needed? New clutch discs? I have the right side case half off already and figured I would ask before I start removing the clutch pack and such.
Thanks in advance.

Picture of the machine because we all like pictures!

You shouldn't be able to move the clutch actuator arm with your fingers at all (it takes a lot of force to do so). I would say that your actuator is assembled incorrectly, check the spring, the actuator itself or both.

**YTZ drew** · 05-01-2015, 09:12 PM

It sounds to me like the roll pin broke in the actuator lever inside the clutch cover.

**HairyJR** · 05-01-2015, 10:21 PM

Without knowing the previous PO repairs had any work been completed requiring the clutch removal. Sounds like there's to much clearance between the clutch shaft rotating socket and the clutch lift rod. I see in your posted pic the lift rod setting in the main shaft, hopefully you placed it there after removing the lifter plate (bearing holder). Its been over twenty years since I worked on a 200x but maybe the spline washer was left out or this actually happened to me, installed a new clutch assembly and it wouldn't release, found the fiber plates where to thick which pushed the pressure plate further from the clutch shaft, larger gap, measured and replaced plates with correct thickness, worked fine.

"HJ"

**f76** · 05-01-2015, 10:55 PM

Thanks for the replies. I do not believe the motor has ever been opened up. The roll pin on the actuator shaft is fine, spring correctly installed. Yes i just placed the lift rod there, it was correctly installed with the lifter plate on first. I want to measure the disc thickness but need to buy the spanner socket first for clutch removal.

**oscarmayer** · 05-01-2015, 11:06 PM

ok dumb question. the piece sticking out, was it like that when you took the 4 bolts and springs off?
my sig has a link to factory service manuals.

http://www.bikebandit.com/oem-parts/...m1898#sch10113
$ 8 should be outside the bearing. it is what the pivot arm pushes to release the clutch. did you put it there or was it there already?

13 is the throw-out bearing
7 is the plate that you put 4 bolts through and holds the springs down.

**yaegerb** · 05-01-2015, 11:20 PM

You are heading in the right direction with opening up the clutch pack. If the spring and actuator are in correctly it could be your metal and fiber discs or something wrong or needing to be replaced in the pack. Let us know what you find, I am now curious considering you can move the actuator with your hand. That shouldn't be happening......ever

**oscarmayer** · 05-01-2015, 11:35 PM

if it is off the bike, he should be able to move it by hand, but on the bike, you have to have some really strong fingers to move it. I can sorta budge mine some but like I said strong fingers. (that's what she said!)

**yaegerb** · 05-01-2015, 11:42 PM

I will respectfully disagree. Even off the bike, makes no difference. If you can move the actuator by hand, kudos to you, or take a look at your assembly as well. Can you move the a few MM's?, sure.....can you actuate the clutch pack...ummm no.

**f76** · 06-03-2015, 08:30 PM

Thought I would post my findings to close the issue. Got the spanner socket, took clutch apart, disks all look immaculate. Everything looked fantastic so I put it all back together and the issue was resolved. Not sure what caused the weak clutch engagement but taking it all apart and putting it back together fixed it.

**Jmoozy27** · 06-03-2015, 11:43 PM

I guess sometimes they just need a little attention. How is it running? What is your plans for it.

**f76** · 06-04-2015, 08:13 AM

Runs great! I'm selling it actually. Could use the cash.

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200x clutch help needed

200x clutch help needed