clutch adjustment on ytm 200

[mcbain]

I have a YTM 200. I bought clutch plates off ebay a few years ago and decided to install them the other day. until i opened it up and saw they were the wrong plates!!!!

I have a spare YTM that has a good clutch in it, so i took it from there and installed in my good YTM. Now i'm having problems with the adjusting screw. The manual says to turn the screw COUNTERclockwise until resistance is felt. The problem is, when i turned counterclockwise, i never felt any resistance @ all. So i took the cover back off and found that adjusting arm had come right off...i'd unscrewed it right off! Tried it a second time and got the same thing.
I donn't understand, i've followed the book perfectly (i think). Something must be missing. I've adjusted the clutch setting before this, and know how its suppose to work.

any ideas?

[Yamada]

Look at the arm pushing against the clutch. Maybe the hole where the pins holding it is egg-shapped. Or sometime the arm broke and it don't disengage the clutch completely.
Edit*** Did you put the bearing in the center of the clutch?

[mcbain]

i'll look @ it tonight. its all apart on the bench right now anyway.

[mcbain]

the bearing, and the little 'pin' were missing. they had rolled under the table!
that was it!
thanks!

[mcbain]

ok. finally back on this project. i've put this thing back together 100 times and still not working. whenever i put the cover back on, and turn the adjusting arm c-clockwise until resistance, and then back off a bit, i cant adjust the gear shifter. i've broken 2 of those adjusting arms in the process of trying!! i'm down to my last one!
i'm obviously missing something here, but can't seem to figure it out. i have the clymer manual, and i think i'm putting it all back together correctly.
what am i missing?!?

[thefox]

So what is it doing now? It doesn't shift or is the clutch slipping? Will it move at all?

[mcbain]

it doesn't shift. i put the cover on, and once i've turned the clutch adjustment screw until resistance is felt, i can't move the gear shifter at all. i have to back it off about 4-5 full turns before i can move the gear shifter.

[thefox]

Something is deffinatly not right in there, I am going to have to think about this one.

Does it shift fine with the cover off or does it still shift hard? What about then the adjuster is backed way off, how well does it shift then?

[mcbain]

shifts fine with the adjuster backed way off. and with the cover off.
ya, i don't get it either. this thing is driving me bonkers though.
i've missed out on a good month of driving in the snow with this thing out of commission though.

[Derek]

You got me stumped I had a 200 and I tried adjusting the clutch and snap I broke the adjuster arm in half. I will never touch one on a Yamaha again lol.

[mcbain]

ya. like i said above, i've broke two already. and the one i'm using now that i pulled off my parts bike has been welded before (not by me). so its been broken before. sounds like this happens a lot. my other two broke in exactly the same spot.

part of the problem here is i'm not entirely sure how the secondary clutch operates on these things. I don't see what those four springs do, or that bearing in the middle. the four springs are all the way tightened down, so to me it looks like they do nothing. and what does that middle bearing do when that arm is against it.
confusing..

[Derek]

Yea did it crack in half right in the middle of the hole for the pin?

[mcbain]

yup. on two of them now. i've got one good one left. so i need to be carefull with this one.

[Frankencelery]

So...did you ever get this fixed? My 225DX clutch is slipping, so I thought I'd adjust it, but you guys have got me worried about touching it!