72 DT250, crankcase cover wont go on
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  1. #1
    Senior Member Ruri's Avatar
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    Jun 2016

    72 DT250, crankcase cover wont go on

    So I got brand new engine bolts and gaskets in the mail yesterday. Got the DT all ready to reassemble and fire up. Then I realized the SPROCKET (misleading title) cover is being blocked by the clutch push rod and wont sit flush against the case. Anyone know what I did wrong? Do i just need to force the push rod back in? Not sure how to proceed. Thanks!



    Some pictures of what is the issue.
    Last edited by Ruri; 08-28-2016 at 03:01 PM.

  2. #2
    Senior Member arbolmano's Avatar
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    Feb 2012
    Arroyo Grande, Ca
    Never great idea to force anything. Force best left to Yoda, he is far better equipped to handle it. Look to what pushes the rod on the other side, most likely where clutch cable attaches. The light in your head should come on and you will be blessed with enlightenment. Do not glue the gasket on or you face a visit from God of crap when next your there disassembling. Light tack on case only.
    on the "Left Coast"
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  3. #3
    Senior Member SHAG's Avatar
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    Oct 2013
    Bradford, Pa
    Have you tried to push the rod in with your thumb?
    Go like hell, You'll get there quicker!

    2005 BMWR12GS Rock Red 106k miles
    2013 TW200 - 8k- miles
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  5. #4
    Senior Member Ruri's Avatar
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    Jun 2016
    Yes, I've tried pushing it in with light pressure. Doesn't budge. I THINK that the push rod is being blocked by something. It should push in a bit to open the clutch I believe. I think my next step will be to take the clutch plates off and investigate that side of things.

  6. #5
    Senior Member kj7687's Avatar
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    Jul 2010
    Southern California - Inland Empire
    I think you might have to rotate the pushrod a certain way before it can be pushed in?
    KJ, just KJ, ok.

    Current rides:
    2004 GMC Sierra 1500, 1999 Toyota 4Runner

    Past rides: 2015 Yamaha XT 250, 1997 Suzuki DR 200, 2007 Honda Ruckus, 2007 Yamaha TW 200, 2007 Kawasaki Ninja 500, 2009 Kawasaki KLX331S; 1994 GMC Sierra 1500, 1987 Nissan Pathfinder, 1992 Acura Integra, 1986 Honda CRX, 1989 Jeep Cherokee, 1994 Chevrolet Astro Van, 1979 Volkswagen Rabbit, 1984 Jeep Cherokee

  7. #6
    Senior Member Ruri's Avatar
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    Jun 2016
    I haven't messed with the push rod or clutch at all. Just removed covers to replace gaskets. One forum said that a plate could have slid down and is now blocking the pushrod. I am just now about to go back into the shop and start fooling around more.

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