72 DT250, crankcase cover wont go on
Close
    
    
Results 1 to 6 of 6
  1. #1
    Senior Member Ruri's Avatar
    Join Date
    Jun 2016
    Posts
    118

    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!

    CaseCoverwtffff.jpg

    wtfffff.png

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

  2. #2
    Senior Member arbolmano's Avatar
    Join Date
    Feb 2012
    Location
    Arroyo Grande, Ca
    Posts
    784
    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.
    Tonto
    on the "Left Coast"
    2015 BMW F700GS
    2005 V Star 1100
    lost count on TWs, 3?
    More Wagging and less Barking
    Make Love not War

  3. #3
    Senior Member SHAG's Avatar
    Join Date
    Oct 2013
    Location
    Bradford, Pa
    Posts
    985
    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
    2018 X-MAX - 6k- miles

  4. Remove Advertisements
    TW200Forum.com
    Advertisements
     

  5. #4
    Senior Member Ruri's Avatar
    Join Date
    Jun 2016
    Posts
    118
    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.
    -Ruri

  6. #5
    Senior Member kj7687's Avatar
    Join Date
    Jul 2010
    Location
    Southern California - Inland Empire
    Posts
    2,422
    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
    Join Date
    Jun 2016
    Posts
    118
    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.
    -Ruri

Sponosred Links

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  

Similar Threads

  1. WTB Crankcase/Stator cover, left side
    By Scott K Miller in forum TW200 Classifieds
    Replies: 9
    Last Post: 09-01-2015, 08:13 AM
  2. Looking For Right Side Crankcase Cover
    By Haustorium in forum TW200 Classifieds
    Replies: 17
    Last Post: 08-10-2015, 01:00 AM
  3. WTB left side crankcase/stator cover 1996
    By Ben in forum TW200 Classifieds
    Replies: 6
    Last Post: 08-21-2014, 07:28 PM
  4. Crankcase cover removal
    By kgriff in forum Technical Help
    Replies: 3
    Last Post: 07-10-2012, 08:53 AM
  5. wtb crankcase cover
    By jughead919 in forum TW200 Classifieds
    Replies: 1
    Last Post: 09-06-2010, 10:29 PM