XT225 clutch in a TW200
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Thread: XT225 clutch in a TW200

  1. #1
    Junior Member GoNOW's Avatar
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    Hello to the forum.



    My daily driver/beater 1989 TW200 clutch basket, and most other clutch parts, have seen the end of their life span.

    So after reading this topic, https://tw200forum.com/forums/95390/ShowPost.aspx ,I got a lightly used 1994 XT225 clutch assembly off ebay.

    It's far cheaper then what the dealer wants just for a TW200 clutch basket, and the extra disk sure could not hurt.



    But I ran into a problem. The XT225 clutch boss won't fit up. The "main axle" on my TW200 has a different number of splines then on the XT225. So I can't fit the XT225 clutch boss on my TW200 as the XT225 has a more splines on it then the TW200.



    Anyone know a year/make of clutch boss that will fit?



    I got my old TW200 clutch boss to work with the XT225 basket and 6 disc with the help of some spacers, but I would like to get a proper fitting clutch boss since I need to replace it anyway.



    Thanks for any help.

  2. #2
    Senior Member christddel's Avatar
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    Bonjour,

    Sorry for my translation

    You must place the parts, with 6 teeth ... this Parts



    We must also change the crankcase clutch ...For the clutch mechanism is Big larger...



    The adjusting screw of the clutch is replaced, it is longer ...







    Attention to the transmission ratio (number of teeth)


  3. #3
    Junior Member GoNOW's Avatar
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    Thank you for the information. Looks like the 87 TT225 clutch boss is the one I need.



    The '94 XT225 push rod didn't fit into the main drive shaft. The diameter of the push rod is too big. I had to machine it down a little bit.



    Are you talking about changing the clutch cover? My XT225 clutch fit in fine with the stock TW200 side cover.



    Strange how the gear ratio is different, but everything fit fine.



    Thank you

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  5. #4
    Senior Member christddel's Avatar
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    The crankcase clutch can be placed.

    But when you disengage the clutch with the lever, it moves to 1.5 mm and hangs in the crankcase clutch ...



    So it breaks ...I have experienced is my


  6. #5
    Junior Member GoNOW's Avatar
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    My homemade boss spacers on the tw200 boss don't stick out that far, so it seems to have cleared, but I am sure it's going to be a problem with the TT225 boss. Thanks for the heads up.

  7. #6
    Senior Member christddel's Avatar
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    Just for information

    Adjusting screw:

    TW/XT 125: (4 Disc) 5HO-1635601

    TW/XT 125/200: (5 Disc) 2JX-1635600

    XT/TT 225: (6 Disc) 1HX-1635600

    TTR/XT 225: (6 Disc) 4JG-1635600 or 3Y1-1635601




  8. #7
    Banned qwerty's Avatar
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    It's been a long time since I stuck a XT225 clutch in tdub, but I had the entire 225 engine to scavenge from. Sorry, but I simply don't remember which parts I used from which engine, but with some careful selection, everything fit and works fine. Considering the Barnett plates and springs I used, I expect the clutch is pretty much bulletproof. 32,000 miles on it so far, and other than a bit of dragging until the engine warms up, I've nothing to complain about.




  9. #8
    Junior Member GoNOW's Avatar
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    I bought the longer XT225 push rod, part 4JG-16356-00-00. It didn't fit. The diameter of the push rod is too big and it does not look like the one in christddel's photos. I had to spin it down in a lath just a bit to make it fit inside the transmission main shaft



    The strange thing is, the TW200 clutch boss (clutch inner), works just fine with the 6 disc. Maybe my friction plates are warn, I didn't measure, but they looked fine. I will check when I change out the boss to the TTR225 one.

    The TW200 boss is a bit too short on the post where the screws seat in (because it's shorter then the correct 225 one). Once you got the springs and screws tighten down, it's too tight and the clutch is clamped down.

    I used 2 e-clips on each screw to space them out a little and it works great. It does not hit the clutch cover too.



    So, an early count on the minimum parts you need for a 6 disk conversion are.



    225 clutch basket

    225 clutch springs (they are longer then my tw200 once, but the tw200 ones may still work fine. )

    200 or 225 extra disc, friction and metal.

    Push rod. Maybe one from an older TT225.

    8 e-clips for spacers



    Still wondering how I got 6 disc on the TW200 boss. I will know in a week when the TT parts come in and I rip it apart again.



    As far as I know, this 1989 TW200 was on it's original clutch friction disks (with 20k on the odo). So many people have learned to use a clutch on this bike, the basket and boss are shot.

  10. #9
    Banned qwerty's Avatar
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    I've been trying to piece together what fits where. Seems with so many slightly different clutches from so many different models built over such a period of years there are probably a number of different options. Sadly, not all parts from all models are compatible. Many clutch mechanism parts are superceded by modified vesions in later models, and backwards compatibility is not always assured. It seems like every combination of donor and recipient is a fresh trial-and-error project--what works for one doesn't work for another. I expect their are market differences, too, and we are just beginning to run into those problems.




  11. #10
    Senior Member christddel's Avatar
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    Quote Originally Posted by qwerty View Post
    I've been trying to piece together what fits where. Seems with so many slightly different clutches from so many different models built over such a period of years there are probably a number of different options.

    I expect their are market differences, too, and we are just beginning to run into those problems.


    Yes, it's just the problem of choice ..!









    For info: "6 disc on TW200 clutch... Hot


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