TW Clutch Renewal Advice Wanted
Close
    
    
Results 1 to 9 of 9
Like Tree36Likes
  • 4 Post By rogerww
  • 6 Post By socalnative
  • 8 Post By TW-Brian
  • 10 Post By elime
  • 3 Post By rogerww
  • 2 Post By Ken
  • 1 Post By Gastone165
  • 1 Post By TW-Brian
  • 1 Post By Purple

Thread: TW Clutch Renewal Advice Wanted

  1. #1
    Junior Member rogerww's Avatar
    Join Date
    Oct 2012
    Location
    Blairsville GA
    Posts
    18

    TW Clutch Renewal Advice Wanted

    RE: 2004 TW200, 6k miles. The clutch is a typical crappy one, grabby, or usable friction-zone and then it ‘engages itself,’ albeit slowly, without easing the lever out further. I assume a new clutch or clutch assembly, particularly an improved aftermarket such, would provide a better clutch, and smoother friction-zone modulation.

    What do I need to buy in order to do a clutch job properly? What land mines are lurking inside the cases?

    Thanx!

  2. #2
    Senior Member socalnative's Avatar
    Join Date
    Nov 2016
    Location
    So. California, inland empire
    Posts
    309
    From my riding experience, with various mileage TWs, and from some research on the clutch "abruptness" and very short engage/disengage point, I don't think a new or aftermarket clutch will change the grabbiness that much.

    I haven't read anything that indicates a much smoother or better feeling clutch in general happens with new or aftermarket clutch kits.

    But the good new is that internal clutch mechanism is very much like most dirt bikes I've seen.
    Metal and fibre clutch plates, metal clutch basket, springs for tension, throw-out rod in center. There are smaller covers which are a little easier to deal with. You can do it without draining the oil but I always suggest you do it while changing the oil anyways.

    If it's not slipping in 4th or 5th I wouldn't worry about it.
    Make sure the return spring is in the right spot and adjust the cable free-play to get the release point where you want on the lever and just use it.

  3. #3
    Senior Member TW-Brian's Avatar
    Join Date
    Dec 2010
    Location
    Pleasanton, CA
    Posts
    5,670
    It is not difficult to replace the clutch in a TW. What you will need is a new gasket for right side (clutch side) cover. You might also want to order a new lockwasher for the clutch basket. The original lockwasher has two locking ears, so you may not need the new one, but it is a good idea to have it in case you need remove the clutch for a second time.

    It is not even necessary to drain your oil if you just want to lay your bike over on its left side.

    Unless you are extremely lucky and the old gasket comes off cleanly, the most tedious and time consuming part of this job will likely be removing the old gasket which will likely be stuck to the side cover and/or the crankcase.

    It is best to use a proper tool to remove the clutch basket and not just use a screwdriver and jam it between the narrow posts on the basket. These are easily broken and costly to replace. I do not have personal experience with aftermarket replacement clutches, but I have read good reviews about Barnett clutches. You may also want to consider replacing the stock springs with heavy duty springs.

    If you PM me your email address, I will send you some instructions that I prepared for removing a TW kickstarter which requires the removal of the clutch. These instructions also include several tips to ease reassembly.

    Here are examples of several tools for removing the clutch basket.

    This is a universal type of tool that will work for many different bikes.
    100_2822.JPG

    This is one that is specifically made for the TW.
    IMG_1493.jpg

  4. Remove Advertisements
    TW200Forum.com
    Advertisements
     

  5. #4
    Senior Member elime's Avatar
    Join Date
    Jul 2010
    Location
    San Jose, CA
    Posts
    6,955
    Make sure center bolt is adjust correctly. Red arrow.

    P9260023 (2)a.jpgclutcha.jpgP8090023b.jpg

    After market springs help. The short one is stock, the longer is aftermarket:

    PA260151.JPGP2210826a.jpg

    Barnett Kevlar clutches are very good but cost about twice as much as a stock one. This guy accepted my offer of $70 so don't pay the asking price if you go this way. The kit includes new springs.

    YAMAHA BARNETT CLUTCH KIT TW200 TW 200 1978 - 2015 | eBay

    Use a torque wrench and don't over tighten the bolts or you will break the clutch basket.
    Long live the internal combustion engine!

  6. #5
    Junior Member rogerww's Avatar
    Join Date
    Oct 2012
    Location
    Blairsville GA
    Posts
    18
    Thanx, one and awl!
    JerseyJeeper, Ken and littletommy like this.

  7. #6
    Ken
    Ken is offline
    Senior Member Ken's Avatar
    Join Date
    Aug 2016
    Location
    Houston, Texas
    Posts
    1,900
    I went ahead and ordered a set. Mine have 42000 miles on them. If these don't do better I'll go back to stock, they lasted since 1993. Thanks

  8. #7
    Senior Member Gastone165's Avatar
    Join Date
    Dec 2017
    Location
    Western Washington
    Posts
    208
    Quick question. I don’t have a service manual so I’m inquiring what the torque is for the main nut on the clutch basket. I just installed a Kickstarter on my 2002. The assembly went well. I had to make a tool to hold the clutch but it was simple and worked well. I just used a scrap piece of aluminum. All the Kickstarter parts have gone in fairly easy. Just got to torque it and button it up.
    littletommy likes this.
    1972 Yamaha DT 175, 1974 Kawasaki 125, 1976 Suzuki TM 250, 1979 Yamaha 750, 1977 Husquvarna 360, 1979 Husquvarna 250, (2) 1980 Suzuki RM 400’s, 1971 Husquvarna 400, 1983 Honda V65 Magna, 1987 Suzuki 230 Quad, 1987 TW200, 1990 TW200, 1996 Honda XR 650, 1998 Yamaha 300 King Quad, 2000 Harley Davidson Heritage, 2006 Kawasaki KLX 250s, 2007 Arctic Cat 650 Quad, 2010 Polaris Sportsman 850 Quad, 2006 Yamaha Grizzly 660 Quad, 2002 TW200, 1995 TW200, 2008 TW200, 2016 TW200.

  9. #8
    Senior Member TW-Brian's Avatar
    Join Date
    Dec 2010
    Location
    Pleasanton, CA
    Posts
    5,670
    Quote Originally Posted by Gastone165 View Post
    Quick question. I don’t have a service manual so I’m inquiring what the torque is for the main nut on the clutch basket. I just installed a Kickstarter on my 2002. The assembly went well. I had to make a tool to hold the clutch but it was simple and worked well. I just used a scrap piece of aluminum. All the Kickstarter parts have gone in fairly easy. Just got to torque it and button it up.
    Pretty fancy clutch holding tool!

    I never use a torque wrench so I can't help you with a value, I just just torque it to a medium grunt with a shorter handled wrench than the one shown in your picture. It is not going to come loose once you bend up the locking tab to secure it in place.

  10. #9
    Super Moderator Purple's Avatar
    Join Date
    Mar 2015
    Location
    Ynys Môn
    Posts
    4,547
    littletommy likes this.
    (Warning - Forum may contain nuts) ...... Hidden Content

    TW200 - 1998 - Japanese import - 7000 miles on the clock - TW225 Special Edition 2007
    - Hidden Content

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. GPS, Headlight, general advice wanted
    By Zoart in forum Technical Help
    Replies: 13
    Last Post: 11-29-2014, 10:02 PM
  2. Clutch Switch WANTED
    By 50short in forum TW200 Classifieds
    Replies: 1
    Last Post: 04-23-2014, 07:19 AM
  3. Wanted: TW200 Clutch Basket
    By mrbracket in forum TW200 Classifieds
    Replies: 6
    Last Post: 01-19-2013, 06:27 PM
  4. Need advice on clutch behavior!
    By Gator in forum Technical Help
    Replies: 12
    Last Post: 09-06-2012, 04:34 PM
  5. Carb Soaking Advice Wanted
    By lorddaftbiker in forum Technical Help
    Replies: 2
    Last Post: 06-23-2011, 11:18 AM