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Discussion Starter #1
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, http://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.
 

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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)

 

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Discussion Starter #3
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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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


 

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Discussion Starter #5
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.
 

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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



 

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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.
 

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Discussion Starter #8
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.
 

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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.
 

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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.

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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Discussion Starter #11
Excellent photos. Thank you for posting them.



It does look like you can get 6 disc on the TW200 boss. Sure the friction disk hangs out a bit, but it's not touching the boss anyway. As long as the steel disk does not slip out, it looks close but I don't see it moving 2mm, then it should be fine.
 

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Excellent photos. Thank you for posting them.



It does look like you can get 6 disc on the TW200 boss. Sure the friction disk hangs out a bit, but it's not touching the boss anyway. As long as the steel disk does not slip out, it looks close but I don't see it moving 2mm, then it should be fine.


1,75 mm Exactly...With same that trip clutch lever

Vidéo / mesure...



Sorry, sorry, for my translation, I'm better in picture
 

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Hey guys I have a TW200 and I really like it. My house borders the apalachicola national forest so I ride sand trails just to get to my house. Also I know of woods roads that are short-cuts for me to go up town. I love my TW but the only problem is when I get it out on the street, mini-vans pass me and going on the interstate would be out of the question. The power and suspension travel is a little lacking on the TW...

So my question is:

Is the WR good on the road like I could ride it over to my brothers house 2hrs away on the interstate? But also good enough to ride sand trails around my house with plenty of power all around and hit bumps and jumps all the good stuff?

I'm 5'10" and 145lbs.
 

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Discussion Starter #15
You should.



A. Start a new thread instead of posting in one about a clutch.

B. Ask that question in a forum relating to WRs.





Hey guys I have a TW200 and I really like it. My house borders the apalachicola national forest so I ride sand trails just to get to my house. Also I know of woods roads that are short-cuts for me to go up town. I love my TW but the only problem is when I get it out on the street, mini-vans pass me and going on the interstate would be out of the question. The power and suspension travel is a little lacking on the TW...

So my question is:

Is the WR good on the road like I could ride it over to my brothers house 2hrs away on the interstate? But also good enough to ride sand trails around my house with plenty of power all around and hit bumps and jumps all the good stuff?

I'm 5'10" and 145lbs.
 

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Discussion Starter #16
I just installed the TT225 clutch boss and side cover. Everything fit up just fine. The TT side cover has the oil fill hole in a much better position then the TW one.



I took some measurements.

My clutch friction disk are 3mm. With them installed on the TW200 boss, I have 2.55mm between the last metal plate and the end of the TW boss.

Assuming if I had new friction disk of 3.1mm, that would give 1.95mm between the end of the boss and the last metal plate.



Now christddel, took some great measurements. Assuming he showed full travel, that puts puts us at 1.75mm of possible travel.



That gives us 0.2mm of spare room, worse case. The friction disk is approx 1mm (I forgot to measure), so the things would have to move an additional 1.2mm before a steel plate would pass the boss and fall out.



So, with the addition of a XT/TTR225 clutch basket, and some spacers under the springs, you can run 6 friction disk in a tw200 without changing the boss or side cover, or having a steel friction plate float out. I put 200 miles on my TW with it like that, and if I didn't get the TT boss for cheaper then a new TW boss, I would have keep running it like that.
 

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Hi at all,



I've checked some details too.



The clutch boss:

2JX-16371-00-00 (TW125 2002-2004, TW200 1987-2011)

36X-16371-00-00 (TW125 1999-2001, BW200 1985-1988)

5H0-16371-01-00 (SR185 1981-1982, XT125 1982-1983, XT200 1982-1983)

All of these parts are nearly exactly the same parts. All 3 parts are made for a 4 or 5 disk clutch, because the hight is the same.



The pressure plate:

5H0-16351-00-00

5N0-16351-00-00

The pressure plate makes the difference between a 4 and a 5 disk clutch.

5N0 is for 4 disks

5H0 is for 5 disks, but this pressure plate will be also used on the 6 disk clutch.



The problem:

To find a clutch boss, witch fits on the original transmisson axle.

The plate between the clutch boss and the bearing from the axle does have the partnumber 5H0-16154-00-00.

All of these bikes are using this plate:

TW125, TW200, BW200, SR185, XT125, XT200 ....

And also the TT225 1986-1987!!!!!!

AND THE TT225 DOES HAVE A 6 DISK CLUTCH!!!!

The partnumber from this clutch boss is 1KH-16371-00-00.

-> The only problem, this part isn't available from Yamaha as new part.





And now to find a fitting outer clutch basket isn't a problem.

Partnumer:

1KH-16150-00-00 (TT225 1986-1987, XT225 1992-2007, TTR225 1999-2004, TTR230 2005-2011)





-> I will write later a bit more.
 

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So, the next infos.



If you use the clutch basket 1KH-16150-00-00, than you don't have to use a different primery drive gear, because the TT225 and the TW200 are using the same one: 5H0-16111-00-00





So, here is the list, with the parts which you need for a 6 disk clutch:

1KH-16371-00-00 - clutch boss from TT225 1986-1987

1KH-16150-00-00 - outer clutch basket (TT225 1986-1987, XT225 1992-2007, TTR225 1999-2004, TTR230 2005-2011)



You don't need more parts.

But keep in mind, the TTR225 parts are not available anymore from Yamaha. You only can get it as used part.



Best Regards, Sebastian
 

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Sebastian,
Do you need a differant longer clutch rod or can the tw200' one be used with the 1987 TT225 boss and basket?
To confirm if you had 1986/87 TT225 clutch boss, basket and plate they would fit right in? (No side cover or rod needed)
Thanks,
 
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