Cycle News is a weekly magazine that covers all aspects of motorcycling including Supercross, Motocross and MotoGP as well as new motorcycles
Issue link: https://magazine.cyclenews.com/i/125699
N N " '" :. o .... '" ~ By Rod Breaker ~ W Z ~ DISASSEMBLING ~ YAMAHA DT-1 CLUTCH THE u With as many DT-l 's in service as there are, both on and off the roads, the failure of clutches has been neglible, but there is always someone who will abuse the clutch and thus the basis behind this article. The particular machine in fact was not dismantled because of clutch problems, but the rider had taken a hard spill on the gearshift lever and in jamming the lever into the dirt, he had caused the shifting apparatus to jump out of place by dislodging the ratchet dog spring. Although I have only dismantled to the clutch in these photos, all that is left' to work on the shift mechanism is to pull off the clutch hub. Clu tch work on the DT-1 is abou t the same as any other machine, but before you start, you should first purchase a new clutch cover gasket and any parts that you think you will need. 2) The clutch cover need not be disconnected from the cables or the oil lines, but the oil line banjo on the cylinder must be removed or it will be ruptured when pulling .way the cover. If it is necessary to remove the cover from the machine, remove the two screw (arrows) holding the oil pump cover end unhook the oil pump cable and the oil feed line from the oil tank and plug it off with one of the screws. 4) Remove the eight Phillips-head screws securing the clutch cover (arrow). Back off the rear brake adjustment until the brake lever can be pushed down out of the way of the cover and prop it there with something placed under the footpeg. Now the cover, complete with the oil pump, can be easily removed. If it is a little subborn, tap it lightly with a plastic mollet. 5) Remove the six 1) Use 17mm wrench to remove center plug beneath engine and drain the oil. Do not remove the plug with the screwdriver slot as this holds the shifter detent, Thoroughly draining the oil before removing the chainesse cover will make for a neater working area, (this is very important it you are working on the machine in the kitchen or your bedroom); PDflJj( ~}l -00---.... SACHS ..:.~ All models in stock II ~ Cecil's Cycle Center 640 S. Escondido BlVd.• Escondido (714) 745-1615 screws (arrows' holding the clutch pressure The kickstarter arm must be removed before the cover can be t8k'en off. Remove the pinch bolt and pull from the shaft, Directly beneath the kickstarter shaft is the extention fOr the shifter shaft that was designed to be used with a right-hand shift. This has a rubber plug that must be removed at this time. 3) JUST L1IE A MOTOCROSS OAI CREEl RANCH plate and take off the pressure plate and the clutch push piece directly beneath it, These screws should be removed by unscrewing each one a coup'e of turns at a time. I t is also 8 good idea to reach inside of the clutch shaft and fish out the 5/16 in, steel ball with a magnet. If this is left inside. it could possibly fall out and become lost if the machine is leaned on its side. • 6) The plates can n\llN be fished out individually with 8 small piece of wire with 8 hook bent into the end. If further removal i. necessary, use a 29mm (or 1·1/8 inch) socket on the center nut. If difficulty arises in removing this nut, engage 1st gear and apply the rear brake to hold the shaft while the nut is being broken loose. 7) If the entire clutch has been removed, great care must be taken when reassembling that this washer has not slipped down off the shaft area, as this will mean dissassembling it again. That is all there is to it. To reassemble, just follow these pictures in the reverse order. (213) 894-9218 WARREN WILSON MOTORS South 01 -';ordolf in MOfQIICYCLI Illlll-IIIVICI S"PUhNI~, ('alir. 9000 SEPULVEDA BLVD. Torsten Hallman Racing, Inc, Wesl Coast DIs!. for PENTON Motorcycles Torsl.n H.llman Spl~I.1 deslen 1I.II.fS & raclae Iqulpmtnl u.s. DIsI, for TrllI.bore Molo.cross Ilr•• For dI.ler Info. wfllt or c.1I 5345 nmktn 51., La Mlsa, C.1. 92041 (114) 461-1402 ~ i'}hCCI..... ~~ (imichrome ~hlneS Suddenly fL', ":". Slmlchrome is • h_y 1"/ I Jo" quICk IS. bunny OMPETlTlQN Tub. 51 CHEMICALS C.n 53.45 , '713 EsI•• SIIIII 'low. F.lls;lowa 50126 .".,,4 '.S.',.C. 51'S / "He, Mr. De'aler'" We carryall types of insurance coverage - garage liability fire - theft & dealer bonds S." Up To 251 JOHN I. MAYNARD INS. 3441 Motor Ave., L.A., Ca. (211) 83&-5211 YAMAHA ~ fONTANA Yamaha-Sach's- 9008 Sierra Ave. Hodaka-Maico- Fontana, Ca'lif, CZ Sales(714) 822·2252 Parts ~ Service Motocross Engineers are exclusive U.s. Importer for Arthur Browning English Racing Lealhers. Most flexible, abrasive resislanl chrome tanned hide. Weigh I of garment is I 3/4 pounds. Fully lined with red Nylon, elastic crolch and reinforced fly seam. Velcro leg fasteners (no more zipper pinches). Color is black with yellow/red, yellow/blue or yellow/green side strips. Sizes: 32", 34", 36" waisl. Price S67.00.See your dealer or contacl: Arthur Browning english Racing Leathers MOTOCROSS ENGINEERSOST OFFICE BOX 261 NORTH WILBRAHAM