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Makotosun

69 dt1 250 clutch not engaging

  • gusto
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Replied by gusto on topic 69 dt1 250 clutch not engaging

thx i realize the bearing is two parts a washer and bearing listed as one in diagram. so think its right. i did have it slip off the spacer before maybe it did it again. im gonna have to check.

im working on a xs650 clutch too but thank god its doing ok. they are a little different in where the bearing goes.

the mx250 clutch looks like a dt1 250 one in washer sequence
08 Aug 2026 15:43 #11

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Replied by gusto on topic 69 dt1 250 clutch not engaging

imgur.com/a/qnoGyLa
got clutch to work right after removing this gear to the left of clutch that tied into basket gear. for some reason the gear seems a little wobbly like it needs a different washer or extra washer on back to help clear the race bearing. anyone know what washer goes behind this or if theres three washers total? thx
09 Aug 2026 13:41 #12

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Replied by gusto on topic 69 dt1 250 clutch not engaging

got a kick diagram finnaly. looks like gear is 29 and im missing a 28 washer.  it s wave washer 2 dollars plus shipping n tax.  
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Last edit: 09 Aug 2026 18:11 by gusto. Reason: miss typed number
09 Aug 2026 13:53 #13

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Replied by RT325 on topic 69 dt1 250 clutch not engaging

Those gears do get floppy & wear as they sit on the shaft but missing a washer or not isn't going to affect the clutch operation. Unless i'm missing the point of what you're saying sorry.
09 Aug 2026 18:33 #14

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Replied by gusto on topic 69 dt1 250 clutch not engaging

yeah your right it wasnt the washer. i must of just put the bearing in right when i had the idle gear off. i had a time with it again but finally got it working. it would bind when i would crank the nut tight. now im waiting on a friend to weld a clutch tool since i couldnt find one online for the 250. i got some clutch plyers but afraid a tool might be better as i dont wanta damage the clutch boss when i torque her. its a celebration now i got it right!
oh yeah i put a idle gear in that has a bunch of cut out holes because that was in the manual.  do yall think the solid gear is better?  i feel like ones lighter but will the hole one take in gunk and be unbalanced?  or will it break easier?  i feel like i didnt need to change this but i did.
Last edit: 21 Aug 2026 23:26 by gusto.
21 Aug 2026 23:20 #15

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Replied by RT325 on topic 69 dt1 250 clutch not engaging

The one with holes might be from a YZ from a similar year to your bike. Just yamaha's way of saving weight any way they can. If it fits & has the same teeth count it'll do the same job. Your choice but nothing to gain on a trail bike.
22 Aug 2026 03:11 #16

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