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DT2 Clutch Release

  • phrog44
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DT2 Clutch Release was created by phrog44

I am making slow progress restoring my one owner 1972 DT2.  I am now finding that I can't get the clutch to disengage.  I have made all the adjustment I can, with no help.  The clutch release pulls very hard but never enough to release the clutch.  I have not pulled the clutch apart yet.  I would assume that worn pressure plates or springs would present the opposite result, letting the clutch slip.  What do i check next?
05 Nov 2022 08:32 #1

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  • Ht1kid
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Replied by Ht1kid on topic DT2 Clutch Release

Have you had your engine apart? If not your clutch plates may be stuck you can pull your clutch lever towards the handlebar and zip tie it for a few hours and put your bike in gear and rock your bike back and forward to free the plates
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05 Nov 2022 09:26 #2

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Replied by Tom P on topic DT2 Clutch Release

Yep, the plates are stuck. Use the method suggested by HT1Kid. I used a less intelligent method and probably wrecked my friction plates, which I later replaced because they were slipping badly afterwards.
05 Nov 2022 09:40 #3

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Replied by MarkT on topic DT2 Clutch Release

Sounds like worm gear in left case might be stuck/damaged/stripped.
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
05 Nov 2022 10:10 #4

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Replied by AirborneSilva on topic DT2 Clutch Release

Like Mark said it could be your worm gear, if it looks like the picture below it needs to be replaced.  You can get a replacement from KDI, they make a brass piece that works very well.

 
2023 Tenere T7
1976 DT400C
1975 DT400
1981 DT175H
1972 DT2 250
1980 GT80
1972 JT2
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05 Nov 2022 14:42 #5

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  • phrog44
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Replied by phrog44 on topic DT2 Clutch Release

Thanks for reply.  I will definitely try that and post the results.
15 Nov 2022 06:05 #6

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Replied by phrog44 on topic DT2 Clutch Release

The worm gear looks okay but, I may replace it anyway.  Brass seems like it may work better.  It has never worked well.  Meanwhile, I will try HT1kid's suggestion.
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15 Nov 2022 06:12 #7

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Replied by adguy2112 on topic DT2 Clutch Release

Not that this is the issue but I replaced the clutch cable on my DT1 and the difference was incredible. 
Last edit: 15 Nov 2022 08:21 by adguy2112.
15 Nov 2022 08:05 #8

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Replied by phrog44 on topic DT2 Clutch Release

No luck so far.  Would it help to partially disassemble the clutch, such as removing the pressure plate, the clutch boss, etc.?
15 Nov 2022 13:01 #9

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Replied by phrog44 on topic DT2 Clutch Release

You're right that the cable is not the cause in this case but, being that it is 50 years old, a new one would probably make it work smoother once I get it working.
15 Nov 2022 13:05 #10

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