Clutch no longer works

[juntunen]

Hello, my clutch wire recently snapped and in the process the lever on the engine block that controlls the clutch and the other end of the clutch wire goes into. Well this lever no longer works it just moves freely with no resistance. A friend of mine told me to lift it up and reposition it to get the clutch working again but after an hour of trying i just dont get it. Ive also tried to practise on a spare engine block thats open so i can see what im doing better but no luck.
I have a yamaha dt125x 2006
Thank you in advance and sorry for weak english its my second language

[Calum]

Hello there,

There isn't much too the clutch arm. Basically the clutch arm has a cam on it and a rod with a ball a bearing followed by another rod.

When you pull the lever, it actuates the cam which pushes the rods to overcome the clutch springs which is holding the clutch plates down.

Based on that description, assuming nothing else has changed, either you haven't adjusted the clutch cable enough, or the fact you've pulled the cam out may have caused the push rod to take it's gap, meaning the cam is no longer engaging the rod.

I am not sure if that's even possible, I have always put the rods in before the clutch arm and I've never had an issue. So it's probably that you haven't adjusted the clutch cable properly.

[juntunen]

@Calum thanks for responding, i removed the clutch wire and tried to use the lever with my hands but no matter the position of the lever it doesnt engage the clutch so i dont think its the wire

[Calum]

https://www.fowlersparts.co.uk/main/img/assemblies/large/a657ca561064c1db3436c5e554187dac.png

As you can see, it's incredibly simple design, so it'll be something easy.

[juntunen]

@Calum do you think i need to open the engine all the way to fix it?

[Calum]

No you don't need to open up the engine all the way. It's just a push rod system, if the clutch cam isn't engaging with the push rod then it might be because the push rod has fallen beneath the cam arm so you're not able to position the cam behind the push rod.

I've never had this happen to me personally, I don't recall this being an issue, but the design is very simple so there is very little to go wrong.

What commonly happens is that the ball bearing inside the engine can get misplaced, which presents itself in a similar manner as you're describing. But this is not possible without dismantling the engine.

In essence what you have can be pictured as below:
|_._

The | is the cam that you slot from the top of the engine.

When the cable is pulled, it twists the cam which acts on the first pushrod denoted here by _. This is space separated with a ball bearing, denoted by . which pushes a further push rod denoted by _.

What might be possible is that you've ended up in situation where you've pulled the cam out and now the setup is like:
|
_._

The cam is now resting on top of the push rod and is no longer engaged with it. So when you pull the lever, nothing happens.

I can't remember whether this is even possible, but if it is then you'll notice the cam is sitting a lot higher outside the engine and would be obvious. I am not sure if the pushrods are under load, but if they're not, then leaning the bike over towards the clutch may cause the rods/ball to move allowing the cam to be lowered appropriately.

If that doesn't work, then no it's not a full dismantlement. It's just a case of taking the clutch cover off, and taking the clutch pressure plate off to expose the push rods. Extracting them (by leaning the bike over careful not to misplace the ball bearing) and then inserting the cam in first.

BUT I REALLY don't think that's what is happening here. It's probably more likely that the clutch just needs adjusting. I'd recommend referring to the Haynes manual for this.