Question about 2005 Yamaha TW 200

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2008 Yamaha TW 200 clutch will not engage

The bike starts and runs ok but when I put it in gear and release the clutch nothing happens as if still in neutral.There is a slight click from the transmission when I put it in first gear as if it is engaging but nothing after that.Tried the clutch adjustment as per the owners manuel but did not help.I do not hear any abnormal noises, what am I up against here.

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  • Anonymous May 07, 2009

    Sounds like my issue Im fixing right now. I pulled off the right side engine cover to find the clutch was completely burnt and disintegrating. Appears the bike was running low on oil. Thats my fault for not checking after purchase.. Anyway, that would be a good place to start looking.

  • tombones May 11, 2010

    What kind of oil is in the gearbox? Is it 10w40 motor oil or motor oil with "special" additives or a synthetic oil? Ask the prior owner if need be. Chances are the clutch is burned up due to lack of oil or the wrong oil was used causing the clutch to slip big time.

  • tombones May 11, 2010

    Give us some more background. It is a 2008 right? Anyone ever been inside the gearbox? Hit any tree stumps or large rocks lately? Prior to the clutch problem, was the bike shifting okay?

  • Dick
    Dick May 11, 2010

    Does this happen in every gear? When the bike is off and you shift into gear can you push the bike with the clutch out? If so you may have a broken output shaft from the motor. I'd call that extremely rare but possible.

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  • Yamaha Master
  • 40,028 Answers

Hi, Tony225 for this scenario you will need your service/owners manual if you can't find the best tool you ever bought for your Yamaha, despair not, for a mere zero $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
Yamaha TW200 Trailway Discussion Forum
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YAMAHA TW200E Owner Manual

Posted on Jun 12, 2017

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Posted on Jan 02, 2017

  • 3567 Answers

SOURCE: 2008 Yamaha TW200 will not move when clutch released

Here are the possibilities > > Bent clutch push rod, missing push rod ball bearing or push rod, worn out actuator shaft cam, Missing friction disk (5), or pressure plate (4), totally worn out friction disks, clutch plates not installed in the correct sequence, extremely weak clutch springs, stripped teeth on the clutch hub, wrong clutch cable length (inner cable vs outer cable), broken shaft, bent then broken shift fork stems, broken slider gear dogs and a missing shift fork pin.

You didn't say if anyone had worked on the clutch or gearbox so I am throwing in nearly EVERYTHING possible that could create the problem. A little more background and most of the above can be ruled out. Get back to us.

Posted on Apr 22, 2009

  • 1 Answer

SOURCE: Remove seat and battery Yamaha tw-200

There are two seat bolts under the seat that must be removed. Obviously, if the underside of the fender is covered in mud, you'll have to clean it first. A metric socket works best to remove the bolts.

After removal of the seat bolts, lift the back of the seat, then pull straight back; a plastic flange on the front of the seat hooks under the tank, and so you have to pull it backwards to remove it.

With the seat off, removing the battery is pretty easy. A rubber strap holds the battery down; unhook and remove it. Unscrew the lead wires and unhook them (negative first), then pull the battery out.

Install a replacement battery by reversing these steps. Yamaha recommends charging a new battery before installing it.

Posted on May 27, 2009

  • 11 Answers

SOURCE: yamaha tw 125

The noise you hear is valve clatter. You should not adjust your timing chain. Instead get a manual and find the vlave clearances for that bike. (Ex. The exaughst valve may be .006" and the intake valve may be .004") Then you'll need a feeler gauge, and to do this you'll remove the valve covers and get the engine to TDC (Top Dead Center) This is where the piston is at the very top of it's stroke and both valves are shut. (compression stroke) You must then loosen the rocker arm nut to the point that you can insert the feeler gauge between the rocker arm and the top of the valve run the nut down tight to the feeler gauge and then pull gauge out and repeat on the other valve.

Posted on Aug 24, 2009

co7196
  • 3433 Answers

SOURCE: remove clutch pack on yamaha tw-200

Remove the side cover that the is hiding behind. The pessure plate is like a car, held on by bolts on its perimeter. Remove the pressure plate and the disc can be remove. Remember the first dis is fiber, the next is metal and on and on. You should end with a fiber against the flywheel. Note how the notches on the tangs are arranged. facing out or facing in, aligned or staggared. Soake the fiber disd in motor cycle motor oil for an hour before assembly. If there is an alen screw with a lock nut in the center of the pressure plat, that is a pusrod and will need adjusting after assembly and before the side cover is put on. If so, let me know. Good LKuck,Ned

Posted on Nov 12, 2009

  • 6 Answers

SOURCE: Yamaha TW 200 cuts out at high rpm

I have a tw200 and when I have this problem its from the cam chain slipping back a notch when I unload it from my truck. I leave it in gear so when I let off the cluch it acts as a brake. I ride by my self so thats why I load it that way. I am guessing you load and unload your tw the same way. So remove the timing cover and make sure you are tdc on both the upper and lower timing marks. The bike will run if the timming is off a bit. It's really easy to set the timing on these bikes. It's easier to look for how to on the xt 200 if you need more help.

Posted on Jan 07, 2010

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its time to change your clutch kit, here's the best one for your TW200
http://www.starcycle-usa.com/servlet/Detail?no=12114

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