littlebriar

Yeah, it looks like it's got an aftermarket lever. That must be the problem. I don't have the stock lever as I bought it the way it is now. Looks like I'll have to buy some more parts. I looks like I'm going to need about another 1/4" of adjustment. Thanks for the reply.

I just put a new clutch in my shee and am having problems adjusting it. When I align the arrows on the lever as instructed, there is way too much play on the cable and I can't take up the slack. I installed a new cable and had the same problem so it's not a stretched cable. What am I doing wrong?

OK, sounds like the hole is not a problem. I couldn't get a close up picture good enough to send. The metal piece is about 1/2" long and appears to have gotten tangled up in the gears. It's mangled pretty bad. Definitely not shavings from clutch wear. I think he must have left a washer behind on the last repair. Thanks for the help guys. I'm going to give it one last look over and then put it back together.

I'm new to the forum so if this has already been covered, forgive me. I did a search but didn't come up with anything. I'm looking for a good (inexpensive) source for a stock or standard replacement clutch. I am replacing a Barnett.

No, the hole is shown in the photo on the first post. It's inside the crank cover and leads into the rear of the crankcase. As I look at an exploded view, it looks like the hole does not lead into the crankcase but rather some sort of chamber to the rear of the crankcase. I think I'm OK. I thought maybe the hole had blown through into the crankcase. Of course, if that was the case, I doubt if the thing would run. The engine runs fine so I must be OK. Still can't find out where the mangled metal came from though. I found an exploded view at yamahaoftroy.com and that has helped a lot. Maybe I find find something missing?

Thanks for the reply. My hole is completely open at the bottom. I can stick an allen wrench right through to inside the crankcase. Is that normal?

What is the 1/2" diameter machined hole that is above the kick start shaft that leads into the crankcase? On mine, the hole is about 1/2 to 3/4 in deep. I have attached a picture which shows the one I'm worried about. It looks like it's open to the crankcase. Maybe the casting blew out in the bottom of the hole? I took the cover off to replace the clutch and found some loose metal parts which were all bent up in the bottom of the case. I'm trying to figure out where the parts came from and while looking around I found the hole in question. There's some jagged edges down in the bottom of the hole and I looks like something broke in there. The bike runs fine. I think maybe the last guy to own the bike must have left something in the case when he replaced the clutch. Any help would be appreciated.