Clutch Adj

[DaytonaBarnFind]

Engine is back from a very reputable builder, and I'm trying to adjust the clutch, but I can't get enough pull to engage it at all.  Even with the adjuster screw all the way in and the cable screw all the way out, I get a little action.  Seems to me it may be missing ball?  Looks like the parts diagram shows two, one in the clutch basket (Right side of Eng) and another of the left side?  Don't seem to have one of those and I'm not sure where that one would go. The Push Rod protrudes 1.75 from the case.  Is it possible to Right side ball got got lost or potentially never installed?   Can I push one in from the left side ?  Thanks in advance...

[1976RD400C]

Yes, you pull the rod out of the motor and install the ball. If there is one in there it will fall out once the rod is out and you tilt the bike to the side. There should be another ball in the pivoting arm that the cable pulls too.

[SoCal250]

the 2 balls are Yamaha 93505-16006-00 BALL
If you don't have the OE one, it's a 5/16" ball which you should be able to find in the hardware section at your local Ace

[DaytonaBarnFind]

Thanks and that's what I figured, Inserted a new ball (from Ace H:)) and pushed it home. The push rod now sticks pout about 1 5/8 from case.  Side cover on,  adjusted the set screw and free play, but now I've got no pull.  Pulling on the lever feels like I'm bending something.  I'm going to pull the right side and see what's up, unless anyone has a better idea?  Thx

[1976RD400C]

Why is the rod sticking out less now the ball is in? It should stick out of the case about 1 7/8" if all is good.

[DaytonaBarnFind]

The shaft sticks out 2 1/8th now.  So something is up?

[dgorms]

One too many balls.

[DaytonaBarnFind]

Not me:)  Pulled the rod out and the Ace Ball came out with it.  Can see the other ball thru the seal.  Reinstalled the rod and its 1.75 long. The rod is 23 centimeters long, or just over 9 inches.  I'm still coming in short of the desired 1 7/8?  Are all the rod's the same length over the years of RD's?  No clutch pull at all even with the adjuster all the way in...

I appreciate the help.  It's been 30years since I messed around with RD's and I"m not getting any smarter...

[SoCal250]

You didn't mention, but I assume we're talking about an RD400.
Is it possible that a push rod from an RD350 may have found it's way into your setup? I haven't compared the two but I would guess the RD350 rod may be a little shorter.
The RD350 shares the same rod (237-16357-01-00 ROD, PUSH 2) with the RD250, R5, CS5, CS3, RD200, and CS1.
The RD400 shares the same rod (328-16357-00-00 PUSH ROD) with the XS360, XS400, TR3, TD3, and 73-74 TZ350. Looks like it's just over 9" from the photo on Partzilla, which matches up with what you're measuring:

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[m in sc]

350 one is smaller in diameter vs the 400 actually. just barely. we found that out on matts 400 vs a 350 one

[DaytonaBarnFind]

Got the clutch to grab, but for a new clutch the adj is out a ways. Builder thinks is the thick stack clutch.  Next time I change oil, will take a look.  Thank you all for the assistance...

[AAAltered]

When you pull apart the basket, measure the steels.  There are two types, thicker and thinner.
Maybe you have all thick's, or a mix?

[m in sc]

out how? is the screw @ the LH cover too far IN or OUT?