Yamaha TY175 Clutch Issue

[wezzo]

Hi. I have an ongoing problem with the clutch on my TY175. In a nutshell when in gear and with the lever in, the clutch is not quite disengaging. There is the correct amount of play at the lever and at the adjuster behind the case on the left hand side.

I understand there is a couple of different pushrod options with the TY. Some drawings show a Rod, ball and mushroom and some without the ball bearing. I’ve taken the clutch off and there is no ball bearing. However adding a ball bearing means that the pressure plate sits too high. 
 

I'm also led to understand that the washers that sit under the inner and outer baskets are different sizes. Could it be that I have these around the wrong way? If so which one goes where (assuming they are different thickness)?
 

Any advice appreciated as I’ve had this thing apart plenty of times trying to sort it.

Thanks

[lemur]

You need the bearing in there because during operation the T shaped shaft spins relative to the straight shaft, the bearing turns that pressure into point loads in the centre of the 2 shafts, without the bearing between them the shafts will experience considerable more friction.

Your clutch is out of engagement by the same diameter as the clutch rod 🤓 add a bearing the same diameter as the clutch rods measure and it should work.

Edited 4 hours ago by lemur