New install, no start up yet, clutch doesn't seem to be working

yoothgeye · Jul 9, 2010

OK, I have installed my china 68.5cc engine, been taking my time with the install, put the chain on last night and when I pull the clutch lever the gear does not disengage, there is still drag on the engine if I try to turn the rear wheel, the plug is still out and I when I turn the pedals or rear tire I can hear it turning the engine.

I have adjusted the clutch cable and have pushed the lever in by hand as far as possible with no different results. If I look in behind the cover as I pull the clutch lever I can see the shaft twist from the flat spot to the rounded side and it pushes the little shaft in that does through the drive gear, but the gear does not disengage.

Is there a part I'm missing? Is there a step I'm missing? Is there an adjustment I'm missing?

Here's the bike, chain tensioner is not in it's permanent location, I have to remove a couple links, and the chain was hitting the tire till I moved the wheel off a little.

AussieSteve · Jul 9, 2010

First point - it's better to attach pics than to use inline {img} tags, for the benefit of those accessing the site via mobile.
With attachments, only a thumbnail shows, unless clicked on.
(Not griping, just a pointer.)

Next, what is that stuff wrapped around the muffler?

Third - I hate to be the bearer of bad news, but that rear engine mount is a disaster waiting to happen. It must be mounted squarely to the tube. (Then fabricate a suitable front mount.)
The way it's set up, the mounting studs will break. (A very common problem.)
Also, the way it is the carb is on a pretty steep angle.

Finally, the real problem. Often, from the factory, the clutch plates stick on these engines. The clutch might need adjustment, but I suspect that this is your problem.
One thing that works is to remove the RHS side-cover, jam some folded rag into the primary gears to lock them, then, with the clutch in and some weight on the bike, try to jolt the bike forwards to free up the plates.
Let us know if that doesn't work and I'll give you some pointers on clutch disassembly and adjustment.

Al.Fisherman · Jul 9, 2010

yoothgeye · Jul 9, 2010

AussieSteve said:
First point - it's better to attach pics than to use inline {img} tags

Noted.

Next, what is that stuff wrapped around the muffler?

Exhaust wrap.

Third - I hate to be the bearer of bad news, but that rear engine mount is a disaster waiting to happen.

Easy, so the rear factory mount is fine as long as it is mounted squarely, then deal with the front. Got it.

Finally, the real problem. Often, from the factory, the clutch plates stick on these engines.

Good to know it's common. Thanks.

AussieSteve · Jul 9, 2010

Wow, Ron, that'll keep yoothgeye busy. (yoothgeye, Ron is the resident engine-mount expert. You'll find many of those links very useful.)

Let us know if the clutch refuses to free up.

Forgot to ask, why the exhaust wrap?

yoothgeye · Jul 9, 2010

AussieSteve said:
Forgot to ask, why the exhaust wrap?

Mostly for looks, going for the hot rod look, but thought it couldn't hurt either.

Al.Fisherman · Jul 10, 2010

AussieSteve said:
Wow, Ron, that'll keep yoothgeye busy. (yoothgeye, Ron is the resident engine-mount expert. You'll find many of those links very useful.)

Let us know if the clutch refuses to free up.

Forgot to ask, why the exhaust wrap?

Why the long list?? I'm sure that like me you get tired of the same questions being asked time after time. Shows that some would rather ask then do a little search first. So I went through 100's of threads picking out a few that will help NOOBS like I was once. I'd do a search and find page after page of threads on the same subject. Picked some of what I thought would help the best and compiled a NOOB list. Wish I had come across something like this when I first started and was a NOOB NOOB NOOB like all of us were.

yoothgeye · Jul 11, 2010

Al.Fisherman said:
Why the long list?? I'm sure that like me you get tired of the same questions being asked time after time. Shows that some would rather ask then do a little search first. So I went through 100's of threads picking out a few that will help NOOBS like I was once. I'd do a search and find page after page of threads on the same subject. Picked some of what I thought would help the best and compiled a NOOB list. Wish I had come across something like this when I first started and was a NOOB NOOB NOOB like all of us were.

Nobody questioned your long list, in fact, it was informative and I'm pretty sure you were praised for it. So that makes me wonder, is this "NOOB" dig at me or all "NOOBS" in general, because that is something I haven't noticed until now about this site. I have been a member of many online forums for years, one in fact for almost 10 years now, I have been a moderator and a staffer, and on that site we have avoided any "NOOB" talk because we were all there once. People asking the same questions can get old, but we found it easier and more welcoming to just answer them or politely pointing them in the right direction without drawing attention to it. I've found it takes just as much energy to give someone a quick answer as to tell them they are a "NOOB" who needs to learn to search. Not trying to start an argument, I was just offering some family friendly advice. Sorry for the sideline.

Anyway...

I have remounted the engine using the factory rear mount squarely on the seat tube, gotta look through my pile of junk for the correct scraps and fire up the welder for my front mount, once accomplished I will focus back on the clutch.

Stan4d · Jul 11, 2010

I wish that I had seen all of the info that Al gave when I did my first build. Read it manytimes. Use whatever hints you can.

Al.Fisherman said:
Why the long list?? I'm sure that like me you get tired of the same questions being asked time after time.

Al,
Very good work there, it deserves recognition!!
I have taken the liberty to copy your post, slightly edit it and start a stickie thread. If it is easier for you in the future, just use this link.
http://www.motoredbikes.com/showthread.php?t=28231

yoothgeye · Jul 11, 2010

Stan4d said:
I wish that I had seen all of the info that Al gave when I did my first build. Read it manytimes. Use whatever hints you can.

I agree, the list was great and useful and set up well.

New install, no start up yet, clutch doesn't seem to be working

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