Engine wont start please help!

Discussion in '2-Stroke Engines' started by kovan, Jul 7, 2010.

  1. kovan

    kovan New Member

    Hello fellow motorists.

    I just bought my first 2 stroke motor about a week ago. i had to take it to a custom welder to get a custom mount. i got everything together and all is good but one problem. it wont start. i no i have everything connected and fitted correctly. my uncle is a mechanic so i took it to him and he is mind boggled. the problem is that when i pull the clutch in it goes into neutral then i start peddling and let the clutch out and the gears are not turning. also the generator is not spinning either. but it all changes when you take the spark plug out. everything runs just like it is supposed to gears turn but there is no spark to fire up the engine because the spark plug has been disconnected. i have tried everything please help!!!

    Thanks,
    Kovan
     

  2. srdavo

    srdavo Active Member

  3. Vistaman73

    Vistaman73 Member

    sounds like the clutch is slipping due to the compression of the engine. Hope thats it, simple fix, there are threads all over the site, you can easily find them. But all you should have to due is tighten the starnut enough so that it doesnt rub the pads when the lever is pulled in. You may have got a bad engine and some may be bad in the clutch mech. Good luck, any more info would help.
     
  4. Stan4d

    Stan4d Banned

    http://motoredbikes.com/showthread.php?t=27957
    This thread seems to closely match your description of the symptoms. Sounds like a broken woodruff key. There is enough friction to turn when not under a load, but when you add compression you have no movement.
     
  5. kovan

    kovan New Member

    are you talking about starnut on top of the sprocket inside the gearbox?
     
  6. GearNut

    GearNut Active Member

    Yes. It is called "flower nut"
    1. remove the small lock screw from the clutch outer plate.
    2. squeeze the clutch lever in and use wire or tape to hold it in.
    3. Using only your fingers, no tools, turn flower nut in until it is snug, then back it out 1/2 to 1 turn.
    4. Remove wire or tape from hand lever and release clutch. Try out the clutch action by walking the bike around. Squeeze the clutch lever and the clutch should slip. Release the hand lever and the clutch should grab.
    Do not run the engine with the little lock screw and gear cover removed!
    6.You may need to fine tune the position of the flower nut.
    Each time you need to turn the flower nut, squeeze the hand lever to release the clutch spring pressure off of the flower nut and the flower nut will turn easily with your fingers.
    7. Adjust flower nut so the next available screw slot aligns with the screw hole in the clutch outer plate and install the lock screw. It is easiest to tighten the lock screw when the clutch lever is released and the clutch outer plate is held securely by the clutch spring tension.
    8. Reinstall the gear case/ clutch cover.
     
  7. kovan

    kovan New Member

    i did what you said and yet i am still having a problem the gears in are not catching at all. and the slight chance when they do decide to catch it is only until you pull the clutch again it will stop catching
     
  8. Stan4d

    Stan4d Banned

    Check the position of the clutch arm.....when you had it off to install the chain was the flat side towards the motor?
     
  9. kovan

    kovan New Member

    yes it is and when i pull the clutch in it turns to a more rounded cylinder like figure
     
  10. GearNut

    GearNut Active Member

    This is beginning to sound like one of the woodruff keys has sheared.
    This has been a very frequent diagnosis recently, very strange.

    Before getting all involved in the how to's of checking the woodruff keys;

    1. Be sure that the nut in the center of the engine sprocket is tight.
    2. Be sure that the nut in the center of the clutch is tight.
    You will need to remove the clutch outer plate in order to gain access to the clutch center nut.
    3. Be sure that the slotted screw in the center of the pinion gear (small gear that drives the clutch ring gear) is tight.
     
  11. AussieSteve

    AussieSteve Active Member

    It is a bit, isn't it?

    kovan, besides the other suggestions and before dismantling the clutch, disconnect the clutch cable altogether, then roll the bike forward and see if it slips still.
     
  12. GearNut

    GearNut Active Member

    Hmmm...... another loose clutch spring adjustment perhaps?
     
  13. kovan

    kovan New Member

    wow thank you i followed your directions and it was the woddruff key. i took the key of and it fell into pieces. i went to a local Harley Davidson dealership and they showed me right the right part. $2.13 later... problem is solved bike runs great had to adjust the clutch a tad but all is good for now thank you very much!!!
     
  14. GearNut

    GearNut Active Member

    I am glad to hear that you got it all worked out!
    If you don't mind me asking, which key was it?
    I also would like to know the part# of the key that the Harley dealership sold you, both for my own reference, and I have been a Harley mechanic for 17 years. (I can get a bag of 10 keys for $7.00 or so) I am wondering which Harley key it is. The oil pump keys I think are a little too small, and the pinion shaft key seems to be the correct thickness, but a little too large overall.

    Edit: I bet it is a kick starter ratchet gear key.
     
  15. Stan4d

    Stan4d Banned

    It is a possibility that the key is not used on a Harley at all. Many dealerships purchase hardware from otherplaces in bulk, might be just a key that is in the parts that outside vendors supply.
     
  16. kovan

    kovan New Member

    well i went to the dealership and they looked for a similar key via typing in the part number from a reference and they couldn't find one the also had a separate section street bikes and they had the part but i couldn't find the part number on the receipt and or the part or the bag is came in. i will give them a call Monday they are not open weekends
     
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