wood ruff key dropped,don't know what to do.

Discussion in '2-Stroke Engines' started by wan37, Jan 1, 2012.

  1. wan37

    wan37 Member

    I have a grubee sky hawk engine and installing a centrifugal clutch and had to wait for the new grinder to get here,so I put the new cover on and check out if the pedals would hit.Yes they did so ordered a shorter one piece crank,then turned bike upside down and remove the old .I got the new die grinder and cut the key way grove in the new centrifugal clutch went to put the wood ruff key on the shaft and drop it behind the bigger clutch gear being a the bike was still upside down...and can't shake it out if it still in there.This my problem I don't care if I lost the little key just will buy a new one,but don't want it to mess any thing up being some where behind the gear and I don't know how to take all that stuff apart......please someone tell me what to do...Thanks
     

  2. motorpsycho

    motorpsycho Active Member

    if the key went behind the clutch gear, all you have to do is remove the flower nut in the center of the gear and slide the gear off.
    this is the bigger gear towards the rear of the engine on the right side.
    when you remove the flower nut, take out the little phillips locking screw and then unscrew the flower nut. count the number of turns it takes to get the flower nut off because you will want to screw it back on the same number of turns so your clutch will be adjusted right. but, if you're putting on a cetrifugal clutch, don;t you have to remove the manual clutch anyway?
    if the cranks hit the cover, why didn't you just buy a set of off-set cranks instead of buying a whole new shaft?
    this woudl have saved you a ton of trouble.
     
  3. wan37

    wan37 Member

    Thanks motor .I have a one piece crank and could not find a wider one piece crank there all out of them.It's tight on wallet for changing over to 3 piece crank,plus I found a deal a 5 1/2 crank for $8.49 on a closeout free shipping.I feel better now about what you said about the big clutch gear....Thanks a bunch
     
  4. motorpsycho

    motorpsycho Active Member

    yep. it's easy to remove that clutch gear. some of the clutch pads may fall out when you take the gear off, but don't worry, just pop them back into the clutch drum...they just sit in there.
    BUT, if you pull the gear off, the clutch drum will still be on the shaft and i have no idea how to get that off....you may need a puller to get it off, i'm not sure.
    I have never gone that far into the clutch.
     
  5. wan37

    wan37 Member

    I'm there now it looks like a nut is all to take it I'm hoping.thanks
     
  6. wan37

    wan37 Member

    I not going to pull the drum off tonight. maybe tomorrow.thanks motor again I have to check it out more before I remove the clutch drum.so any suggestion would help.
     
  7. Al.Fisherman

    Al.Fisherman Active Member

    Most likely all you need to do is remove the machine screw that keeps the flower nut in place, remove the flower nut, remove the flywheel, and maybe a clutch pad or two. A magnet may help in the extraction of the key. You may want to remove the spark plug so you can rotate the clutch gears easily. A socket and breaker bar (14mm) on the nut holding the magnet on works well.
     
  8. wan37

    wan37 Member

    Thanks al I'm all the way to the clutch pads there a center nut.How do I take the nut that holds the pads plate on every thing move so do I hold a socket on the chain little gear and a socket on the clutch pad plate or what?Thanks
     
  9. Al.Fisherman

    Al.Fisherman Active Member

    The plate that holds the clutch pads is not bolted on. It is a tight fit with a woodruff key to keep it from spinning on the shaft. Most kits include a gear puller with them, some don't. Here is what the puller looks like and how to use it. This puller will remove both clutch gears and the chain drive gear. Not needed for the magnet in the magneto.
    [​IMG]...[​IMG]
    If your kit did not come with one, I have loaner pullers to let out. You pay postage both ways (about the cost of the puller itself), but they can be bought from one of our vendors, but shipping is way too much unless you buy multiple items. They are nice to keep on hand.
     
  10. HeadSmess

    HeadSmess Well-Known Member

    make sure to thread that puller in tight before tightening the central bolt/puller part. very fine, easily damaged threads and when they go...uh oh!

    the magnet should work :)

    the benefit of a "loaner" puller is that it will work...ive had one or two supplied with kits that were useless...
     
  11. Big Red

    Big Red Active Member

    Al, I've removed a few entire clutches and as I recall, there is a nut with a star type washer under it that holds on the clutch base. The clutch gear is held on to the base by a press ring, but it all comes off the shaft as one peice. So even if you take the press ring off, don't you have to remove the big nut before you use the puller? It's not really bolted on, It's NUTTED on, isnt it?
    Big Red.
    P.S. I did not know that the puller would also remove the drive gear. SEE, I can still learn things at my age.
     
    Last edited: Jan 2, 2012
  12. wan37

    wan37 Member

    I really don't know way I need the puller which I have 1 but it looks like a regular nut the holds the clutch pad gear on.I just need to know how to loosen nut,when i go to loosen it i need to hold on the gear nut on the drive chain gear right.I'm kinda slow tonight so bare with me....thanks
     
  13. Al.Fisherman

    Al.Fisherman Active Member

    It's been so long that I've broken a HT down (2009) I missed that..Start at the first picture and advance forward. http://s982.photobucket.com/albums/ae309/Ron-Becker/Chinese HT breakdown/ (complete album) You will see each step in removing the clutch. Sorry.. the nut just slipped my mind....but the (proper tool) puller is needed. While in there take a syringe pack grease in it and lubricate the small ball bearings. Before using the puller, make sure that the puller is bottomed out in the clutch housing. Some tools, the threads need cleaning up. I had to use a 3 cornered file to clean up threads on 2 of mine. Without ensuring that the puller is bottomed out can lead to striped threads on the puller.

    [​IMG] [​IMG]
     
    Last edited: Jan 3, 2012
  14. Big Red

    Big Red Active Member

    Nut Off

    wan, I don't know how everyone else does it, but I just put a heavy screwdriver between the shaft and one of the three large pins. The nut is never on tight enough to bend a pin. Make sure the screwdriver, metal bar, ect, is set as close to the clutch as possible. I've done it this way for years and never bent one. There may be a better way, but you've asked this question a couple of times and so far no one says how to lock the clutch for removal. If there is a better way I want to know also.
    I've also jammed up the clutch/crank gear but I know that CAN'T be the recommended way. It works, but there has to be a better way.
    Shiney Side Up,
    Big Red.
    P.S. Al is right about greasing the small bearings behind the press ring. BUT ONLY A LITTLE GREASE. Too much and it will just wind up on the pads and that ain't a good thing.
     
    Last edited: Jan 3, 2012
  15. Big Red

    Big Red Active Member

    Clutch

    Sorry wan, I didn't answer everything in my last post. Yes, the nut comes off first, but the clutch base is pressed on is why you also need the puller. To put it back on you just line it up to the key, push it on as far as it will go, then use the nut to drive it all the way home.
    Shiney Side Up,
    Big Red.
     
  16. wan37

    wan37 Member

    I think I can do this now after these instruction. Al great photo post it's pretty simple now, and big red thanks you guys are great.I would be lost with out this forum and great response.Red the screw driver worked on the small gear before so when I remove nut I'll try jamming it again on the big gear.kudos again.
     
  17. HeadSmess

    HeadSmess Well-Known Member

    reds way...a screwdriver between clutch pins,

    jam a pice of hardwood between the gears...

    and my favourite, wrap some chain around the sprocket and let it jam in the case.

    or jam anything between sprocket and case. as long as its easily "unjammed" when required
     
  18. Big Red

    Big Red Active Member

    As many times as I've seen a chain jump off and jam in the case I should have thought of that one myself. Good one Bro, I'll try it next time.
    I never seem to have any "hardwood" around, just little pieces of plywood. I think it would work, just chew it up some.
    If someone with a welder wants to try an experiment, How about welding a short peice of chain to the end of a iron bar. Wrap the chain on the drive gear and hold on to the bar. If it works you could sell it on e-bay as a clutch/drive gear nut removal tool. If anyone gets rich off this I want 10% for using my idea:jester:.
    Shiney Side Up,
    Big Red.
     
  19. wan37

    wan37 Member

    Thanks headsmess never thought about the chain thing,I should of just like red said as many time the chains have jammed on me. I got it off though with the chain jammed and I used a air impact gun but was very careful.I also tried the screw driver between the pins red,I broke two screw drivers..lol. I'm really happy that I didn't break any thing else.I cussed that little key a bunch........lol
     
    Last edited: Jan 4, 2012
  20. Big Red

    Big Red Active Member

    Tools

    That'll teach ya not to buy tools made in china :jester:
    Shiney Side Up,
    Big Red.
     
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