Clutch is STILL always engaged

[Junster]

Ok Patdon10 I think you have this assembled right. The ball goes in the hole in the drive shaft before the pin goes in. The shaft in the cover never touches the ball. Your description of "the flat end on the pin" that's how it's suppose to be. What I'm wondering is where the original ball and pin went? If the original ball broke apart and is still buried in there it's never going to work. If you decide to disassemble the clutch it's up to you. There's a couple threads in the drive section with good pics showing how.

 

[Junster]

Here a post with a pic showing what's in there.

http://www.motoredbikes.com/showthread.php?t=20150

 

[Patdon10]

yeah, I'm less frustrated today, so I think I will take the clutch apart. Can someone point me to a thread that gives detailed instructions on how to do this? Maybe I can find out what's seizing. I don't think the ball broke apart, I really think it was never there, because I had no pin in the first place. Who knows, I may find a suprise.

 

[Junster]

Here a post with a blowup of the whole assembly.

http://www.motoredbikes.com/showthread.php?t=4554&highlight=clutch+bearing

 

[dan48cc]

please dont grind or cut anything, i think i might have the answer for you. it is so simple you will most likely laugh but i happened to me and after calling the seller this is what i was told.
with the clutch locked to the engine. stand beside the bike and put your weight on the seat, walk the bike backwards. this will clunk and carry on but perservere. keep walking the bike backwards till you hear a big ping or a heavier clunk and the problem will be solved. it seems that these little mass produced engines are not always properly checked when leaving the factory and some of the clutch mechanisms have dags on them that cause them to jam. i did this on one of my bikes and fixed it first go. had to walk it back about 5 metres beforeit happened. let me know how you go.

 

[Patdon10]

Ok. I'll give it a try. Will the bike still be under compression backwards? When you say clutch locked, you mean pull the clutch handle and press the button to lock it, correct?

What can I use as a shim between the ball and pin? It's clear that there is too much space between the ball and pin because the arm won't even touch it (flat side or round side), but with 2 balls in, I think there is a little bit too much of the pin sticking out.

 

[dan48cc]

engaged clutch

Ok. I'll give it a try. Will the bike still be under compression backwards? When you say clutch locked, you mean pull the clutch handle and press the button to lock it, correct?

What can I use as a shim between the ball and pin? It's clear that there is too much space between the ball and pin because the arm won't even touch it (flat side or round side), but with 2 balls in, I think there is a little bit too much of the pin sticking out.

by locked i mean with the handle out and drive engaged. the motor will still have compression but will not start as of the slow speeds at which you are moving. the problem you are having is that inside where the pin goes is jammed. by rotating it backwards it should release and the pin and ballshould come out alot further giving you the extra length you need. then you will onl need the one ball or maybe even none at all and the clutch should work as normal. my engine doesnt have the ball just the pin. hope it works.

 

[Patdon10]

Alright, I want to take this thing apart to see if I can figure anything out. I have the right side cover plate off. I was able to break loose that screw as you can see from the whole in the picture. How do you take the little "star plate" off of the middle so I can get to the brass piece underneath. I can see that when I turn the arm, the clutch WANTS to push out but clearly, something is jambed.

 

[Patdon10]

by locked i mean with the handle out and drive engaged. the motor will still have compression but will not start as of the slow speeds at which you are moving. the problem you are having is that inside where the pin goes is jammed. by rotating it backwards it should release and the pin and ballshould come out alot further giving you the extra length you need. then you will onl need the one ball or maybe even none at all and the clutch should work as normal. my engine doesnt have the ball just the pin. hope it works.

yeah, I'll definately try that out tomorrow when I get the chain on.

 

[dan48cc]

as far as pulling it apart i cannot give you any further info as i dont know that engine. mine is similar but as i yet have not pulled it apart i dont want to give you a bum steer with it. good luck though i hope you can sort it out