Chains Can't get the chain door on the motor open!

Discussion in 'Transmission / Drivetrain' started by RuiGomes, Jul 16, 2012.

  1. RuiGomes

    RuiGomes New Member

    I've bought a regular 2T "Happy Time" engine and I mounted everything succesfully, but now I can't get that "door" that covers the engine gear so I can get the chain through there.

    I've used WD40 and even asked my dad which is my go to guy when things don't open and he failed to open that too.

    As I have my clutch already installed, I've tried to activate the clutch and manually pass the chain, but it doesn't go all the way through (not sure why), when the first chain bit is almost leaving the gear, the gear itself stops moving.

    Any ideas to fix this problem? I really want to get my bike out there!

  2. motorpsycho

    motorpsycho Active Member

    The chain door...i like that name.
    those screws can be a pain to got off, and normally you end up rounding the heads off before they will come loose. the best way is to use a manual impact driver (it's a screwdriver looking this and you hit it with a hammer) to get those screws out.
    sometimes tho, you can get lucky with a regular screw driver and a hammer.
    you can hold a screwdriver on the screw (hold the screwdriver with a pair of channel locks to keep your hand safe). push in and twist the screwdriver counter clock wise while someone hits the end of the screwdriver with a hammer (make sure it's someone you trust). sometimes this will break the screws loose, but you have to be careful doing it this can get hit with the hammer.

    well, if the clutch is adjusted correctly, you should be able to spin the gear easily. Try putting a screwdriver against the gear between the teeth and pushing it to see if it will turn with the clutch handle squeezed in.
    you can (and i've done it several times) feed the chain in on top of the sprocket and use a screwdriver to rotate the gear. this will pull the chain in and around the sprocket.
    once you get a small amount of chain out of the bottom , you can just grab the chain and pull it through.

    if your gear won't spin 360 degrees, either your clutch isn't adjusted enough, or the clutch plate is stuck to the clutch pads.
    you can also have someone push the clutch lever on the side of the engine in as far as it can go if you don't have the clutch adjusted right yet.
    put a bar on the clutch lever on the left side of the engine, and use the bar as leverage to push the clutch arm in towards the engine. not too much tho...don't want to break that arm off.
    This SHOULD cause the clutch to disengauge so the gear will rotate.
    if not, you may have to take the right side cover off of the engine, and pull the clutch pressure plate off to see if the clutch is stuck. sometimes these engines will sit on a shipping dock for a long time and rust can build up causing the clutch to stick.

    by the way, wd 40 is not oil or a good's made for displacing water.
    Last edited: Jul 16, 2012
  3. Lunardog

    Lunardog Member

    Also,if your case is like mine at the bottom of the channel you are trying to feed your chain thru,just below the gear is round channel for a bolt that goes thru the case. When you feed a chain thru manually the first link will dangle and catch on this lip. Use a flashlight and a small screwdriver and feed the chain in untill it stops, pull it back half a link and look in with the flashligh and you should be able to guide it up and over this lip with the screwdriver as you feed it in.
  4. RuiGomes

    RuiGomes New Member

    The gear is spinning properly (not super free, but it moves with ease, it just doesn't keep spinning as a regular gear would).

    The thing is that I can get the chain through all the way, but when it is barely visible on the other side I just can't rotate the gear anymore.

    Here's a pic:


    As you can see, I've managed to get the chain through from the top to the bottom, but I can't move it any further, no mater how hard I pull the chain or how hard I push the gear with a screwdriver or by hand.
  5. timtooth

    timtooth Member

    Your going have to take that cover off and use your sparkplug tool to rotate the chain around your gear.
    Motorpsycho gave you good advice by using a hammer and screwdriver it work.
  6. Fabian

    Fabian Well-Known Member

    "The chain door" - just brilliant terminology.

    That's become my new phrase of the week!!!

    Thanks so much RuiGomes
  7. RuiGomes

    RuiGomes New Member

    Are you aware that there are numerous countries where English is not the primary language? I can properly speak English, but as you may tell, as we don't use this kind of technical English everyday it gets harder to learn and use.
    Anyway, feel free to mock me as you wish, but not everyone was "lucky enough" to be born on a English speaking country, and I think that I made myself clear enough.
  8. MotorBicycleRacing

    MotorBicycleRacing Well-Known Member

    How about taking a piece of wire and putting it through the
    hole in the open chain link.

    Then thread the wire around where the sprocket is and use that
    to pull the chain through and around the sprocket.

    You will still need to have the clutch pulled in.

    Your English is very good, in fact better than many native speakers! :)
  9. MotorBicycleRacing

    MotorBicycleRacing Well-Known Member

    I just looked at your photo.

    You have the chain through but........

    You are keeping the clutch arm pulled over, right?
    The gear won't turn if the clutch isn't engaged.

  10. motorpsycho

    motorpsycho Active Member

    from the point you are at with the chain, you should be able to just grab the chain with your hand and pull it around.
    if the sprocket won't turn, either the chain is binding up on something under the cover, or your clutch still isn't disengaging enough.
    but if your clutch wasn't disengaging, you never would have gotten the chain as far as you did.
    try this:
    remove the spark plug and see if you can pull the chain through.
    I have a feeling that you are turning the sprocket, while turning the engine over at the same time and the compression is what's making the sprocket stop.
    IF you pull the spark plug and are able to pull the chain the rest of the way through, you're clutch is still out of adjustment.
  11. Lunardog

    Lunardog Member

    If you rotate the chain until it catches at the bottom and then fish the end out you have gone too far and allowed it to jump a tooth and bunch up inside the case near the top where you cant see. MBR gave you a good idea. Use a small piece of wire on the first link as you feed it in and make sure it does not stop at any point while you feed it.
  12. Fabian

    Fabian Well-Known Member

    @ RuiGomes - please don't think that i am mocking you. Honestly i am not in any way mocking you.
    A "chain door" perfectly describes the clutch actuation housing because in an around about way, it is effectively a "door",,,,,, a "chain door".

    It's such a unique and novel way of describing the clutch actuation housing - in fact i like the name so much that i want to make it my own :grin5: