Seriously though, you guys are rockstars— I had pretty much resigned to the idea that I’d have to crack the engine to fix this prior to posting here but I’m so glad I did. I will make an update once I get parts and do the swap. Thanks for all of the wisdom
@Gordy @Dogsoldier @zean
This procedure is technically done by splitting the case... however this is a cheap motor so you can do it my way. 1. Remove clutch basket and assembly(do not loose wordruff key.
2. Remove drive cover and chain(do not lose bucking bar and ball)
3. Using dead blow or peice of wood and hammer drive clutch shaft out thru drive side.(bearing may go with shaft).
4. Carefully press new bearing into case OR on to drive side of shaft.
5. Carefully drive shaft into motor via drive side with dead blow.
6. When shat is correctly seated in case Carefully place woodruff key (if using new key it may need some sanding to fit)in slot and install sprocket with locking washer.
7. Place woodruff key again and use breaker bar and gear puller/installer to seat clutch basket(should be roughly 1/8 to 1/16 of inch past crank gear).
8. Install lock washer and nut.
9. Install pads(loosely press into slot. They should have play. Use old pads if u want).
10. Apply spring and plate with flower nut. 11. Install ball then bucking. Then drive cover. 12. Push clutch lever firmly and spin flower nut til stop. Place screw in nearest position. 13. Install cable and chain
14. Check adjustment buy locking handle and roll bike(should roll easy). If not visibly make sure pressure plate is released. Push cable with thumb. If bike roll adjust cable.
15. Release handle and see that engine turns with bike.
16. Intsall cover and test for adjustment(if slipping make sure cable is fully releasing and turn flower nut 1 turn clockwise and test)
This is a comprehensive break down of the way around splitting your case.
It's alittle tedious but easier than spitting a case if your not a skilled mechanic. If you get stuck shoot me a message... when I get stuck I pester impulserocket lol
