New 80cc clutch stuck in gear(no neutral)

Discussion in 'Frame Mounted Engines' started by graucho, Feb 17, 2008.

  1. graucho

    graucho Active Member

    This is my second 80cc installation. The first was smooth, after installation I peddled as normal, released the clutch lever and "bingo" off we went. My second brand new install the clutch is "in gear" out of the package. I push the bike and the engine turns over. (I cant peddle normally,wont go into neutral) I havent started it up yet. My question is, if I peddle it and start it, will it get the tranny parts moving inside and release it so it will pop into neutral when called for. Or shoud there be a spring pushing the small rod out tward the clutch swing arm cover? Id appreciate any info. Thanks graucho.
    Byrdie likes this.

  2. markshelfer

    markshelfer New Member

    I dont see why you shouldn't start it, it might fix it, or it could be the problem you mentioned with the spring. But getting her moving shouldnt hurt.
  3. Papasaun

    Papasaun Guest

    Be sure that all the parts are installed! Not only the little rod, but also the ball bearing behind it. Before I would start it up I would take the right side cover off and give it a good looking over and check. It might hurt something awful if it started and then you couldn't get it shut off quick if you needed to!

  4. Scottm

    Scottm Guest

    I agree totally. Check this thread and look at the diagrams it's part #24 on the specs list , thanks davo and kronic.
    Last edited by a moderator: Feb 18, 2008
  5. thatsdax

    thatsdax Guest

    the Clutch..

    The Clutch pressure plate is a flex plate which is your spring. Check the Star nut and make sure it is tight. Sounds to me like it is lose. Also... There is no such thing as an 80cc engine kit. Not from Asia . Thanks.. Enjoy the ride...
  6. graucho

    graucho Active Member

    Thanks to all from graucho

    Thanks to all that responded. What I did was... took off all covers and took a peek. Everything seemed in place> the little rod and ball bearing was there. So... I took out the spark plug (to reduce compression) put in 2 drops of oil for lubrication, went out for a 1/2 block ride with the clutch stuck on. YEA! since this was a brand new install something must have been hung=up from thick grease or a tranny part was'nt seated. But taking it out for a peddal (without starting it) must have moved everything into place. Thanks again. Graucho
  7. mickey

    mickey Guest

    Excellent! I think this is the second post about clutches not releasing on new HT's until the motor has been spun a bit. I wonder if this is the start of a trend.
  8. iRide Customs

    iRide Customs Member

    Glad to hear things are working for you.

    BTW, is that a NWChoppers frame and for you have pictured in your avatar??

  9. graucho

    graucho Active Member


    Yep, Built it, rode it, put engine on it, sold it. FUN project. graucho
  10. Jammer

    Jammer New Member

    New Build, Clutch engaged, cant get in to Neutral

    I have had the SAME thing happen to me. I am just putting this thing together. It hasnt been ridden yet. The motor has been engaged since I got it out of the box. I tried all the suggestons listed in this post. The bearing and the rod are in there. With the left cover off I tried to push the rod in ad it wont give. I have tried with the left cover on and the clutch arm. I have pulled off the right side, and it looks like everything is in place. I have put a socket on the nut by the clutch and manually turned the engine over, hoping that it knock something back in to place like Graucho.

    Hopefully others have had this happen, and Im missing something. There may be another suggestion out there, or a bid of confidence !!!
  11. graucho

    graucho Active Member

    Hi jammer, first look at the bottom photos to make sure you are clear of which way the rod goes in and out. (sorry if you already know) Then let us know if you went for a short ride with the plug out. I know its stuck in gear, the plug out will reduce the compression since it will be very hard to peddle.

    When I did this I was pulling the clutch in and out until I heard a "clunk" then It was easy to peddle with the clutch fully pulled in. It finally popped into neutral. Everything has been OK ever since.

    Attached Files:

  12. Jammer

    Jammer New Member

    Graucho, I got it, New question, Brass cable stop?

    After I made my post, I went out and again turned the engine over while in gear. The pushrod finally slipped into place !! I hadnt had my chain hooked up before to get enough revs to make this occur. SO, now the clutch is working correctly. Thanks for your input, that was really frustrating.

    Another quick question,on the clutch issue. My kit did NOT come with the little brass piece that hooks on to the cable after it comes thru the cable arm. There is only a screw on the end of the cable arm (inline with it) that you tighten down after you thread the cable thru the arm. Seems to me from a leverage point of view that I will need that brass piece to keep the clutch arm tight enough., and from slipping.

    What do you call that brass stop? Can I get it at a hardware store ?

    Thanks again
  13. machiasmort

    machiasmort Active Member

    Believe it or not, Anybody having trouble with cable's, go to home depot. The sell the correct sized galvinized cable there.

    If you need a ball or solid cylindrical end on it, they also sell welding rod. Make sure to get the stuff made for aluminum tho because it's galvinized your welding to! Can be done with a propane torch!

    As far as the brass end goes, shouldn't matter so long as the nut on the end of the arm is tight enough not to let the cable slip. The brass end is only there to keep the end of the cable from freying. If it bothers you, go to Home Depot and get a crip end from near where they keep the cable. $2.00 max!