clutch always engaged

just finished install on grubby gt5 kit. thr problem is that the clutch is always engaged. The swing arm works when lever is pulled. The pin inside the drive sprocket gets pushed in like it should. removed cover opposite side of motor. the silver clutch plate gets pushed out away from the larger of the 2 gears like it should and the thing is still engaged. its still engaged with the silver clutch plate completely removed and no friction or pressure on the larger gear whatsoever. I'm having trouble disasempling the clutch any further than this, I'm not a small engine mechanic. some steps maybe on how to disasemble the clutch would be greatly appriciated.

After months of clutch tinkering, I just leave it engaged. I installed a small front sprocket to make clutchless cranking easier. I kill the motor when I have to stop and refire it when I go. The air stays cleaner since I never idle the engine.
There is an answer out there, but that is how I stay on the road.

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Try this. Remove the clutch actuator cover, left side, exposing the sprocket and the protruding pin. Give the pin a good sharp rap with a hammer. Don't beat it to death but give it a couple of sharp blows. The clutch pads are sometimes stuck from the factory and even with the lever moved as far as it will go the pads won't release. Make sure the ball bearing that rides behind the pin is there and lube all those parts before reassembly. get back to us if this doesn't work.
Tom

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Age and Treachery Will Always Triumph
Over Youth and Skill

Check out Norm's 2 stroke repair center.
Norm's 2 stroke repair center - Bicycle Motor at Motorized Bicycle Forum
Or Motorized Bicycle Trouble Shooting.
Motorized Bicycle Trouble Shooting - Bicycle Motor at Motorized Bicycle Forum

The clutches are really simple in design and not too hard to work on.

guys thank you, I realy appriciate the help. turns out the 10t sprocket nut was assembled so tightly it froze the entire assembly. just like over tightening a couple hub nuts, it freezes the bearings and the wheel won't spin.

??????????

__________________
Age and Treachery Will Always Triumph
Over Youth and Skill

Now that is wierd! The bearings are semi-sealed ball bearing assemblies. If the nut were tightened to the point of death, the only part of the bearing squeezed would be the inner race. It could really care less, wouldn't feel a thing.

all I know is I had the clutch plate completely off and the thing was still engaged. when I loosened the nut holding the drive sprocket (on the other side of the motor) a 1/4 turn at most, the large gear with the clutch pads on it popped free and was able to spin freely from the center assembly for the first time, reassembled everything bike works perfectly.

Well.... Then I would have to say job well done!
I know that ultimate quality control does not play much into these little engines, and perhaps you have delt with a unique issue?

my clutch pin at the sprocket won't push in at all. tried hitting with a hammer and still nothing any ideas?