Chain getting stuck in Clutch Cover

I got a new 415 chain and i'm having serios problems with it. When I pedal the bike it's fine. I was able to start the engine right away on the new chain. However when I stoped and when to start it again the chain jamed inside the clutch cover right on the left screw hole area. I played around with the chain tensioner and unstuck the chain 3x and 3x it james up in the same spot again and again. I'm really getting fed up with gas powered motor's. There so damn picky it's anoying. Atleast when I jump on my road bike I know it wont fail on me. With the motor u never know what problem it's gonna throw at you..

Sincerely frustrated beyond anything....

sounds like your chain is too loose,also you may try filing down the teeth on the sprocket hope this helps amigo

Which sprocket ? The clutch cover or the big back one ? If anything I thought the chain was to tight but I can try and make it tighter. How much slack do u want on the chain ?

top chain run about 1/2" slack at mid span of the chain. If your hanging up in the front sprocket area you might see just where it snagging. if you have a dremmel use a fiber cutting wheel and give the area a little extra room. I know someone else has posted photos of doing this but I'm not sure where to direct you to that post. You might try doing a search.
Norman

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Grind the bolt hole section to make it a tad thiner ?

This is so obvious I feel the fool for sayin it but...

Have you lubed the new chain thoroughly? My new 415 was doing the same thing despite the fact I thought I had oiled it up good, yet when I pulled it back off again I noticed that some of the links would bind and stick.

So I soaked it in a quality chain lube (in a coffee can), wiped it down, reinstalled it, and hit it with the waxy spray lube I normally use.

I haven't had that prob again *shrug*

i think you guys have it all covered here so im backing off

I didn't think of trying that. However if this would be the cause wouldnt it get stuck while pedlading ?

It only jammed a little while pedaling on me like twice while new, I only later noticed it due to a problem rolling the bike backwards, it would sometimes hitch a little. I thought it was an alignment issue (as the pedaling was) until I was feeding the chain back on and she bound up solid. Taking the cover off I saw a link section had jammed because it hadn't bent to follow the sprocket.

I think it was the difference in slack between freewheeling and under load (with mine anyway)

When I had the chain off it seemed fine, I'm even a bit obsessive about lubricating the drive chain as I ride a lot. Yet as I later did a link-by-link inspection I found that some were still binding. It wasn't because they were dry, it was due to the chain being so poorly made some sections were jammed tighter than others.

So I dropped it in a coffee can and dumped a bottle of chain oil on it and let it sit for the night, I didn't bother to work the links much. It works fine now, but I'm going to get a better grade chain this week as the common 415 seems to be garbage anyway.

I dunno if this is your problem, but it surprised me a little

Not all but a high percentage of the kit supplied #415 chains are poorly made and prone to binding. Some even have a twist to them if you lay them on a flat surface and look at them. Ace Hardware, Tractor Supply, Grainger, all carry #41 industrial chain which is the perfect replacement for the #415 kit chain.
As for the sprocket teeth needing filing/grinding, I've never encountered this but some have. The engine drive sprocket's teeth might be a little rough and could benefit from a light dressing to take off the burrs.
Norm was refering to a modification that I do to all engines. ( Chain Noise )There is a small area inside the clutch actuator cover where the chain rubs. I've never had one bind there but a loose chain certainly could bunch up at that spot. You can relieve the area with a Dremel tool and a sanding drum to get clearance for the chain. This also helps reduce chain/clutch noise. Its easy to see; remove the clutch actuator cover and the area in question is on the inside front. Every engine I've inspected showed signs of chain contact there. It only takes removal of about 1/16" material to keep the chain from touching.
Above all make sure your chain tension/alignment is correct. A too loose or tight chain and side pull is the biggest cause of chain/sprocket problems along with improper installation of the rear sprocket.
Tom

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