clutch always engaged

Lucky420 · Sep 8, 2009

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. zpt

wheelbender6 · Sep 8, 2009

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.

2door · Sep 8, 2009

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

GearNut · Sep 8, 2009

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.

Lucky420 · Sep 9, 2009

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. usflg

2door · Sep 9, 2009

Lucky420 said:
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.

??????????

GearNut · Sep 9, 2009

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.

Lucky420 · Sep 9, 2009

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.

dance1

GearNut · Sep 10, 2009

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?

dukeboy87 · Sep 11, 2009

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

2door · Sep 11, 2009

dukeboy87 said:
my clutch pin at the sprocket won't push in at all. tried hitting with a hammer and still nothing any ideas?

You will not be able to push that pin in by hand. The spring you're trying to compress is too strong for that. It requires the mechanical advantage of the clutch actuator cam/arm/cable. You didn't say what your problem is or why you're trying to push the pin in. If your clutch pads are stuck the hammer method usually works. The gentleman who started this thread probably just relieved enough presure by loosening the sprocket but it was not a tight bearing issue. The clutch pads (pucks) simply broke loose when he loosened the sprocket. I hope he retightened it before he tried to ride his bike.
Tom

Lucky420 · Sep 14, 2009

I've found exactly what you need right here

Animated view of the HT Clutch Assembly and countershaft

I found it under Classic Instructions for Building and Repairing Motorized Bicycle Engine Kits on the home page. I hope this helps\

. .wee.

camlifter · Sep 15, 2009

my grubee did that too. i took off the flower nut and still could not roll the bike, as i was using the puller tool to remove the clutch, after just a small turn something popped and the clutch freed up and worked right.

Nill · Sep 16, 2009

I'm having the smae problem

tdaddydolla · Sep 18, 2009

I think i also have same problem; my clutch lever does not releast the sprocket in the engine... no free ride, only gas ride. i tried to pop it with hammer. is it maybe just too tight? if so which side should i loosen spocket? maybe i tightened it by mistake;.. when i attached chain turning engine sproket counter clock first, then scared and then loaded chain by turning clock wise. i think it tightened (sprocket) alot and think thats good but may be why no nuetral?????

Nill · Sep 18, 2009

My problem was solved by tightening the clutch cable more. That allowed me to engane and disengage it properly.

tdaddydolla · Sep 19, 2009

that did not resolve my problem

GearNut · Sep 20, 2009

tdaddydolla said:
that did not resolve my problem

It could be the spring is too tight. Norman shows how to tighten All you have to do differently is turn the chain sprocket the other way, top to the left, with channel lock pliers, to loose the spring instead of tightening it.
Or if that does not work, Follow Norman's tutorial and take you clutch apart. See if you can find anything wrong.

tdaddydolla · Sep 20, 2009

thank you ,..,., all you folks on here who gave me advice; i just unloosened the nuts on the chain crank and clutch plate and tightened appropriate and bam?!?!?!! i'm good.... just need a bigger gas tank, finish break in, add double kick stand and maybe seat extension and sissy bar for possuible girls i pick up.

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clutch always engaged

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