I think I have found the root of the clutch problem today. After finally getting her running decent I took a pretty good ride.... WHAT FUN! Anyhow, the end of the ride wasn't so fun!
Everything was fine and then I noticed the clutch would hardly disengage the engine, I thought first off cable slip/stretch etc. I was only a couple blocks from home so I tried to limp in on the motor (Cause engine was constantly engaged at this point for the most part). I didnt get far, she locked up bad, tire wouldn't turn, uh-oh! Noticed the chain was coming off the engine sprocket, rolling backwards got it loose. Attempting to move was a no go at this point, rear tire locked solid. I managed to get the engine side chain off and pedal home.
Once home I pulled the clutch plate, found the nut that holds the sprocket loose, the sheer pin thrashed and the sprocket bent a bit on the back. (Might be usable still, but I wouldn't use it after the bend) Luckily for me I got two kits so I have the spare sheer pin and sprocket!
I put the new sheer pin and sprocket back on the bike, tightened it down REAL GOOD, and gave her a go...
She's going good again now, and surprise, my clutch feels right FINALLY! Before I could not adjust the cable so when locked in the engine was complete disengaged and still get full grab when let out. Now I am able to get the full action of the clutch with a much shorter cable pull, everything just feels more proper. I think the reason my clutch was funky from the get-go was because that nut wasn't tight enough and not compressing the (internal) clutch spring enough.
So, if you have a funky feeling clutch, or even if you don't, CHECK THE NUT ON THE SPROCKET and make sure its really tight. I suggest you check it often, I will! You will be tempted to leave it alone, cause it's all loaded up with grease from the factory, do yourself a favor, clean that grease out and tighten down the nut! Besides, I found the factory grease in one engine to be super gritty and bad, so better put some clean quality grease in there instead. I had been warned to check the head bolts and intake for loose nuts, but don't recall the sprocket mentioned specifically, CHECK EVERY BOLT on your new engine if you want to avoid grief. If you love your bike you might want to order up a spare sprocket and a couple of sheer pins as well to have on hand in case you run into issues, this way you get right back out on the road instead of waiting for mail order parts....
Happy trails.....
