problems installing engine...

Hi all,

I've been having problems installing my engine.

When putting on the chain the clutch lever was still working. I put chain on bottom part of sprocket, pushed the clutch lever and turned the sprocket to get the chain to come out and connect the two chain ends together.

Installing all other pieces went fine, CDI, throttle handle, clutch handle, carburetor etc.

But the engine won't start!

Now here are the problems:
- Somehow yesterday the setup changed so that without pulling the clutch lever the back wheel spins freely. So the clutch is permanently disengaged and won't engage or disengage anymore.

- I took off the drive gear cover and now it won't fit back on. The bucking bar sticks out too much. I managed to take out the ball bearing this morning and it all looks clean behind it, just a horizontal piece of metal against which the ball bearing pushes.
The clutch lever is facing towards the back of the bike so that the flat part is against the bucking bar.

- When spark plug is disconnected and I turn the back wheel, the piston does not move.

- When spark plug is disconnected from engine but connected to CDI and held to the engine fins it gives no sparks when turning the wheel.

- A kill switch was not provided, is there a homemade solution to this with some wires near the steering wheel? There is rubber between the engine and frame.

I'm really at a loss of what to do next. I don't think the Kenyan bicycle shop that I bought it at knows anything more than I do.

I get a lot of attention on the streets with the engine in the bike but I'd really like to get it running also. Hope some of you can help.

For some pics of the bicycle see: http://www.bit.ly/kenyanbicycles

I did take off the cover on the right side, even removed the flowernut and the screw in the flowernut. Does not seem to make a difference.

Read on the forum that it might have something to do with the woodruff key, don't know where that is located and how to remove it though. I have very limited tools at home here in Kenya, just a multitool and an adjustable wrench.

Could anyone advise on how to make a makeshift kill switch until I buy one at a shop somewhere? Is a wire going from the white engine wire to somewhere on the frame sufficient? Connect the wire to the frame when starting the engine and disconnect when stopping the engine?

Thanks for all your input.

Sadly I did not get the gear puller with my kit. The shop here in Kenya had just a carton box with all the parts in it. No kill switch, no manual...

Most vendors on internet won't send to Africa so that'll be a problem. I'll go to the shop today and try and convince them the engine was not working when I got it and demand a new one. But they don't have many left because they have stopped importing them, most people here now opt to buy the 125cc motorcycles.

So I can just buy a simple switch somewhere and put it between the blue wire of the cdi and the red/black wire of the engine? (Me engine has the following wires: black, red/black, white and CDI has: black, blue) I understand to leave the white wire alone altogether, but is grounding not necessary at all?

Will keep you updated and hopefully post some pictures.

On the motoredbikes forum I found some pictures of disassembling the engine and on one of the pictures there is a spring underneath the clutch plate. On my engine there is no spring, could that also be part of my problems?

link to picture:

http://www.motoredbikes.com/album.php?albumid=808&attachmentid=39521

Went back to the shop today and turns out it was the butterfly nut on the clutch plate, the thread was gone.

See www.bit.ly/kenyanbicycles for a video and some pics.