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Instructions for Building and Repairing Motorized Bicycle Engine Kits Classic posts on building, repairing and modifications.

 
 
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  #1  
Old 03-13-2009, 09:31 PM
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2door 2door is offline
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Default Motorized Bicycle Chain Noise

There has been a lot of discussion about clutch/chain noise from the 2 stroke Chinese engine. I've found one source that anyone with a Dremel tool or a grinding stone in a drill can cure. Both of my engines, one from Dax, the other a Chris Hill motor, had chain interference with the clutch actuator cover. The photos show where I found the chain was hitting inside the cover and what I did to eliminate the contact. After this modification my clutch/chain noise was dramatically reduced. It's easy. Give it a try.
Remove the clutch actuator cover, look for the telltale marks on the inside of the cover where the chain has been hitting. (photo 1) I used a Dremel tool with a sanding drum but any abrasive tool will suffice, to remove enough material to widen the space between the cover and the chain. After grinding the relief area I installed the cover and spun the rear wheel with the clutch dis-engaged, and looked for any spots that were still hitting and then ground off just a little more material.
The attached photos are self explanatory. Any questions, just ask.
Oh, and before you tell me my chains are too loose...no, they're not.
Tom
Attached Images
File Type: jpg Clutch, 1.JPG (104.1 KB, 2461 views)
File Type: jpg Clutch, 3.JPG (102.3 KB, 2202 views)
File Type: jpg Clutch, 5.JPG (124.2 KB, 2141 views)
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Last edited by 2door; 04-02-2012 at 06:58 PM.
  #2  
Old 03-14-2009, 01:49 AM
Large Filipino Large Filipino is offline
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Default re: Motorized Bicycle Chain Noise

Brilliant!
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  #3  
Old 03-14-2009, 08:42 AM
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Default re: Motorized Bicycle Chain Noise

Quote:
Originally Posted by 2door View Post
There has been a lot of discussion about clutch/chain noise from the 2 stroke Chinese engine. I've found one source that anyone with a Dremel tool or a grinding stone in a drill can cure. Both of my engines, one from Dax, the other a Chris Hill motor, had chain inerference with the clutch actuator cover. The photos show where I found the chain was hitting inside the cover and what I did to eliminate the contact. After this modification my clutch/chain noise was dramatically reduced. It's easy. Give it a try.
Remove the clutch actuator cover, look for the telltale markes on the inside of the cover where the chain has been hitting. (photo 1) I used a Dremel tool with a sanding drum but any abrasive tool will suffice, to remove enough material to widen the space between the cover and the chain. After grinding the relief area I installed the cover and spun the rear wheel with the clutch dis-engaged, and looked for any spots that were still hitting and then ground off just a little more material.
The attached photos are self explanatory. Any questions, just ask.
Oh, and before you tell me my chains are too loose...no, they're not.
Tom

Tom, I had noticed the same marks on all of my chain covers. They all made a quick trip to the mill where that was eliminated. Good Find!

John
  #4  
Old 03-14-2009, 12:17 PM
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Default re: Motorized Bicycle Chain Noise

Excellent 2door...

Mine did the same thing in the same spot. You can also see where it was hitting in a different spot.
I was going to do a thread on maintenance and things to look for and all that good stuff, and this is one of the things I was going to point out.

I have since decided not to do that thread.
Attached Images
File Type: jpg Picture013.jpg (159.9 KB, 1655 views)
File Type: jpg Picture012.jpg (166.1 KB, 1706 views)
  #5  
Old 06-28-2009, 10:04 PM
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Default re: Motorized Bicycle Chain Noise

Since I first posted this thread I've found the identical problem on three other engines. That makes five total, two from one supplier the other three from different ones. This tells me it is probably a common problem on most if not all Chinese 2 strokes. This is a modification that almost anyone can make in less than an hour. The reduction in chain to case noise has been very noticable on all my engines so if you'd like to quiet your bike a little give this a try. These photos are a little better than the originals...new camera.
Tom
Attached Images
File Type: jpg Clutch Actuator Cover, 1.JPG (151.7 KB, 1463 views)
File Type: jpg Clutch Actuator Cover, 4.JPG (105.2 KB, 1665 views)
File Type: jpg Clutch Actuator Cover, 5.JPG (149.4 KB, 1514 views)
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  #6  
Old 08-01-2010, 10:36 AM
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Default re: Motorized Bicycle Chain Noise

It's good to know that this is a common problem, and not due to an EFF-up during kit installation.
  #7  
Old 03-04-2013, 08:19 PM
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Default Re: Motorized Bicycle Chain Noise

Just bumping this old thread because I found the same problem on 2 new engines in the last few days. Looks like the factories haven't addressed a problem that's been with us for years.
The situation is exactly as described in this old tutorial that Paul was kind enough to dig out of the archives for me. Thanks, Paul.

Tom
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