No clutch action ! ?

Airbuzz · #1 09-15-2008, 08:54 AM

Hi Forum.
I’m building my first bike with the 47.7cc 2-stroke. My current issue is with the clutch. I am not able to get any movement in the cam pin #25 (per the clutch assy diagram) See picture.

When the handle is squeezed to disengage the clutch, all that results is deformation of the clutch cable.

With the cover and lever off, I am not able to push the cam pin in with hand pressure and I am weary about tapping it in with light hammer blows.

To sum it all up, the clutch seems permanently engaged. There is no turning of the little sprocket free of driving the piston. The only way to have the little sprocket move is to use the sparkplug wrench to turn the engine over (at the little sprocket) or spin the tire to have the chain turn the engine over.

P.S. I wonder if I inadvertently tightened something when turning the engine over thru the little sprocket using the spark plug socket?

Any Ideas? Thank you.

Bikeguy Joe · #2 09-15-2008, 09:02 AM

Remove all the slack from the cable, have a helper push the arm over, and then re-install the cable/cable end, making it very tight so it can slip. Try it again, you should have clutcxh action.

You can't push the rod in by hand with the cover off.

Pablo · #3 09-15-2008, 09:38 AM

Have you taken the RIGHT cover off?

Airbuzz · #4 09-15-2008, 10:31 AM

Hi Guys,

I have already done what you said Bikeguy Joe. If I force the lever arm any more the lever arm will bend. As I said that clutch cam pin can't be pushed in with heavy hand pressure and I'm weary about tapping it in with a mallet or hammer.

Pablo, I haven't taken the opposite side cover off yet. As you can see in the one picture, the cam pin stands out .30 inch., and with pin removed I can see the steel ball inside. Pablo, Did you see my "P.S." statement ? Coulkd that have anything to do with it ?

Pablo · #5 09-15-2008, 11:16 AM

I would take the right cover off and make sure there isn't something jammed in there.

Then I would remove the spark plug and turn the engine over at the nut or rear wheel/tire. All move smoothly?

The remove the small retaining screw, flower nut and clutch plate. This will be a pain with the clutch engaged…..

Tap gently on the pin - it should feel "springy"…...

Airbuzz · #6 09-15-2008, 11:22 AM

I'll remove the cover tonight when I get home Pablo. I appreciate your help.

Airbuzz · #7 09-15-2008, 11:36 AM

Pablo, You say to tap gently on the pin. Is this the #25 cam pin per the clutch assembly diagram that I included in my original post?..The one that I show in my picture? Or is it another pin that is exposed by removing the clutch plate, such as #12 fixed pin or #18 mandrel, both identified in the clutch assy diagram?...Thanks. I appreciate it. I'm new to this.

Pablo · #8 09-15-2008, 11:50 AM

Quote:

Originally Posted by Airbuzz

Pablo, You say to tap gently on the pin. Is this the #25 cam pin per the clutch assembly diagram that I included in my original post?..The one that I show in my picture? .

Yes #25. Just test it to see if you get spring back. Don't wail on it.

**Norman** · #9 09-15-2008, 06:00 PM

you should be able to work the clutch arm with vice grip pliers you might try that before breaking out the hammer.
Go to the classic posts and on page 2 is the info on the clutch and how to adjust it with pictures and all kinds of lying by me.
Norman

Pablo · #10 09-15-2008, 06:37 PM

Just to be 100% clear!!!!

I am NOT advising anyone to hit the clutch arm with a bloody hammer.

What I am telling Airbuzz to do is TAP GENTLY on the protruding PIN shown in the above. Not in attempt to free anything, rather to feel if there is spring back. ALL this AFTER the right side cover is removed for inspection.