Clutch not engaging

RenoRider

New Member
Feb 14, 2009
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Reno
So heres the story. After A LOT of other problems solved by searching the forums here... more and more arise.

So I was riding with my friend. and while riding, the clutch disengages seemingly randomly. At first, I notice that I am losing power, so naturally I turn the throttle a little. I hear the engine revving up like a car in neutral, but notice no power reaching the tire. I try this once or twice more and finally give up, and pull over. I pedal and try to start twice from the side of the road, and it just sputters and dies quickly. the Third time the clutch seems to be dead. and by dead I mean; The clutch will not engage at all. I no longer have to pull the clutch to pedal the bike.

And since this is my first post, i can not post links to pictures.

I opened the right hand side of the engine, and the little flat head screw part on the bottom right of the clutch box will rotate, but the sprokets inside refuse too rotate. Any ideas?

My roommate and I have struggled for the past 2 weeks on this bike project. When one bike is fixed, the other creates a new problem.
 

schwallyjdog

New Member
Feb 11, 2009
29
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Bellevue Ohio
take the side off that has the engaging arm and see if the pin and ball bearing behind it come out. Inspect the arm to see if it is seated properly and the retaining pin holds the arm in. Are your cables binding?
 

drhofferber

New Member
Jun 22, 2008
307
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So heres the story. After A LOT of other problems solved by searching the forums here... more and more arise.

So I was riding with my friend. and while riding, the clutch disengages seemingly randomly. At first, I notice that I am losing power, so naturally I turn the throttle a little. I hear the engine revving up like a car in neutral, but notice no power reaching the tire. I try this once or twice more and finally give up, and pull over. I pedal and try to start twice from the side of the road, and it just sputters and dies quickly. the Third time the clutch seems to be dead. and by dead I mean; The clutch will not engage at all. I no longer have to pull the clutch to pedal the bike.

And since this is my first post, i can not post links to pictures.

I opened the right hand side of the engine, and the little flat head screw part on the bottom right of the clutch box will rotate, but the sprokets inside refuse too rotate. Any ideas?

My roommate and I have struggled for the past 2 weeks on this bike project. When one bike is fixed, the other creates a new problem.
are you from reno, nv? if so...i might be able to help...ive built two bikes...and everything seems to be going well...with TLC...drop me a note...Dennislaff
 

RenoRider

New Member
Feb 14, 2009
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Reno
update. So I went in to see if the woodruff key was the problem. and well, I guess it cant be a problem is theres no key there.

SO. I know the problem, i know i need to buy a new one, put it in there, and should be good to go.

BUT what happened to the old one? I dont know if it fell out once of the few times i took off the cover, and I just did not see it because I didn't know what I was looking for, or could it still be in the clutch or even worse the engine part?
 

toytime

New Member
Mar 20, 2008
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Ontario
The key is so small and when it got sheared, it got even smaller so it could be there but it's not a big issue. I would not be surprised if they forgot to put one in at the factory.
 

RenoRider

New Member
Feb 14, 2009
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Reno
It was running for a good quater to half mile, then hit a small incline, then just POP. the key broke, slipped out, ect ect.
 

toytime

New Member
Mar 20, 2008
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Ontario
As long as it fits the slot in the shaft and sticks up enough for the slot in the gear to make contact you should be fine. Sorry I don't really know the size. Just bring your gear with you to the store.
The one pic shows an "offset" key, not what you are after, the one you want is just flat and not offset. They cost a buck or two at most.
 

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RenoRider

New Member
Feb 14, 2009
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Reno
Ok, with an assortment of new keys at hand, how do i go about installing them? I read the sticky, and its still unclear to me how to install the keys and then the gear ontop without the key slipping
 

drhofferber

New Member
Jun 22, 2008
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go to zoombycycles and they have the key for 3.00...look under crank case....now they also have a diagram for install...now go get it...i cleared my message center out...and the ? still stands...good luck...Dennis
 

toytime

New Member
Mar 20, 2008
550
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Ontario
Just lightly tap the key into place on the shaft. Have the front of the key (the part that will contact the gear first) tilted down a slight bit so that it clears as you slide the gear onto the shaft, otherwise you will bump into the key.
It may seem tight but that is how it is supposed to be- a perfect fit.
 

RenoRider

New Member
Feb 14, 2009
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Reno
How am I supposed to get the whole gear out like in the picture above? ive been trying to do this without that this whole time.
 

toytime

New Member
Mar 20, 2008
550
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Ontario
You should have got a little black "puller" with your kit. It may be that "extra" thing you always wondered about. It fits into the palm of your hand. It is made to screw into your gear and as you tighten the centre bolt, it draws the gear off.
These pics show what a "real" puller looks like and show you how they work, really simple, if you think about it.
You could try to hold the weight of the bike up by holding onto the gear only and giving the shaft a good blow with a hammer. The weight of the bike, along with the blow from the hammer usually works. If you try this, remember to screw the nut onto the shaft until it is flush with the shaft so that your hammer does not mushroom the threads, ruining your shaft. It may not be smart to do this if you are not used to doing things like this but one good blow usually works.
 

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RenoRider

New Member
Feb 14, 2009
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Reno
Ok, key is set. bike is rideable now. thanks to everyone, especially you toytime.

But now I think I loss a little power in the process, just me or could have something gone wrong?
 

toytime

New Member
Mar 20, 2008
550
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Ontario
If you think about it, nothing you worked on has any effect on performance. All you did was stop the gear from spinning in place , a gear that drives your clutch, which transfers the power over to your drive sprocket.
Glad to hear your back in action!