Help with clutch ...

T

Ted66

New Member
Hello. I know that maybe this type of problem has been already discussed somewhere around this forum.. But hear me out first.
I have a 80cc china engine kit which I've been using it for almost 4000km (~2 500 miles) with some problems here and there, small ones that I could fix myself or with some help.. but recently something odd happened to my bike.
First, some background: that day I was running some errands around my town and stopped at a local store, in which I spent roughly 20mins or so. Up until that point, I've ridden my bike for around 20miles or so, that day, without problems. When I came back from the store I found myself not being able to disengage the clutch. Even if I manually push as hard as I can the cam that the clutch cable should pull when disengaging. Of course, I took off the right side cover (clutch cover) and tried to adjust the flower nut so I can at least pedal on my way home and further investigate the problem. But, since I cant disengage the clutch, I cant adjust the flower nut. Tried to hit it with a hammer and screwdriver, but I was too afraid to mess up or break it.
Any suggestions? I have to mention that the clutch cable and clutch itself were working perfectly (cable adjusted properly) before entering the store.
And the cam is pulled all the way in by the clutch cable. As I said, I cant disengage the clutch even if I push the cam myself all the way in. The cable pulls the cam inward all the way, but the clutch does not disengage.

What can I do? It seems its stuck.
I've read a lot here about stuck engaged clutches, but most threads were about new engines being locked from the factory. But here its not like that.

Thank you all for taking the time to respond. And sorry if I have bad English, i'm not a native English speaker.
Looking forward for replies.

Ted
 
Welcome to the forum Ted, sorry we didn’t see this earlier. Are the sprocket side cover bolts tight? If they have loosened up that would cause your problem. The flower nut will be hard to turn under pressure but will turn, a flat end punch and a hammer will do it. Under the clutch plate in the big gear are 50 to 60 ball bearings, if they have failed and caused a out of round wobble that could be the cause.
 
Greg58 said:
Welcome to the forum Ted, sorry we didn’t see this earlier. Are the sprocket side cover bolts tight? If they have loosened up that would cause your problem. The flower nut will be hard to turn under pressure but will turn, a flat end punch and a hammer will do it. Under the clutch plate in the big gear are 50 to 60 ball bearings, if they have failed and caused a out of round wobble that could be the cause.
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Thank you for replying.
Yes, I made sure the sprocket side cover bolts are tight. No difference
Then I took them out and examined the bucking bar and the clutch camshaft. The camshaft is very worn out and does not make contact with the bucking bar anymore, let alone push it hard enough to disengage the clutch.

Ordered new camshaft, new clutch arm, new bucking bar and a new ball bearing.
MY question is how do I assemble the clutch arm to the camshaft?? There does not seem to be a way to screw it in, does it have to be hammered in? I'm a little bit afraid to break something.

Thank you for taking the time to read, hope you can reply
 
Mine has a dowel pin holding it in, some have a shoulder that requires turning the arm 180 or pointing it forward and lifting it out.
 
Greg58 said:
Mine has a dowel pin holding it in, some have a shoulder that requires turning the arm 180 or pointing it forward and lifting it out.
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For me they look like having grooves. The camshaft is designed to fit in the grooves of the clutch arm and vice versa. Yet I don't see how to put them together without using a hammer. Is that OK?
 

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Splined shafts will require a press or hammer, find a socket or piece of pipe the size of the arm opening and use that to tap on to apply equal pressure. Be sure to get the arm angle correct.
 
Like I said earlier the dowel pin holds the shaft in the side cover, it fits in the groove in the shaft.
 
Greg58 said:
Like I said earlier the dowel pin holds the shaft in the side cover, it fits in the groove in the shaft.
Click to expand...

Thank you so much for the help
But I can't find any dowel pin in the side cover.
Am I looking where I shouldn't?
 

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