I am beginning my 49cc kit install, and noticed that the clutch lever is very loose, and I can't get the clutch to disengage.

Should the clutch lever be able to move almost 90 degrees with no resistance?

Any position I put the clutch lever in does not allow the sprocket to turn freely.

Am I doing something wrong? Or do I need to tear down the clutch mechanism?

Have you pushed it all the way over, (toward the engine) then hooked up the cable? It should point somewhat straight back when it's in the right position.

Did you remove the cover for anything?

I have not removed the cover.

There is no resistance at all to the entire arc the lever can move in, and no position frees the sprocket to rotate.

I am considering removing the cover to look.

OK ...

I opened up the cover.

The center pin, the one I guess is used to operate the clutch, is just sitting in there loose ... it looks like it is all the way down and in, and does not want to spring up and out at all.

Here is a high res pic, 1/2 a meg.

Post edited by: kbarrett, at: 2008/02/22 03:01

Considering the amount of stuffmissing fromthe original shipment ... I am wondering if what I got was one of your suppler's customer returns?

Any ideas on how I should proceed? I'd like to just get this to work.

I've got the clutch cover off, and the sprocket nut off, and can see the #8 steel ball just sorta stuck down there ... no play at all. Part 26, the bucking bar(?) just drops all the way in, the cam shaft shifting rod has to go almost its entire travel to even touch the top of it.

The clutch cover just sits there, tight against the clutchpads, no matter what you do with the bucking bar or the shifting rod.

With the clutch cover off, you can see the threaded rod it is attached to just stuck in the on position ... doesn't budge a millimeter when you move the shifting rod.

Something in there is well and truly stuck, and I am not going to be able to get any further in without a pulling tool ... so I think I'll just stop right now.

I could probably fix this myself with the right tool and replacement parts for whatever is screwed up in there ... and some instruction.

I'll not proceed any further without talking to you.

Post edited by: kbarrett, at: 2008/02/22 08:23

Spooky? Oh Spooky....

I think you'll need the tool and a small adjustment of the clutch.

I got the starnut off the back of the clutch, and checked the pads and all ...

And when I put the star nut back on, everything worked fine.

I think the factory person assembling this was in a tearing hurry ... he just had everything reefed down to the point nothing moved. Now the clutch works fine. The lever is a little off ( points out a bit instead of back ), but I should be able to get it off and put it back on right.

I guess I did figure it out myself ... I just reassembled in a careful manner and now it all works.

If the clutch is too loose, I now know how to tighten it back up ....

Post edited by: kbarrett, at: 2008/02/23 23:17

EXELLENT.