Was intrigued by the idea of a gas bicycle engine
Just moved to Atlanta from NY and will be perfect for transportation, as public transit here.. well...

So I took the plunge and ordered the kit. I have absolutely no knowledge of engines.. bought new screwdrivers, wrenches, for this project.. so I guess these might be silly questions..

Installed the kit on my mountain bike.. 3 things holding me back from the bliss of riding my new bike:

1. Chain - had to shorten it, was way too long. I got a tool which allowed me to shorten the chain, but I can't get it back together - the tool isn't big enough for the chain! Do you guys use a motorcycle chain tool?

2. Part chain connects to on engine (sprocket?) is extremely tight, and it takes a lot of force to turn it, even with the chain. Did I miss something? Should/can it be adjusted?

3. Clutch - I had it working OK until I removed the cover to work on the chain.. now the clutch lever can turn around 360 degrees - whereas before it had a limited range of motion. Any ideas here? I was unable to find a diagram of the clutch anywhere.

Thanks to anyone who would even try to help me. I'm a bit over my head here. I've spent my entire weekend on this project.. but now I need "professional help..."

wakiki wrote:
I guess these might be silly questions..

NEVER!~!



1. Chain - had to shorten it, was way too long. I got a tool which allowed me to shorten the chain, but I can't get it back together - the tool isn't big enough for the chain! Do you guys use a motorcycle chain tool?
Can't you just put it back together using the master link that came with it? You pressed out a pin, removed a link and now you should have two open ends the master link will go into.

2. Part chain connects to on engine (sprocket?) is extremely tight, and it takes a lot of force to turn it, even with the chain. Did I miss something? Should/can it be adjusted?
Normal, it's pretty tight for the first several revolutions, ride it and don't worry about it.

3. Clutch - I had it working OK until I removed the cover to work on the chain.. now the clutch lever can turn around 360 degrees - whereas before it had a limited range of motion. Any ideas here? I was unable to find a diagram of the clutch anywhere.
You may have lost the little roll pin that goes in there...the worse case scenario is the lever/arm will try to come out of the case and will have to be pushed back down once in awhile. Best to find a roll pin or tension pin at Lowe's or any hardware (auto parts) store and replace it. If you remove the cover and the arm, you can see where it came out of. It is there to keep the lever/arm and shaft in place.

Thanks to anyone who would even try to help me. I'm a bit over my head here. I've spent my entire weekend on this project.. but now I need "professional help..."

BTW- Welcome. Don't buy too many tools, you won't need them- a 10mm wrench, a small socket set with metric sockets, a couple of each type of screw driver, and a small pair of locking pliers will do almost anything on your engine.

For the roll pin/tension pin, until I get one, is the clutch going to serve any purpose?

I will try to find the "master link" - I guess it fell out when I was opening the chain package.

Thanks so much for your help!!
Also, when I say it is tight, I mean it takes serious force to get it to turn at all - should it be *that* tight? Wheel turns freely, just tight at the engine.

The clutch will still work fine, the arm may work it's way up so it won't push the rod but you can push the arm back down.

Yes, it's (sprocket) that tight.

thanks so much for all the help.. I'd be pulling my hair out otherwise.. actually I'm still pulling my hair out, but more slowly..

Having trouble seeing how the clutch is supposed to function, and where that pin you mentioned would go. I took some pictures..

View inside clutch..

The pin/piece in the center - (I can pull it out fully and stick it back in - I don't see any groove or thread or anything where it would catch onto anything - just a simple metal cylinder.



Post edited by: wakiki, at: 2008/08/19 08:22

Another pic.. everything look ok?

Post edited by: wakiki, at: 2008/08/19 08:23

And one more pic. I'm trying to figure out where that missing pin would go?


Post edited by: wakiki, at: 2008/08/19 08:25

O.K....see the hole halfway down the outside cover where the pin would go? Also, see the groove on the shaft that the pin rides in to hold the arm/shaft from creeping up in the case?

That hole looks a little elongated. Some folks have JB Weld-ed a nail in the hole. Put the shaft in and put a nail in the hole, mark for length and cut the nail. JB Weld into place. Re-assemble after 12 hours.

The shaft can still be removed when turned to the proper position.

Post edited by: wakiki, at: 2008/08/19 21:16

I understand that the pin will prevent the arm/shaft from creeping up. However, I still don't see what the arm/shaft does mechanically - is that "pin" in the center - photo 2 - supposed to stick out? mine does not, unless I pull it out.

(Having trouble understanding how the clutch on this system would work to disengage the sprocket when, say, waiting at a red light.)

Sorry for bugging you so much!

Post edited by: wakiki, at: 2008/08/19 21:16

The simple explaination is thus- the arm/shaft rotate when you pull the lever. The rotation of the shaft causes the flat part at the end to act as a cam, and that pushes the "pin" otherwise known as the clutch rod in. That being pushed in pushes the clutch plate out away from the driven side of the clutch, disengaging it. There is a ball (or should be) behind the clutch rod that lets the clutch rotate and the rod not rotate.

Awesome! I'm really glad I asked, because I found a small metal ball (actually, 2) on the floor when I was cleaning up - so that must have fallen out when I took out the clutch rod! I guess I will put one of those balls back in behind the clutch rod. No wonder the clutch rod doesn't stick out!

Geez.. should I let you know where to send the bill?

Uh, I'm not sure I want to know how or why you found two balls on the floor.....

The bill is in the mail.

Yes, it seems I've been busting other balls, aside from yours.

I will replace the ball. Sorry, can't help you though

I've got an issue with my clutch not engaging or disengaging. I've got the pin and ball in there but when I move the clutch arm either way theres no give once it hits the pin and the sprocket is still engaged with the motor either way. Is there a spring or something thats supposed to be behind the pin and ball that pushes the clutch plate away?

I think I got it. It was just EXTREMELY sticky. To the point where when disengaged I had to stand on one of the pedals to break it loose.

Got the bike working more or less - except I have NO CLUTCH - i.e. the clutch does nothing. I had to use the brakes to kill the engine!

Any ideas? I don't even know what to try..

Post edited by: wakiki, at: 2008/08/30 22:56

Post edited by: wakiki, at: 2008/08/31 00:48

Well, I loosened the star nut on the back of the clutch. Now, the clutch is doing the opposite - the wheel spins fairly freely, but does not turn the engine - again, the clutch does nothing.

I took out the clutch rod to lubricate it, and there is chalky junk in there behind the clutch rod, which I tried to clean out as best I could.

The clutch is useless in present form.. any ideas? Spent all day on this, don't know what else to do!