Weird clutch

[Worty]

Ok, completed the round trip to see Bergs and MWAS to get the cush collar flange machined down from 8mm to 5mm - tested it on one of Berg's motors and it was good - also good on mine   When I get half a chance, I'll chuck it all together, although Bergs has recommended I check the run out of the clutch to see if my adapted key 'fix' for the clutch centre is good.

Gearbox end cover arrived today - doesn't look too bad overall.  Can get a 11mm drill down the clutch arm spindle hole snugly with very little movement - doesn't seem any point in bushing it really.  Am I right in saying that the kick start and gear lever bushes should be replaced??  I get some oil weep through the kickstart but nothing really from the gear lever on the existing cover.   I assume the cover is heated for removal and installation?

[berger]

worty the clutch arm is 7/16ths and 11mm is a bit less so you should be ok with the bit of slop you found with the drill in the hole. the kicker and gear bushes are steel so they don't normally need replacing and if you do replace them [ heat up the case ] you won't really gain anything because the shafts will be worn, you are overthinking again ----------- get it fired up and out again

[Worty]

worty the clutch arm is 7/16ths and 11mm is a bit less so you should be ok with the bit of slop you found with the drill in the hole. the kicker and gear bushes are steel so they don't normally need replacing and if you do replace them [ heat up the case ] you won't really gain anything because the shafts will be worn, you are overthinking again ----------- get it fired up and out again

Sorry Bergs 

[Worty]

Offered up the machined cush drive sleeve to the motor with the sprocket - guess what, bang in line with the chainwheel and enough thread for the nut

Next job is to check the chainwheel runs true after my 'fix'.

On the gearbox clutch lever - I'll do what Bergs suggests otherwise he may shout at me again

[berger]

worty pin thee tabs back and listen or tha'll gerra thick ear 

[Worty]

worty pin thee tabs back and listen or tha'll gerra thick ear 

😱😱😱😱😱😜

[Worty]

Right, banged up the clutch nut to around 70lbs, according to my torque wrench, and with copious amounts of Loctite.  Don't seem to have any up and down run-out after my clutch centre fix.  Sprocket and chainwheel line up perfectly.

Now then, I'd put the old primary chain back on with the clutch locking tool and foot on brake to tighten - no problem on the clutch.   When I got to the cush drive, it was a bit of a 'b&^%$*d.  First major thing, what the 'ferk' is the size of that hex on the Peugeot 405 tool.   When I measured it, it was 34.5mm which meant my 34 was too small and 36 was a bit big (did work in the end though).  I don't have a 35 socket.  Next, the tool engaging with the nut wasn't as convincing as I'd hoped, with a bit of slippage.  However, with my foot on the brake, the primary chain on and the clutch locking tool engaged, I proceeded (couldn't use the torque wrench as I don't have an adapter from 1/2 to 3/4 on my 'large' socket set).  Managed to get the lobes at max with full strain on the big ratchet, before the rear brake cable snapped  - should have used Cols sprocket locking set up!!   With loads of Loctite, and a few final hefty punches  with a big hammer and flat ended punch, it seems to be pretty solid - split pin in and, hopefully, it won't come off.

If there is a next time, I may even consider the SRM item.

[Richard Hinton]

Start with the easy things first replace cable, if no better look at lever arm and adjustment in gear box. if still problem then you need to get casing cover off and look at clutch. is it reasonably secure will have a bit of wobble but should not be on lateral drive shaft (pull and push it)

today is hard to get the proper tab washers to lock the clutch knut onto the drive shaft, I make the best I can but to make sure I use lock tight and an air gun and drive the knut fully home, but you will need an air gun to remove as well.

What does wear though and you may have to drill and bush it is the clutch arm top of gear box these wear and then is hard to adjust clutch, check for play.