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Join Date: Jan 2011
Location: Smack in the middle of Illinois
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I don't know if this will help, but here's how I do it;
Remove all the clutches - slip the centrifugal clutch hub on the crankshaft and install the one way clutch - with the spark plug out of the engine, the clutch hub should freewheel counter clockwise, but lock and turn the crank when turned clockwise - once that has been straightened out, remove the parts and lay them out exactly the way you are going to install them
Now install the manual clutch basket and clutch hub - tighten the clutch nut as much as possible with out special tools - slip the kick lever onto it's shaft and operate it by hand - the kick gears should move, engage and the inner clutch hub should spin counter clockwise - if that works, install the clutch plates and one spring - just snug the spring (don'y tighten completely) - again operate the kick lever - both the inner and outer clutch hubs should turn CCW
If all is working well up to this point - install the centrifugal clutch hub and one way clutch - now when you operate the kick lever, the clutch should try to turn the crankshaft, but with only one spring holding the pressure plate, the clutch might slip while turning the crankshaft. If all is well up to this point, install the centrifugal clutch and tighten it as much as possible with out special tools - again check operation by hand - if all is well, install the rest of the clutch springs and snug all of them -again check operation by hand - the crankshaft should turn CW with little resistance - if all is right, install the spark plug, remove the clutch springs and pressure plate, tighten the clutch shaft nut to specification - with the clutch nut tight and the plates installed, hold the clutch plates in place with one hand and operate the kick lever - the engine might turn some until it comes up on compression and stops turning, at this point, the inner clutch hub should spin and the driven plates should slip allowing the inner hub to turn while the basket remains stationary because compression is preventing the crank from turning
If all is well up to this point, install the pressure plate, springs and tighten the clutch spring bolts no tighter than 7 foot pounds - take the spark plug out and operate the kick lever by hand - the crankdhaft should turn clockwise when the kick lever is operated by hand. NOTE: never apply more than hand pressure to the kick lever with the RH engine cover removed - excessive force could damage the crankcase.
Finally, tighter the centrifugal clutch nut to spec and test operation once more - if all is right, install the clutch cover and operate the kick lever by hand one more time - install the spark plug, kick the engine over normally - if all works correctly, fill the engine with oil, install the spark plug cap and start the engine - the job is now done.
Let me know if this helps or at what point there is a problem.
General information - the electric starter turns the engine by the LH end of the crankshaft while the kick starter turns the crank from the RH end - just so you know they are totally separate starting systems.
Last edited by Here 2 help; 05-03-2019 at 12:48 PM.
Reason: After thought