The clutch will not disengage ! I bought this bike for my wife from a guy in Cali. USA. As soon as I got it I noticed the throttle had no freeplay and also the clutch. I adjusted the throttle and the clutch to proper freeplay. Once I started the bike the motor sounded really good, but then I stepped it into gear & it died, as it tried to launch foward.

I have pulled the cover, removed all the steels and fibers. The steels had some minor rust which I scuffed off thinking this was causing it. I check the basket and hub for wear, but everything is in smooth & good condition. Have new ones but I see no reason to replace them. My thought is the clutch pack is wrong. Maybe too thick !

Here is why I think that:

With the cover off and the clutch assembled, when I pull on the cable to disengage the clutch it must be pulled really far before everything becomes free & the wheel spins while in gear.

Fibers are approx. (3mm).120/.116 thick, the steels are (1.5mm) .060" thick. 7 fibers and 6 steels. Inner has a larger I.D. to clear the 2 spring rings. The outer looks different then the other 5 standard fibers. Can't really describe what looks different except that it is covered in fiber material, were the other 5 have like little fiber pads and show steel between them. Don't missunderstand me it has pads also but you don't see steel between them.

Does any one know what the total pack hight should be ?

Would like to purchase all new fibers and steels, Andy I see fiber's for sale, but how about the steels ?

Any suggestion ?
_________________