7
B)
Squirt oil down the cable sleeve: Route clutch cable through the ball-mount on the engine with the big
spring around the cable jacket and ahead of the ball mount. The big spring serves as a cable heat shield.
C)
Insert cable wire through small spring and route through clutch arm and attach brass cable-end and
screw. Adjust cable tension to allow very slight play in arm. Handlebar clutch lever must be in the
released or outward position to complete this operation.
D)
Activate lever a few times, and check clutch arm for slight free play:
About 1/16” engine clutch arm
free play is required with the handle bar lever in the released in what is called the clutch engaged
position or the engine will fail to start if cable is too tight. Re-adjust as required.
E)
Basics of clutch operation:
The handlebar lever pulls the cable that moves the engine clutch arm. In
turn the clutch arm pushes a rod through the motor that pushes the clutch plate out. ( similar to a car
clutch.) Releasing the handle bar lever engages the clutch and provides engine torque to the drive chain
or to start the engine. The friction of 15 pads on the clutch plate allows the engine to start, and also
transmits engine torque to the drive chain. When the bike is in pedal mode the handle bar clutch lever is
locked inward held by the push button. In pedal mode the bike then operates in default as it would
without any engine. Periodic clutch adjustment is necessary to maintain efficient operation
*NOTE:
Cut
off excess cable extending from clutch arm, before operation, to avoid possible interference with pedals,
chain, your legs, etc.
See Figure #4.
Clutch arm: Clutch cable Note brass screw lock at the end;
1/16” free play:
Figure #4 Additional cable adjustment can be made at mid cable joint.
NOTE: If Clutch cable is not adjusted correctly the engine will not start. Check for 1/16 “ clutch cable
arm free play with handle bar lever released.
Carburetor and Throttle Installation
THROTTLE with kill switch:
See Wiring Diagram for Kill Switch
wiring Hook up:
Drill small hole in handle bar for pin lock.
