Hey guys, so I'm rebuilding the clutch from cable to clutch disks since when I first got it three months ago it would start second kick cold first kick warm but when you put it in gear it would jump a tiny bit but when letting out the clutch it wouldn't do anything.  My big question is I haven't seen the ball bearing that's supposed to be in there and looking down that tiny hole it resides in I can't tell if it's there or not.  Any thoughts, comments (be nice) or great ideas?  Thanks, Tony

If ya talking the ball in past the pushrod, it's a big one 8mm [5/16] & goes in ahead of the clutch mushroom from the clutch side. Then shaft steps down to the pushrod size of 1/4--6.5mm or thereabouts. I'll get the diagram in a minute. Ok, 13 in the pic. Only goes in from the right side.

 

Ok start again. Have you been in the clutch side--plates out & back in etc. Try backing off the adjustment on the left in the actuator to give the pushrod clearance. It sounds bad enough that if you put it in gear [not running] it'd roll along like its disengaged or just dragging a little but not enough to turn the motor through compression. Cold be various reasons like burn out fibers [which would stink bad] or incorrectly assembled clutch--new plates but one plate short--& the pressure plate is contacting the center hub before compressing the plates. Been there done all of that in my mix n match similar motors over the years.

 Hey RT325, thanks for the responses.  I have the clutch system torn completely apart but I never saw the ball bearing come out of it's little hiding place and looking in there is just too small of a space for my old eyes to see anything.  I'm worried that if I put it back together and the ball bearing isn't there that I will be screwed.  Is there an easy way to get it out?  Here's a picture, I know the ball bearing goes inside the tube (for a lack of a better word), that the mushroomed push rod goes in, but I can't tell if there's one in there or not..  

Oh, ok. If ya pull the long pushrod out the other side & can't see daylight right through it'll be in there. give the pushrod a bit of a tap or quick push & the bearing will fly out--then hide under the bench--then ya not sure if it came out or not lol. Just magnetise a screwdriver & it'll come out with that but drop off as is a heavy 8m one so keep ya eye on it.

or tip motor over & will fall out. I'm over-complicating things haha.

Thank you RT325, that's exactly what I needed to know!

Or you can use a coat hanger and push it out it’s easy and free 

Thanks, another good idea... 

I use a magnet because if I didn't lose the ball yet, I probably will when I lean the bike over to remove it.