Puch clutch help?

Chris /
goodphoto
Aug 30, 2005 10:14PM

I have a one speed 1977 puch maxi.

In order to start, the starter cable (clutch) has to be pulled to its maximum tightness for the clutch to "grab" the declutching lever must be pulled very hard. I have already swapped the clutch hub with a spare used clutch hub, they both appeared to have clutch pad life left.

Right now it too hard to start with lever (hurts hand) so I resort to using vice grips to pull the cable up ( if you can picture that) Anyways, is there another part that could be worn or needs adjustment. possibly the declutching shaft?

Right now I will take any suggestions because I can't think of anything!!

Thanks,

Chris

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Re: Puch clutch help?

Leon Swarmer /
50plus
Aug 30, 2005 11:55PM

I'm assuming you have already adjusted the cable itself...?

Leon

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Re: Puch clutch help?

Chris /
goodphoto OP
Aug 31, 2005 12:30AM

Yes. The previous owner had over stretched the cable, which is why I thought the clutch hub pads had been worn, but they werent worn. I bought a new cable and installed it.

The problem is not the cable length, the declutching lever must be pulled fully open, and hard, in order for the clutch to "catch" the crank. I hope everyone can understand what I am trying to explain. this is very frustrating.. because my girlfriend cant start her own bike. My lever is easy to pull and catches at about 3/4 pull of the lever. HErs if you dont pull it as hard as you possibly can it just slips.

I can post a picture of the clutch hub if that would help??? Although they look fine. Maybe I am missing a part???

Chris

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Re: Puch clutch help?

Chris Paz /
chrispaz
Aug 31, 2005 01:22AM

if the clutch cable is stretched you can just tighten it at the clutch lever. Fully adjust the tensioner located on the right side of the frame, so it is fully slackened. Then loosen the set screw on the clutch cable. Grab the cable with a pair of vice grips. While you have tension on the cable via the vice grips, tighten the set screw back down. Get the set screw good and tight. Now the cable should be quite taunt. If you can still not start the bike with ease, then just adjust the tensioner on the side of the bike. Regardless of how stretched the cable you will be able to adjusted it. Just snip off the extra cable by the lever and tuck the rest into the slot. I like to Wrap the frayed end with electrical tape so prevent accidental stabbings.

Chris Paz

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Re: Puch clutch help?

Chris /
goodphoto OP
Aug 31, 2005 02:52AM

No. I am not sure if you understand the cable is fine, it has been replaced already. The problem is even with the cable as tight as can be, I still have to pull very hard on the lever. The actual declutching device may not be working properly. It has nothing to do with the cable. It has something to do with the internal mechanism of the clutch. When you pull on the starter handle, you move the declutching lever, which presses against the plate in there causing it to move together with the crankshaft, which starts the moped. But with mine you have to pull on the cable like a beast to get it to catch.

Can anyone solve this problem or has had a similar problem... I have no Idea what it is...

Sorry for the long posts I just am trying to be as descriptive as possible.

Thanks,

CHris

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Re: Puch clutch help?

Daniel Van Donsel /
daniel
Aug 31, 2005 07:12AM

It sounds like the problem may be a worn or broken/missing part in the lever itself and you are not getting the correct amount of leverage... just a thought!

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Re: Puch clutch help?

Chris /
goodphoto OP
Aug 31, 2005 12:58PM

The weird thing is that I tried a different crankcase with lever too.

So I dont know if it has anything to do with that. These are questions for true puch experts. What does the declutchings shaft push on to start the rotation of the crank? Does it press against the clutch cover or against a washer (thrust washer) maybe I am missing a part in there. Please anyone????

Thanks

CHris

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Re: Puch clutch help?

Chris /
goodphoto OP
Aug 31, 2005 01:33PM

I took a closer look and found that the thrust washer was not there . SO I replaced it and it still seems like I have to pull on the handle very hard to get it to grab.. Its hard to explain, but the cable has to be so tight that the declutching lever is almost fully pulled, then when I pull on the lever it opens that lever just a few mm's, then it grabs, I know this is not how it is supposed to work.

Plus if I have the cable too tight the clutch is always partially engaged so the bike runs like crap... So I am still using vice grips to pull on the cable...

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Re: Puch clutch help?

Jason Luther /
amory
Aug 31, 2005 09:20PM

is this a stock motor? has someone (i am not nameing names) increased the compression of the engine (removed gaskets, shaved head etc)? my puch has about 135 lbs of compression and is hard to kick over. my morini also has increased compression and i have to start peddleing down the street and then engage the clutch or else the starting clutch just slips. just a thought.

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Re: Puch clutch help?

Chris /
goodphoto OP
Aug 31, 2005 11:03PM

I wish that was the case. It is a stock e50 motor, it does have good compression. But there is definitely something wrong with the mechanism for pushing in on the clutch plate or something related to the clutch hub itself, although I have tried different clutch shafts and different hubs both of which appeared to be in good condition.. I cant figure out why the clutch must be pulled so hard..

Has anyone experienced my situation? Please Help?

Thanks,

Chris

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Re: Puch clutch help?

Tom Carney /
gt6plus
Aug 31, 2005 11:53PM

Your clutch arm isn't bent is it?

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Re: Puch clutch help?

Chris /
goodphoto OP
Sep 01, 2005 01:35AM

No because I have tried two different crankcase cover/lever assemblys. I am sure they are not bent.

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Re: Puch clutch help?

Jim Leighton /
j44
Sep 03, 2005 10:13PM

Clutch doesn't always release stalling the motor. This is a 1977 Sachs on a Go Trek by Yardman. Help. Thanks Jim.

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