I have a CoolSports 250, sport model. It has the vertical 250cc engine, air-cooled, manual transmission. I recently replace a toasted clutch, and can't seem to get it back together correctly. It took so long to finally get all the parts I needed, I cant recall how the clutch is engaged. The clutch lever pulls a spring loaded rod, which is located ON the side cover. I am not sure what contact this spring loaded rod makes. I have a steel pin, looks to be about 3 inches long, that I have no clue as to where it should be placed. My initial assumption was that this spring loaded rod mad contact with this pin, pushing the clutch plates inward. This doesnt appear to be accurate.

Does anyone have a diagram as to how these components go together?

 

This clutch job has been a complete NIGHTMARE! The clutch basket I ordered as a replacement does not match up 100%, and it uses 6 plates instead of 7. The oil slinger I ordered to replace a damaged one is slightly larger, bumping into the clutch basket.

So, given that engines are relatively cheap, I am thinking that I may be better off picking up a replacement. The time and materials I have invested in this clutch replacement is getting to a point where an engine replacement would indeed be more economical.

I have a friend who has an 86 ATC 200X engine, CDI, carb, exhaust, EVERYTHING. My question to the Chinese quad gurus out there, will this engine mount up?

I am thinking that if I went to the ATC engine, I would have increased reliability, and parts accessibility. Not to mention, the 200x engine would probably out perform the chinese 250.

Thoughts, anyone?