OK, so my first problem was that it would not start with the key. I then used the pull cord so often that IT finally broke. I bought and replaced the solenoid and that did nothing. So I purchased a new starter and began watching all of the videos on replacement. I tried and tried to remove the bottom bolt without getting into the clutch removal method to no avail. I even saw one video where the owner drilled a hole in the back of the clutch base plate so he could get a socket on the bottom bolt. I looked at doing that but the hole would have been too low and would have had to go through the metal attachment plate. So even though I didn't want to get into clutch and secondary removal, it appeared to be my only option. I also watched a video on clutch removal and since I didn't want to wait for a clutch removal tool to arrive I looked into DIY methods. One guy suggested removing the long 7/16" clutch bolt and installing about a 3" cap head bolt into the threads followed by a 3/4" fine thread bolt. When the 3/4" bolt hits the top of the cap head bolt it begins to pull the clutch from its shaft. I couldn't find the cap head bolt but I did find a fine thread 3/4" bolt. Another video suggested using a deep socket and a short socket and then the 3/4" bolt to pull the clutch. I went with the later method but just let me state that when using this method, don't use cheap Chinese sockets from the dollar store as your spacers. One socket cracked and the small socket crushed and was almost trapped inside the clutch before it let go.

All in all, I was able to get everything removed, the starter installed and everything reinstalled. I turned the key and she started right up but when I put her in gear, nothing. If I press the yellow button, it will creep about an inch either in low or reverse but that's it. The belt looked fine when I replaced it but my machine although running won't move. I also noticed that the display on my instrument cluster is flashing.

So does the group have any thoughts on this? I probably should have left the cover off so I could have seen what was going on when placed in gear but I was so thrilled that she started I just wanted to get it all put back together. The shifter moves back and forth and the lever on the transmission also moves so I don't think that it is an issue with those.

 

Well today I installed a recoil kit and now she starts both with the key and the pull cord. Still no movement in forward or reverse. So I pulled the clutch cover and I have found the culprit. The center bolt on the secondary is backing out. I tried several times to tighten it and even had to put a bar between the outer rim of the secondary and the foot rest support to prevent it from spinning while I applied pressure on the socket wrench while tightening. After several failed attempts at this I removed the bolt and noticed that the lock washer was broken. I replaced it with another and tightened it up again. Got about 50 feet and she let go again. Tightened it again and got another 25 feet and loose again.

I almost have this problem solved but can not seem to get this bolt to stay tight.

Any suggestions?????