JCL MP 250 A starter clutch replacement By 4950cycle (Read 7,617 times)

[4950cycle]

Well, this is going just like the usual. I got my gaskets today from Motopartsmax.com in the mail. I only needed one of the gaskets for this repair and it was all broken up in the package. I was so mad . This project seems to have been going like this from the start. Every vendor besides Absolutely scooters has been an idiot. This one (Motopartsmax.com) sent a set of brittle Chinese gaskets in a very flexable padded minilla envelope. Well, need I say more. Anyway, I don't have time to send stuff up and down the road anymore. So I'm going to use the gasket broke completly through in two places and try to make it work with blue RTV in the damaged areas of the gasket. Especially on the bottom section of the case cover where it has to contain the crankcase oil. I will fill it with oil after the RTV cures tomorrow and will leave it for a night and make sure the motor doesn't leak oil. Then the centerstand running test to make sure all my fixing was sucessful. Then I will start puting all the plastics and such back on the scoot. Tomorrow I will post some pics of the new starter clutch on motor right before the cover went on this afternoon.

[alleyoop]

HAHAHAHA, that is funny as shit but you have company so don't feel to bad 4950cycle. Same shit happened to me I also ordered a set of gaskets and like you only need one at the moment. I want to even go taller with the the tranny gears, the OEMs were 13/40 and I have 16/37 right now but I ordered 18/36 gears and naturally need a gasket. Well the damn thing came like yours folded on one end to fit the envelope. Dumb SOBs that they are I tell you, they just don't care as long as they get the money. But like you I well add a little red atv where the two folds are on the gasket. Never a dull moment I tell you with these dumb vendors.
Alleyoop

[4950cycle]

You ain't kiddin, Always Drama with these guys ( we know who we are speaking of ) ; Different ratios inside Hhaa. I like it. Didn't know they offered different gear sets for these. Right now my girlfriend's JCL 250 seems to have almost perffect ratios for the job at hand. If I can keep it running. Next I'll have to pull the whole front end apart on it to find out why the ignitions cutting in and out ! But so often I run into the wrong ratios for the job at hand on two wheeled vehicles. Got lucky again though, I have a Ninja EX250 I'm slowly converting into a trike for my Dad. Since it was geared from the factory to pull a respectable 1/4 mile time for the motorcycle reviews in the magazines to help promote them, It has almost the perffect gearing also for a trike with a heavier load. One less thing I have to customize on it for the job.

[insanetexan]

Anytime you need a gasket just go to the local auto parts store and buy the roll gasket that way you can make your own. used to do that all the time for the car i owned and it is a lot cheaper. all you have to do is lay the gasket material on the item and tap it lightly with a hammer(preferably brass) and you will have a perfect gasket.

[alleyoop]

Yep, I have a roll of the gasket material but it is a little hard when the motor is still in the scoot to put a piece on and tap it around. That works great if the piece is faceing up and your taping down on it. Done that many times and it either cuts around the edge or leaves a nice indentation that you can cut around it.
Alleyoop

[4950cycle]

Next time I won't be so lazy and I will follow your advice on the home made gaskets. Got the motor all buttoned up. RTV hopefully cured now and filled it with oil. Letting it sit over night with a clean piece of cardboard under it. This way I will see if it leaks so much as a drop of oil. If no leaks , I will post the couple end pics and start puting the scoot all back together again.

[4950cycle]

Oh, I forgot that on those trike scooters there are sprockets mounted off a jackshaft type thingy. So you have the luxury of being able to change your final ratio. I read your post over again and realized what your fraction like numbers meant. PS I am posting end pics of starter clutch project in just a minute.

[4950cycle]

This is a pic of the flywheel , Starter clutch and the stater in the cover to the side. As you can see I have put blue RTV around the base of gasket where it was broke in a couple places. This will hopefully help in makeing the case oil tight. Remember, this is a part of the crankcase that holds all your oil. I bolted the cover on right after this pic.

Attachments:

[alleyoop]

The Trikes have the same tranny gearing just like the 2 wheel scoots. Which is what I am talking about the Actual Gears in the Tranny that you can also change out on your 2 wheeler. You can go Lower higher Ratios gears which will give you a lot of pull but less top end or you can go with Taller gearing which will give you less pull but more top end.

The Trikes also have TWO sprockets one is your Drive Sprocket and the other is on your Differential. Usually on the Trikes the way they have the Axle mouned to the swingarm you cannot change the Sprocket on the Differential because of clearance problems but you can change the Drive Sprocket.
Which by the way was one of the first things I changed, the trike came with a 24 tooth Drive Sprocket and I put in a 29 tooth drive sprocket.

Here are the Tranny Gears that can also be changed:
Alleyoop






And this is the Drive Sprocket I changed from 24 Teeth to 29 Teeth.

[4950cycle]

I meant to post this pic before the pic on "MY" post before this. You can kind of see the new starter clutch I bolted the flywheel to after putting it on first (the starter clutch). That is the way it should be done I found out . First put the starter clutch on the shaft. Then bolt the flywheel to it with the three allen bolts. And handle the key and keyway on the flywheel accordingly. Make sure you use the same holes that the allen bolts were already in. I noticed my flywheel was balanced and putting the allen bolt in different holes than before might make it slightly out of balance. If you have a problem with the crank shaft trying to spin when you tighten the allen bolts open up the timing chain cover on the other side of the motor (same cover to do your valve adjustment with) and stop everything from turning by sticking a screwdriver in the timing chain and sprocket .

Attachments:

[4950cycle]

I closed her all up and let the RTV cure for 24 hours empty. Filled the crankcase with a little over a Qt of oil. And let it sit overnight with a piece of clean cardboard under it to see if she leaked so much as a drop. Success, Not a drop of oil on the cardboard the next morning. ;D

Attachments:

[4950cycle]

Put the exhaust back on, put the airbox back on, reconnected some electrical connections and connected the battery for a centerstand running test. She stammered a little at first. But after I got it used to running again it runs great. Starts within a turn or two of the motor everytime cold or hot. Runs solid at every RPM range. And last but certainly NOT LEAST ! Doesn't STALL no matter how you treat the throttle or how hot or cold it is. Just wish I wasn't one of the unlucky ones who got this JCL with one of the Linhia's with a faulty starter clutch. Remember, this scoot only had 750 miles on it when this failed. Jeff at Mudville scooter and small engine repair said that the starter clutch is a weakness in the Yamaha YP 250s and these Linhia Yamaha knock offs. Now I have to figure out how to fix the ignition that cuts out for no apparent reason on and off.

[4950cycle]

So your going for taller gears or shorter (quick) gears in this trike Ally ? Looks like your trying to make your scoot quicker (less top end). Probably to pull that extra weight of your three wheel setup better ?

[alleyoop]

Congratulations on getting your ride up and running like it should. Good job on putting the new Clutch starter and taking pictures.

No, Taller gears means I am going for EVEN more top end than the ones I put in which are 16/37 and I am going with 18/36 gears, remember the Orignials were 13/40 gears. Out of the crate with the 13/40 gears it would do 50mph at over 8000 rpms.

Now with the mods I have on it at 5100 rpms I am doing 50mph 6100 rpms I am doing 60mph motor is just purring.
Alleyoop

[4950cycle]

Who offers all these gear sets for these Linhia 250 motors Ally. This is a nice thing to know about these. To be able to customize your final ratio like that is a luxury for a belt driven vehicle. And BTW, How much $ per gear set ?