DONE !

I'm finally done with the project, perfect timing since it's spring in Montreal !
that was definitely a cool winter project, stay tuned for the vids !

The exhaust that comes with the kit is attached in a weird angle, I changed the angle using a couple of 45 degres copper fittings.

Brake System

Since the rims won't allow any brake pads, I had to use the old backpedal brake system.
It's pretty simple, I just screwed an aluminium plate on the old sprocket and attached a cable to it, controled by a brake lever.
When I pull the lever, the plate (the sproket) rotate backwards just like when you pedal backwards.
The spring allows the brake drum to come back in position after applying the brakes.

Chain roller installed

I've installed the chain roller on the frame, since the engine is so low in the frame, the lower part of the chain had to go under the rear arm.
The chain was almost too short but i move the rear wheel forward as much as possible.
Everything is pretty tight but the chain will get loose after a couple of miles.

Centrifugal Clutch Installation Guide

1. Start by removing the right side engine cover by unscrewing the 5 screws.
Be careful with the gasket, it might stick a little bit.







2. Unscrew the big screw that keeps the small gear in place.
You'll need to block the gears rotation, for this, use a piece of copper wire so you don't damage the teeth.
A screwdriver alone might not be enough, use a wrench to help.








3. use the gear puller that comes with the engine kit, it's packed alone in a plastic bag.
Screw it by hand on the gear (it's threaded inside)
Then use a wrench to unscrew the whole, the gear should slowly pop out as you turn the wrench.
Once the gear is removed, remove the pin on the axle too using small pliers.





4. At this point, you need to install the new side cover but the studs from the big wheel won't allow it to fit.
You'll have to grind them to allow a perfect clearance with the side cover.
Be sure to mask with tape the center of the clutch cover to prevent any metal particles to get inside the clutch.







5. Now the new side cover fits perfectly, don't forget to intall the gasket.
I reused the same 3 bolts for the back but i used the 2 that come with the clutch kit for the front (they're shorter)





6. Now it's time to install the new centrifugal clutch, just slip it on and screw it in place (you might need to block the sprocket on the other side to prevent any rotation).
Don't forget the washers.





7. Then you just have to install the final cover, once again you'll have some clearance issues so I decided to cut some gaskets out of thick carboard, this will prevent the cover from touching the centrifugal clutch.
Rotate the engine to be sure the spacing is good.




8. DONE !
Put your home made gaskets in place using the remaining screws (2 long ones at the front, 2 short ones at the back).

You're ready to go !
No more messing wth the clutch lever (you might want to get rid of the clutch lever on the left side of the engine).

Finally attached the sprocket on the rear wheel.

I've read in the engine manual that they suggest to glue the sprocket on the hub with 5 min epoxy.
The thing is, the sprocket sits on the base of the spokes, I thought the surface wasn't big enough to have a nice epoxy bond.
So i cut away a ring of fabric (It's actually a fake Shamwow that some guy sold me in the street, i'm such an ass to have bought that) that i soaked with epoxy.
I used NU-LUSTRE-55 instead, same epoxy but dries in 24h :)

On the sprocket side, i carved little lines with my Dremel to have even better bond.
Once soaked, the ring of fake shamwow thickness is almost nothing so the alignment with the chain won't change.
Then I bolted the backplates and the whole assembly seems very strong !

The dismantled NEW DEPARTURE hub, i had to open it to remove all the sand from the sandblast and give it a good cleaning.