clutch wont disengage

[motopunk]

i installed the spacer first on the shaft before istalling the bushing bearing and the whole clutch assembly ... i hope i could help solving your problem... 

YOU SIR ARE A STAR!...clutch sorted with spacer and a bit of adjustment on the cable. Cant understand why it worked before disassembly and not afterwards 

Just need to get the d**n thing to start now!. Got compression, fuel (wet plug) and a good spark but will it fire...will it F@*k...even tried bumping it til i'm about to keel over 

wet plug is a sign of too rich adjustment on the carb, but my question in first: did the engine run before you worked on the clutch??... and before changing any jets, make sure that the crankcase is not half full with gas. i do a simple method: close the petcock, drain the carb, pull the plug . than throttle fully open and one finger with a towel on the sparkplug-hole for soft pressure and pumping with the kickstarter the engine dry inside.
if the engine is clean, try the normal starting procedur. 

[KevinTwoStk]

Dirty carb? Clogged choke or clogged pilot jet? Old premix in the tank? Clogged air filter? Is the air filter in good shape?

Are you sure your on the right thread? 

Pretty sure.  The clutch issue seems to be sorted out, but now the bike won't fire.

[motopunk]

Dirty carb? Clogged choke or clogged pilot jet? Old premix in the tank? Clogged air filter? Is the air filter in good shape?

Are you sure your on the right thread? 

Pretty sure.  The clutch issue seems to be sorted out, but now the bike won't fire.

i think we dont have to wait long time to hear the engine running... 

[sandblaster]

Dirty carb? Clogged choke or clogged pilot jet? Old premix in the tank? Clogged air filter? Is the air filter in good shape?

Are you sure your on the right thread? 

Pretty sure.  The clutch issue seems to be sorted out, but now the bike won't fire.

Doah!

[stig]

Thanks for the help folks but i'll have to put this on hold over the weekend as my lads moving house. Its all hand to the pumps and then playtime afterwards.

I'll check the carb settings etc and get back to you.

and yes, clutch issue resolved    THANK YOU!

[motopunk]

 ... little help = big finish... 

[stig]

Well sorry for the delay in getting back to you but things got put on hold as i've spent all my spare time working at my lads new home getting them settled.

In the meantime....
a few nights back I ordered a new plug and plug cap, remade the end of the HT lead.
I then dismantled the carb and treated it to a sonic cleaner. Checked all the jets were good and clear, needle undamaged and reassembled. Set the air screw to 1 and half turns as per the manual.
Again today we tried to get it going...still no go. I want to try to bump it down the raod as we live on a hill but the bikes too high for me as i'm only a short R's at 5' 6" and dont fancy my chances jumping aboard and then trying to stop upright whether it fires or not

Have checked and theres def a good spark and fuels getting through leaving the plug wet after prolonged kicking

running outta ideas now 

[don46]

Check the flywheel to make sure the key has not sheared, it has been know to happen.  Fuel and spark should equal run unless they happen at the wrong time, also check the reeds, they could be an issue.

[motopunk]

Check the flywheel to make sure the key has not sheared, it has been know to happen.  Fuel and spark should equal run unless they happen at the wrong time, also check the reeds, they could be an issue.

and also lay the bike for a short time to the left side to float the carb before first cold start... 

[stig]

Thanks folks for all the assistance. Its running!!!!! RESULT

Tried several things over the last few nights...double checked the carb settings inc set float height
double checked wiring and found a dodgy connector so remade that. removed flywheel to find key helf missing so made a new one and cleaned up the mating surfaces on the crank end so its a snug fit, checked the reeds were OK

Tonight when my lad came around and I had a second set of hands so managed to check things out whilst he turned it over. Reassembled everything and gave it a try...3 kicks and it burst into life

Not quite sure which of the bits were at fault and actually causing the problem but if I had to make a guess it'd be the wiring or the timing/flywheel seating

BTW, if anyone needs a pdf copy of the 1991 125/250 H2 workshop manual I have one...give me a shout and i'll host it for download (if thats allowed on the forum, if not admin please remove this comment)