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[Sascha]

So I put a drill bit in to test it and it went more than 40mm into the hole...
Lets assume I have a 6x40mm bolt... to find the threaded fixing piece, I would imagine I have to turn the master nut (big crewed up bolt on the side of the engine case) to the right?! How far?
-Sascha

There is not really a way to take a meaningful picture of the bolt installed in the case.

Find the page in your parts manual for the "Kick Starter - Right Crankcase Cover" The bolt is a standard 6x40mm bolt and it threads into the fixing piece to provide a clamping force against the clutch adjuster. I suspect the fixing piece might still be inside the case but out of position and the bolt is hitting it when you try to put it in. You might try pushing the bolt in until it hits and then gently turning it on the off chance the fixing piece is still in place the bolt might screw right back in it.

If that doesn't work (and maybe even if it does if you want to be sure) you will have to take your right cover off. Whether the fixing piece is missing or whether it is in there but blocking the bolt from going in the hole, your clutch will not stay adjusted unless this mechanism is assembled correctly.

[Dgormley]

Sasha, the big"crewed" up bolt is your clutch adjuster. There is a bolt that goes through the little hole that attaches to a fixing piece that snugs the adjuster in place. You'll have to pull that side cover and see whats going on. If you do a search under clutch adjustment you will find the proper method for adjustment. Do you have a book, or manual yet?..................D

[Sascha]

Does anyone (by chance) have a picture that they can post of this 'fixing piece' behind the motor casing that I can see... ?
-Sascha

Sasha, the big"crewed" up bolt is your clutch adjuster. There is a bolt that goes through the little hole that attaches to a fixing piece that snugs the adjuster in place. You'll have to pull that side cover and see whats going on. If you do a search under clutch adjustment you will find the proper method for adjustment. Do you have a book, or manual yet?..................D

[cyclon36]

Here's a pic. The one on the left is the adjuster that you see from the outside. The part on the right is the inner part. When the adjustment screw gets turned, it moves that part in and out of the adjuster. The latch on the bottom of that piece that you see is what the clutch cable gets attached to.

[Sascha]

Okay, now we are getting somewhere...

So, I understand that the latch on the bottom of the part on the right is where the cable is attached to... Mines connected now.

I see the part on the left is the big 'bolt' that i have to turn to the right.

Now, once I turn the big bolt to the right, and i put the 6x40mm screw in, where does it connect to on the piece on the right in your picture? is there a hole it goes into on that part?
-Sascha

Here's a pic. The one on the left is the adjuster that you see from the outside. The part on the right is the inner part. When the adjustment screw gets turned, it moves that part in and out of the adjuster. The latch on the bottom of that piece that you see is what the clutch cable gets attached to.

[cyclon36]

There is a hole in the adjuster piece with spines inside. The piece on the right gets inserted into this and is pushed in and out by the splines force against the spiral cutout.

[Sascha]

BINGO... thats what I needed to know...

So when I put the bolt in, it will thread into the adjuster piece (the piece that is big and grey that I can see from on the engine casing). In short, the adjuster is the 'end nut' as the bolt threads into it, so I dont need to open it, i just need to put a bolt in... Im going to give it a run tonight and I will let you guys know how it goes.

-Sascha

There is a hole in the adjuster piece with spines inside. The piece on the right gets inserted into this and is pushed in and out by the splines force against the spiral cutout.