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Old 05-31-2015, 08:16 PM   #1
ScreechinHalt
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Question 1977 amf harley

Dealing with popping and backfiring. It has a crank seal bad behind the clutch and when it pops it blows smoke out of there. have replaced points, condenser, coil, plug and wire and rebuilt carb and flipped the reeds over cause I could see some light thew them. points are set @.022 @ TDC and plug is gapped @ .025. no idea where to go from here. any suggestions on how to pull the clutch so I can replace the crank seal if that could be the prob?
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Old 06-01-2015, 08:06 PM   #2
tew45
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Default Re: 1977 amf harley

Do you have a service manual? If so it is in the manual. However just start by removing the clutch cover and stuff starts falling out so watch what comes out and when. I would pull the engine and do the work on a bench. Working on the clutch and engine is a little hard for me to do while installed since I almost have to stand on mu head to do it. Put the engine on the bench and turn the clutch upward then parts do not fallout and get lost. Plus with the engine out you can check condition of the motor mounts, and wiring and grounds. Be sure it is timed in forward and reverse.
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Old 06-02-2015, 06:48 AM   #3
ScreechinHalt
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Default Re: 1977 amf harley

Thanks for that info tew45. It is set at the factory timing marks now and once I get the engine started ( which takes a bit of cranking ) it runs better in reverse than forward, BUT...once in forward it sounds like a misfire and smoke comes out not only around the pulley's but also from another area around the carb. I hesitate to say it's coming thru the reeds because I've not been able to see light thru the reed plate since I flipped them. The gaskets on both sides of the reed plate are made from gasket material and show no sign of a blowout. It has no power in forward and pops when you give it gas but will sit and idle fine. Advance the timing and it don't pop as much but it seems to run better fully advanced. So far the only thing that I haven't replaced on the Engine is the crank seal and am wondering if that may be " sucking " air and causing my power loss and popping. Point gap is @ .022 at TDC and are just open on the timing dots on both sides of TDC mark. The plug is set @ .025 and after it's set running @ an idle the plug shows it's burning thin white. Not sure where to go from here other than the crank seal.
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Old 06-02-2015, 07:22 AM   #4
Lochlin
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Default Re: 1977 amf harley

Don't trust those factory timing marks. I had the best luck making small adjustments until I got it right. Timing these carts is notoriously tough. I got so frustrated with it I converted to electronic ignitions but that conversion is a lot of cash.

Get yourself some new reeds. They are cheap and easy to install.

That clutch can be a bear to get off. I use a wheel puller to get mine off. A lot of other people use clutch bolts. These have an extension on them and screw down into the middle of the clutch (it's threaded) and against the end of the crank. Tightening this bolt while tapping it will then "push" the clutch off of the shaft.
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Old 06-02-2015, 08:26 AM   #5
tew45
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Default Re: 1977 amf harley

You should see a little light through the reed valve when at rest. I use a timing stop now when I time an engine (I tell how to make one in the threads) it is precise and don't have to look through the little holes. It takes a really special puller to remove the flywheel. I made some a couple of years ago. If you still have troubles I can let you borrow it. Also the engine does seem to have more pep in reverse (due to engine design) but nothing wrong at all with that. The popping and sputtering is spark related. Try to look at the points while the sputtering is happening. Also it could be the start switch being intermittent some (maybe) I think the seals are not the major cause of sputtering and popping (still? a slight possibility) usually bad seals will not let the engine run.
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Old 06-02-2015, 08:54 PM   #6
ScreechinHalt
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Default Re: 1977 amf harley

Thanks again for the info. The engine seems to want to run better with the points advanced as far as they will go however it dosent take care of the popping. The points and condenser are new as well as the coil and plug wire but I notice that when I check spark @ the plug it seems a bit weak (dull yellow in color). That being said though it will still give quite a jolt!! LOL. The points are producing a white spark. Maybe got ahold of a bad plug. It has been quite frustrating. No I don't have a manual but know a guy that might. He owns a cart shop but wont work on Harleys anymore and that's ok cause Ive almost got this project completed on my own and it is my 1st cart. Im the type that likes to do everything myself unless I just am not able to figure it out on my own and I think this qualifies. Ive built a lot of small engines and repaired a whole lot more but this one has been a real eye opener. I'm a seasoned old dog but never too old to learn something new. Thanks again for the info people. Heres to learning!!!
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Old 06-02-2015, 09:07 PM   #7
tew45
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Default Re: 1977 amf harley

http://www.buggiesgonewild.com/columbia-parcars/ will give you a manual. New condensers are from China and are sometimes bad. If you have a god spark at the points I would suspect the condenser since the condenser is supposed to hold reduce the sparking at the points. Also seems like the timing is still off for radical adjustments are rarely needed usually when the wrong point set is used.
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Old 06-03-2015, 07:24 AM   #8
73eldo
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Default Re: 1977 amf harley

With a leaking crank seal you won't get it to run correctly. You won't be able to get a proper mixture so you are going to get missfires which lets fuel build in the muffler which occasionally will get lit off and go boom.
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Old 06-03-2015, 08:08 AM   #9
ScreechinHalt
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Cool Re: 1977 amf harley

73ELDO, that's exactly what I was afraid of. Since its a 2 stroke with a reed valve and the engine has to be air tight for it to run correctly. Thank you.
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Old 06-03-2015, 09:18 AM   #10
tew45
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Default Re: 1977 amf harley

I been wrong before! Will be wrong again.
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