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I am working on my girls Honda Sport 50 (It's a C110). I recently bought an overbore piston, Cleaned the carb, had the cylinder bored out, and relapped the valves. I got it running, but I have an issue.

The bike idles fine when in neutral, but when I pull the clutch lever, the motor stalls. This happens whether it's pulled in all the way, or just a little bit. I can sometimes keep it running if I pull the lever with the engine at high revs, but I know something is wrong. My first thought was that there may be an electric switch that is shorting (no battery as of yet, and the wiring is screwy still), but I looked, and pulled the clutch cover; no switches that I can see.

Does anybody have any clue what is wrong with it? I was able to ride it down the block without using the clutch, and it runs alright, but not with the clutch.
 

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There should be some kind of bearing surface between the throwout mechanism and the clutch. Sounds to me that this surface is not being lubricated, and is dragging the engine down when you activate it. You may have to take the side cover off to see why.
 

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That diagram isn't the best, but it appears that rotating #17 against #16 (which has little ramps), makes it push against #24. That, in turn, presses against the clutch through bearing #33. That bearing sticking, or there is a lack of oil where #24 makes contact with the center of the clutch drive plate, could be the source of the binding. Since this should be a wet clutch, there should be plenty of oil. But, taking off cover #2 should let you see what's going on in there. It appears that #16 catches in that cover to keep it from turning, so watch for that. It also appears that #21 holds ball bearings in #17 from falling out, another thing to watch for.
 
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