Hangkai 3.6 hp Review: Clutch Repair (Part 1: Teardown)

Replacing the clutch in the Hangkai 3.6 HP outboard motor. This video shows how to remove a worn out clutch. A follow-up video will show installing a new one.

[@fridder.]

Thank you for taking the time to make these videos, they are very informative and cover a LOT more than every other video about these motors out there.

[@BoilerDan1]

Thanks. I retired a couple of years ago and the videos give me purpose 😂. I appreciate your feedback.

[@karendurrett8302]

Hi Dan, we just bought a 3.5 Hangkai and are so hoping that it lasts! We have enjoyed your journey so far and truly appreciate the videos! I only have 1 hr on it so there is a bit to go before we know if it is going to work! So far so good! You make learning this motor so much easier, thanks!

[@BoilerDan1]

Your welcome! I've covered lots of areas, hope you can find one to match any issues you may have. I'm happy to try and answer questions, just realize I'm no expert, I'm just on a journey with this motor too!

[@johnshelnutt1787]

Karen ive bought 2 myself, theres a few of us online to help out

[@JJG323]

Hi Karen, how did the motor hold up?

[@levi55ify]

your videos on the Hangkai motor have been very helpful! i have an old 70's merc that has a part that needs to be replaced but it is difficult working on it. these videos have definitely helped me decide on buying one especially after seeing how simple it is to work on

[@BoilerDan1]

Thanks for watching and taking the time to comment! 👍👍

[@frankgourlay66]

Love your videos Dan. Helped so much over the last few weeks

[@BoilerDan1]

Your welcome. You can also click the Thanks button below the video screen and add $1 to support my future videos 😂. A new feature that will be useful in my adventures 👍

[@calebstephenson8186]

I love your videos, please keep making them! Just an idea, if you replace the heavy clutch spring in the center with a lighter spring, it shouldengage quicker. If you go light enough, it should engage as soon as you pull the pull string keeping the wear down to almost nothing and keeping that water pump continuously running. I have never tried it, but would be curious to see the difference.

[@BoilerDan1]

Great idea, I'll see if I can get a lighter spring and update as I go!

[@TylerLL2112]

BoilerDan1 I’m curious about this one.. that may be something I decide to do. Maybe only after mine fails. My 3.6hp is coming today so I’ll be getting it ready to go. With your videos, I should be able to fix damn near anything on this little fella. Dan, did someone say a Honda carb fits on this Hangkai?

[@BoilerDan1]

I'm hoping yes that the carb will fit! But I've not confirmed that as of yet. The new clutch I ordered is for a Honda... It looks the same, and the diameter is correct. Just hope the bolt holes match up! I'll look into the carb match when I get a chance. Enjoy your new motor! Keep a wrench handy.... (0:

[@TylerLL2112]

BoilerDan1 Haha I’ve already needed to bust out a wrench. Fixed a couple issues I ran into. I noticed I don’t get much water coming out of mine. Impeller is good and the gasket on the outlet isn’t covering any holes. Now, I tested that inside a bucket (for lack of a better word) so I’m wondering if the prop was swirling the water too much. It’s a simple little machine. I hope I can keep it running.

[@BoilerDan1]

Yes, the prop would create too much air in the mix. But don't over accelerate if you remove the prop.

[@TylerLL2112]

I think that “copper” tube is copper washed steel. I’ve had my hangkai for 8 hours and it’s dead. I went maybe 200 yard before it went kaput. It was doing a great job until then. I broke the pull cord on the water so I need to address that. Oddly, mine came with grease in the gearbox. I replaced it with CRC marine gear oil. I’m running a 30:1 mix with royal purple synthetic. So... I have a project to work on. Should have went for a 2hp Evinrude and just rebuilt the carb and other odds and ends to make it run. I had a BIT more faith in the hangkai than I should have. I will report back after I tear into it. Love the videos and your help Dan!

[@BoilerDan1]

YIKES.... Hope others read the comments, as experience is a great teacher.... :0(

[@BoilerDan1]

Did you see where my spark plug went bad almost right away? I'm just adding to what can or might have gone bad..... Maybe you changed the spark plug already?

[@johnshelnutt1787]

Tyler replace spark plug, they will go out real quick, we can give u the different type u need. . u can always part it out if u have to if its really done, lord knws there arent a lot of parts for these an a lot of people are buying them.

[@TylerLL2112]

Weird I didn’t see Dans other messages. I was able to get everything running and back together. I just haven’t taken it back out for a good go. I went to the same area it cut out on me before and switched to an electric motor because it was 9:00pm and that thing was obnoxious. I also bought a 1985 Evinrude I’m getting running again. Once I got it running, I checked to see if the water pump was doing anything at the telltale and it wasn’t so, I killed it and I’m waiting on parts. I think I enjoy working on these too much. But at the same time... I don’t want them going out on the water.😂 I wasn’t going to try a plug because I was just put off by it dying so soon. So, I’ll throw a new one in now that I’ve cooled down about the situation.

[@BoilerDan1]

@@TylerLL2112 At least you have a sense of humor about it. My new clutch has arrived, I'll install it in the next couple of days.... I should have ordered two 😂

[@kennethmkirschprofessional267]

Interesting about somehow keeping the clutch open, and bolted. Or perhaps lining a rubber sleeve “shoe” inside the housing so it will be thicker and engage sooner with more grip? Maybe I can salvage my new HangKai by somehow locking down that clutch so the shaft will always spin? Look forward to seeing your new clutch instal!

[@BoilerDan1]

I was thinking about that, but concerned that if it did slip, the friction.... I'd end up with a fire.... NOT GOOD ON A RUBBER RAFT IN THE MIDDLE OF A LAKE! ha ha ha.... (0:

[@BoilerDan1]

Just removing the spring would probably have the same effect?

[@kennethmkirschprofessional267]

Or as Caleb said, put in a lighter spring, or somehow stretch out the existing spring a bit to loosen its tension?

[@dakodaspencershmacked5089]

Would doing this make it more difficult to start, since you'll be turning more than just the motor to start it?

[@BoilerDan1]

I'm guessing only slightly more to pull the start cord? I'm more thinking of getting a lighter spring so that it opens up sooner. Once I receive the new clutch, I'll check that out prior to installation and include that in the installation video. Thanks for watching!

[@timdegroat5068]

8 months times 3 miles a day..is about 720 miles I got out of this motor and it still runs...but now I have to figure out how to extract those hex bolts and replace the clutch pads..

[@BoilerDan1]

I had heard that salt water could be a little tough on this motor. Maybe that has something to do with the bolts freezing? Thanks again for contributing to my tale of a tale! 👍

[@smorrow0816]

Thanks for all the work you are doing on this...Couple questions: What is the better replacement part number for the spark plug? Why are the clutches wearing out so fast? What part numbers did you get for a replacement clutch and lighter spring? Thanks for all you are doing!

[@BoilerDan1]

Spark Plugs: Highest recommendation of received was for the NGK brand part # BM6Y I had first put in a Champion CJ8 and it was working fine, but doing some research and other viewers suggested the NGK brand, so I made the switch. Prime-Line Spring, Extension, 7/16 in. x 1-7/8 in. - .047 Diameter (LINK: www.homedepot.com/p/Prime-Line-Spring-Extension-7-16-in-x-1-7-8-in-047-Diameter-SP-9605/202639133?cm_mmc=ecc-_-THD_ORDER_CONFIRMATION_BOSS_STH-_-20191021_THD_ORDER_CONFIRMATION_BOSS_STH-_-Product_URL__W844205603withTHD But I don't know yet if it will fit or not. The one in the video was from Menards: Extension Spring Part # 88195 size 15/32 X 1 13/16 but I had to alter it. The clutch also fits the Honda GX31 or GX35. Here is an Amazon Link: www.amazon.com/gp/product/B07J6F4J6M/ref=ox_sc_saved_title_1?smid=A26QN2ZDA6KSBT&psc=1. I think it wears out because the spring is too strong for what they are using it for... But I don't really know?

[@darylphipps2919]

As a whole it does look pretty straight forward to operate and repair. Hopefully the replacement clutch will either last longer or be able to upgrade from a weed-eater type clutch?

[@BoilerDan1]

I agree. Thanks for watching!

[@richardsargent5895]

Thank you very much for your videos ProveIs this the motor I want to buy ? Lol . No of course not. Is it the cheapest thing out there For emergency use. Yes It seems to be. Your videos have been very Enlightening and helpfulIn getting my Hancock 3.6 ready for service. One of the 1st things I noticed beforeI saw your video on the clutchWas that it took a very high RPM for the clutch to be engaged.I was wondering if you thought a weaker throwout Retraction Spring Would fully engage The scientifical cluscientifical clutch sooner and limit burn out of the clutch friction pads? If you haven't attached your new clutch yetPerhaps it would be worth an experimental try. Thanks again for your videos

[@BoilerDan1]

Yes, I have attached a lighter clutch spring. I definitely think it is a better way to do it! If you search my series on the motor I do show my replacing the spring and also putting in a new clutch too! Thanks for watching 👍

[@myparadiseonbantayanisland9030]

How many hours of running did the clutch last?

[@BoilerDan1]

Sorry, I didn’t keep track of it. That being said, I noticed it towards the end of the first season….. but definitely started going out that second summer here in the USA. I would recommend changing the tension spring right at the start. I’ve heard of people just removing it and just shutting off the engine when wanting to idle. The tension spring is way too tight for sure.

[@roycornell2001]

gonna save my little motor gonna take it apart tomorow that my engineeer fabricated tomorow and cut the 2 springs 4 brake pads so it should last awhile hoping it works because motor itself runs good wish me luck and thank you for the videos

[@BoilerDan1]

Wish I had your engineer to put some pads on mine!

[@johnshelnutt1787]

Boiler Dan. Thank s for taking Point, on these motors. I have my 2 3.5's i ordered. in box an working on the first one to set up. its been HOT 95 -98 for 2 months here in Montgomery Alabama with heat indexes up to 111 degrees, So im not going to put it in water or my boat til its cools a bit. are u using Ethenol treatment removal additive to remove ethenol out of ur Gas.? Been using it for years in my autos an motorcycles. Not real clear on 2 cycle outboards, Although Ive a robi gas weedwacker an use ethenol removal-an it runs well. Tks John

[@timdegroat5068]

My recoil cord broke at the Sametime my clutch went bad...now I live on the ocean and use this motor for about 3 miles a day in saltwater...the hex heads all 4 snapped trying to get them off on the recoil...

[@BoilerDan1]

That’s not good…. Hope some of my experience videos will help you make repairs! Thanks for watching and taking the time to comment. It’ll help educate others 👍👍

[@Excalibur698]

Hi Dan! Great videos. I bought this 3.5hp two stroke as a backup. I've only had it a few days. The motor fires right up although I needed to replace the plug after letting it idle for about an hour. My question: my shaft and propeller don't spin freely like yours. It's takes some pressure and a wrench to turn the shaft and gears. I removed the lower end just to make sure it was the lower end gears. Was yours like this? When I invrease the rpms the clutch will engage but I don't think the shaft should require so much force to spin.

[@BoilerDan1]

A clarification: Just want to make sure that you added gear oil to the lower gears? That being said, this motor has too strong of a spring in the clutch system. That so at an idle the propeller will not turn. The issue is that you have to get high rpm’s for the propeller to engage. That is also when the water pump wheel starts turning to cool the engine. It also puts excessive wear on the clutch pad. Lucky for you I made a video on my changing the clutch.... but if you’re just getting started, it will work a lot better and your clutch will last longer if you replace the spring. I’m going to put links below to the videos I made replacing the clutch. It will also show the replacement of the spring. NOTE: the 1st video is actually the last but it will show you the spring. I used the one from Menards... The one I mention from Home Depot was too small. 1-spring type kzbin.info/aero/PLjMZtm2hvqrOIvLcah1u1V45Y_R-AKeqm 2. Clutch replacement:; kzbin.info/aero/PLjMZtm2hvqrOIvLcah1u1V45Y_R-AKeqm 3. Clutch putting it back together kzbin.info/aero/PLjMZtm2hvqrOIvLcah1u1V45Y_R-AKeqm 4. Runs great after lighter spring kzbin.info/aero/PLjMZtm2hvqrOIvLcah1u1V45Y_R-AKeqm Let me know if I can help more and I will try. Thanks for watching 👍👍

[@johnshelnutt1787]

FYI Dan jus saw a 3.5 video where fella removed clutch spring completey. Did video him an daughter on water running well. I commented to see how its running still? So all things being even, I had no idea it would run without that spring, course im green on outboards anyway, would save the wear an tear if thats the case.

[@BoilerDan1]

Just received my replacement clutch. Went to Menards and found a less strong spring and will replace the one it came with. I think removing it, it would run without a problem, but I'm hoping this weaker spring will allow me to idle? I'll post the video putting it back together in the coming days. I'll include info on what clutches fit it... Very cheap fix, but will probably need done every season..... or two.

[@johnshelnutt1787]

That would be so helpful to know where u get ur clutchs, ill most likley need to get a inventory of them. Could u include in part 2 as well did u locate a new gasket??. if not can u detail how We could make one?. Thanks Dan u the man. John Montgomery alabama

[@BoilerDan1]

I purchased some gasket sealing stuff that I'll use. But you can also buy gasket sheets to cut yourself at any auto parts store. I'll show it in the video. The clutch I will show type and where to get, so far, they are also easy to get on line via Amazon or eBay. I'll show that on video too.

[@bobbysteckel5824]

Did you add grease to the grease insert? I cant find any videos please help

[@BoilerDan1]

My apologies for not replying. For some unknown reason I have about 6 comments that I did not get a notice of? Yes, I did add grease using a standard grease gun. It only puts grease on the collar where you turn/spin the motor to change direction. It could probably function fine for years without adding more grease.

[@williamhitchcock2861]

You made it harder than it Has to be you don’t have to take the six bolts out and remove the whole thing from the lower leg around the fly wheel there are four Allen screws that are the smaller Allen screws you can just remove those in the motor comes apart without the fly wheel guard and just the clutch the clutch bell will stay with the plate on the lower leg

[@BoilerDan1]

Sounds good, Thanks! I was just doing it as a true unknowing beginner without instructions 👍😅

[@ah2347]

Hey @Boilerdan1, as always love the videos. Update on my journey, at the 9th hour of break in, my motor was at half throttle and suddenly sounded like it was revving up on its own without any input from me. So I turned the throttle to idle. I left it there for a minute and again without input from me, the motor sounded like it was revving up. I turned it off for 5 minutes, turned it on, waited a minute, turned the throttle half way and it sounded okay for a second and then suddenly started revving up super fast. Then I heard a loud pop and the motor turned off. I tried starting it again, the motor turned over, but wouldnt start. I thought my first troubleshooting step should be check the gas then check the spark plug. The spark plug was done for, I replaced it with the NGK and it runs okay after that. Anyway, I had a question regarding the clutch replacement. What clued you into the clutch needing replacement? I watched this and Part 2 and I can't recall you mentioning if you noticed the motor running funny or if you changed the clutch for preventative service reasons. Thanks again in advance.

[@BoilerDan1]

That sounded a little scary! Glad that the spark plug brought it back to life! On the topic of the clutch, I noticed that it didn’t seem to catch unless I was almost at full speed, then I thought I had lost some thrust? But I wasn’t sure…. Then I launched and when I accelerated, I had almost no forward motion! Fortunately I was able to get back to shore and began my adventure on clutch replacement! Another viewer advised that I didn’t need to remove as much as I did? Apparently working from the other end would have been easier? In the process it is obvious that the clutch spring is too heavy for this application. Some even advocate just removing the spring all together! It makes sense, you just need to be aware that your propeller will always turn. That would keep the water pump wheel turn also, which could be a good thing too! At idle, your speed would be slow and just shut down as you pull into dock….. give it some thought. Minimally, I’d find a lighter tension clutch spring. My thoughts anyway 😁

[@ah2347]

@@BoilerDan1 Thanks again... hey so I have a power issue.... I made a little video I was hoping you could take look. The issue is it seems like it loses power for a few seconds and then powers back up over and over. If you get a chance take a look and let me know: kzbin.info6-SpKXc8FXI?feature=share Thanks in advance.

[@BoilerDan1]

An Important error in my video….. I failed to mention that I kept adding snow to keep the water cool. I suggest that you run a hose in the bucket or better yet, just take it out on your boat! I only did the bucket because 1, it was winter & 2, I didn’t have a lake nearby….. It could be getting a little warm.

[@BoilerDan1]

It could also be the amount of oil to gas mixture. During break in, the oil is a little richer. Once you go to the normal mixture that’ll help too.

[@nickb6529]

Does replacing the clutch spring with the weaker menards spring allow you to run at slower speeds? I slowly back-troll a lot and I am looking at doing exactly what you described. Thank you!

[@BoilerDan1]

Yes, it works much better and you can get the propeller to turn at less RPMs. You could also remove the spring, but the propeller would always spin so to stop you’d need to shut it of. But you’d be able to get the slowest speed possible. Thanks for watching 👍 NOTE: In one of the videos I mention a different spring. It didn’t fit, so the Menards one worked out the best.

[@nickb6529]

BoilerDan1 Thank you!

[@nickb6529]

How many hours on the water before the clutch went?

[@BoilerDan1]

I don’t exactly know? But I’d recommend having a spare available! You can tell that it’s wearing out as you get a feel for your motor..... it sounds a little different, like you can hear it slipping and you lose some power (thrust). I do think adding the lighter spring will increase the life of the clutch because it engages easier. Without the lighter spring, I would plan on replacing it at the end of the the summer each year. Mine lasted two seasons however I didn’t take it out all that often.

[@thrashenoutdoorstv3675]

My propeller does not spin..can you please help..brand new..runs great no spin..can you help please

[@BoilerDan1]

The propeller won’t spin until you give it almost full throttle. The spring in the clutch for this motor is too strong. I will attach a link to a video that will show you the clutch. I hope it will help you understand how it works. You should watch all of these to understand the clutch system: 1 kzbin.info/www/bejne/fmXQgXqrerChgas 2 kzbin.info/www/bejne/h6acgJ2Ol7KoqqM 3 kzbin.info/www/bejne/fWXUfapnadGZb80 4 kzbin.info/www/bejne/fWXUfapnadGZb80 Let me know if those helped!

[@thrashenoutdoorstv3675]

Thank you that was it...wasn't at full throttle .

[@taylorreeves6797]

Where can you find replacement parts for these motors, I need a smaller jet?

[@BoilerDan1]

I’ve had success with eBay. Just search Hangkai 3.6 motor parts. I’ve also located the company that makes them. Although a little different/ difficult to work through it, I did find helpful information. Here’s the website…. You’ll need to select English on left side. If you click the vertical lines upper left you’ll get a drop down menu. Select “News” and you’ll find information on repairs and troubleshooting. You might be able to get parts from them directly? NOTE: I’ve never tried that! eBay is where I found the items that I needed. Thanks for watching, hope that helps 👍

[@BoilerDan1]

Oops, forgot to add the website m.hang-kai.com/en/

[@taylorreeves6797]

@@BoilerDan1 great ill check them out, thanks!

[@prestonellsworth6579]

After all the fixes and tweaks would you recommend this motor to a friend?

[@BoilerDan1]

Good Question! To me, the motor overall is sound, but the little things make it a little high maintenance! So to recommend it to a friend would be only after they understood that cheap comes with a price! The fuel lines for example are a little thinner than what you can buy at a local mower supply store. So I just purchased new ones for both inlet and outlet. Cost was $6 but they will last a lot longer. Same with the spark plug, not expensive, but needs to be better than what came on it from the factory. The clutch for sure is something to plan on replacing every season... Again, inexpensive.... But unless you enjoy doing the work, it's not a motor I'd recommend to someone that doesn't enjoy working on the motor. So, overall I would not recommend it to a friend because I wouldn't want to be responsible if they are disappointed. That being said, I WOULD BUY IT AGAIN FOR MYSELF. Mater of fact, I'm considering selling my 2 cycle and starting over with the 4 stroke to evaluate it, and not have to mix oil and gas! I'm also considering a different raft, to one that has a better (solid) back end to attach the motor on. Thanks for watching and participating in the ongoing conversation!

[@prestonellsworth6579]

@@BoilerDan1 thanks for your quick response and all the information you are definitely an asset to a lot of people.

[@johnodonnell820]

Hey I just received my hangkai 3.5 and the exhaust water isn't coming out of the port it is coming out of right above where the motor pivots on the mount... there is a small amount coming from the port when I give more throttle

[@johnodonnell820]

Just wondering if you might have any ideas of what could be going on? Thank you

[@BoilerDan1]

At an idle water will not circulate at all. The pump is hooked up to the propeller shaft and there’s a clutch system that engages as the motor rpm’s increases. If water doesn’t come out at half throttle then there’s could be other issues? Here’s a video that shows the clutch. You might try loosening the clutch mount bolts or replacing the clutch tension spring with a lighter one... Let me know how it goes

[@johnodonnell820]

Yes I understand it doesn't come out on idle..the problem is it's coming out of the wrong area its coming out just above the plastic exhaust port where the motor mount connects to the vertical shaft between the motor head and the exhaust port I'll problem just tear it apart and see how she tics..

[@johnodonnell820]

Thank you for the hasty reply I appreciate it I will try the clutch spring as well

[@BoilerDan1]

I also have a little water that comes out in the same area. There are rubber tube water lines that you can see once you take off the engine cover. The clips that secure them are real cheap.... It might be leaking around them. I've not fully checked mine out because it has never been a large amount and I knew it couldn't be from the motor itself. Also, the clutch has a very thin layer of abrasive that wears out pretty quickly. I gave you the wrong link in my first response. I've made 4 that cover the clutch and spring. Here they are: 1. Tear down - kzbin.info/www/bejne/fmXQgXqrerChgas 2.Clutch replacement - kzbin.info/www/bejne/h6acgJ2Ol7KoqqM 3. Spring replacement - kzbin.info/www/bejne/fWXUfapnadGZb80 4. Motor running with new spring and clutch - kzbin.info/www/bejne/gpXXeod8rZuBY7M Changing the spring to a lighter one has seemed to help, but you can plan on that being a regular replacement project. Although I didn't find an exact match for the spring, I was able to use one I picked up at Menards, just had to bend it open..... Good luck, hope all goes well with yours. Still to cold here for me to go out.

[@NaughtyGoatFarm]

Do you have a video on replacing the water pump impeller?

[@BoilerDan1]

Not as of yet. But when I replaced the clutch, I could see how it would be easy once you open up and remove the shaft. The clutch just slides on and off of the shaft as is evident of it's square opening that matches the shape of the shaft itself. If I ever have to replace it, I'll be sure to record the process. (Oops, maybe I should have said... When I have to replace it! :0)

[@NaughtyGoatFarm]

@@BoilerDan1 thank you. Where is the impeller located?

[@BoilerDan1]

@@NaughtyGoatFarm : It is down close to the bottom of the shaft but before you reach the lower gears for the propeller. In the clutch repair video, I show where the water impeller is located between the 9:35 - 9:50 minute mark. Here is a link to that specific video. Just fast forward to about the 9:35 minute mark. It's covered by a white plastic cover held in place by two screws. Here's the link: kzbin.info/aero/PLjMZtm2hvqrOIvLcah1u1V45Y_R-AKeqm

[@NaughtyGoatFarm]

@@BoilerDan1 thank you again

[@adradic3782]

Hav many hour do you have on your hankai

[@BoilerDan1]

I can only estimate. Somewhere between 50 to 100? I'm considering changing the clutch every season. I will decide that after I run the new one for a while. They are not expensive, less than $15 IS dollars.

[@adradic3782]

I have 18 what s. The sintoms

[@BoilerDan1]

Damir Radic : It had a loss of power to start with and then it just had almost no forward moving. Looking back, it also had a metallic sound when running. I’d recommend you order a clutch and have it on the way!

[@fredhinck8847]

30 hr disposable weed wacker motor, wouldn't be on my boat. You get what you pay for.

[@BoilerDan1]

Not disagreeing with you. I didn’t pay much and am just documenting my adventure. If it helps someone to decide to buy something better, then my efforts are of value. I’ve still enjoyed messing with it! Thanks for watching and taking the time to comment.

[@timdegroat5068]

At 300 bucks...that's less than .40 cents a mile..

[@BoilerDan1]

I'll add a summary here: You can get more life out of both the pull cord and the clutch! 1. Rub Bee's Wax on the pull cord and refrain from pulling it all the way out when starting. 2. When you replace your clutch, put on a much lighter clutch spring. Or you could even just take it off. Your propeller will always spin, but at a low speed, you wouldn't get much motion from it. Not trying to tell you what to do, I just know those two things helped mine out a lot.