Clutch won't come off (Homelite 7-29)

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You mean the pulley rubs the cover? Could be any number of reasons. Is the cover dented? Does the pulley wobble on the crank (there are 2 needle bearingsband races in the hub that need grease and can wear). Is the pulley set out too far? There are shims right under pulley that you remove or add to space it away from the fan housing.

Finally, this is a common issue and why so many covers turn up missing. If it gives me trouble, I just remove them when using and replace it on the shelf.
 
You mean the pulley rubs the cover? Could be any number of reasons. Is the cover dented? Does the pulley wobble on the crank (there are 2 needle bearingsband races in the hub that need grease and can wear). Is the pulley set out too far? There are shims right under pulley that you remove or add to space it away from the fan housing.

Finally, this is a common issue and why so many covers turn up missing. If it gives me trouble, I just remove them when using and replace it on the shelf.
I believe everything is assembled correctly, but the shim was apparently a bit damaged, so I made a new one which now when I think about it maybe a bit thick...
 
Alright. Here it is. I've 3D printed a shim, but I will make it a bit thinner, as I suspect that's way too thick...
 

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I replaced the most inner washer with a thinner one, and a locking one above, and finally tightened the nut, as according to the illustrated parts list to the saw. The choke rod is homemade.
 

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