my first catastrophical failure!

linnix13

Member
Local time
4:18 PM
Joined
Mar 6, 2009
Messages
220
Location
dundas ontario
i was riding up a hill today doing around 30kph when i heard a loud crunch then the engine just revved and crunched and my back tire locked up. so i pulled in the clutch and stopped and looked at my idling engine, it sounded something fierce! it was grinding and crunchin like mad! so i hit the kill switch and walked home. when i got home i pulled of the clutch cover and saw this(the attached pic) so i thought that mabey it was just the gear that failed but when i pulled the gear of and tried to push the bike the clutch gear rotated about 3/5ths then i heard metal on metal and it jammed. so im asuming that the bushing inside must have failed and that jamed the hole clutch and the little gear was forced to snap. once i pulled the clutch in and idled it i thing that the sound i heard was the bushing and the drive shaft scraping each other and the gear was already mangled. so i will pull the engine apart and try to make my own bushing to replace the broken one and i have a new gear on order from zoom bicycles. i hope to be out and riding again soon. this engine has over 3000km on it that a 230lb guy who loves to go 50kph over curbs and jumps rode. so i did not "baby" this engine. i will report back once i get the engine apart. thanks
 

Attachments

  • 100_3098.jpg
    100_3098.jpg
    152.4 KB · Views: 357
Do you have the puller tool to remove that gear?
and to pull the clutch off to see what is jammed

There are no bushings in the case
There are ball bearings under both gears

Check the keys on the shafts

You probably need more than a new gear

Did you ever grease those gears?
 
Last edited:
Do you have the puller tool to remove that gear?

Remove it and check to see if the woodruff key on the shaft failed too

There is no bushing
there is a bearing under the crankcase seal

yeah i have a buddie who has an entire shop at his disposile. he said that when he took the motor apart there was a bushing in there and not a bearing.
the shaft that the big gear is on is the one with the problem not the crank shaft.

im replacing the little gear and my buddie is going to pull the engine apart and try to fix whatever is broken inside the large gears shaft. do you think its hopeless? should i just buy a new engine or should i attempt to re use this one?
 
Do you have the puller tool to remove that gear?
and to pull the clutch off to see what is jammed

The tool usually comes with the new kit

Can you remove the clutch? (big gear)

All you can do is pull it off to see all the broken parts that you will
need to replace then figure out if it is worth it

The clutch freewheel bearings may be shot and jammed

Check the keys on the shafts
 
Last edited:
Do you have the puller tool to remove that gear?
and to pull the clutch off to see what is jammed

The tool usually comes with the new kit

Can you remove the clutch? (big gear)

All you can do is pull it off to see all the broken parts that you will
need to replace then figure out if it is worth it

The clutch freewheel bearings may be shot and jammed

well i cant remove the big gear even with all the bolts taken off. it seems to be jamed. but at the shop they have every puller imaginable
 
not jammed

oh and the clutch wheel is not jamed it just gets very very hard to turn and makes grinding noises at a certain point
 
well i cant remove the big gear even with all the bolts taken off. it seems to be jamed. but at the shop they have every puller imaginable
Its a special double ended 2 piece tool that threads into the center of the clutch to pull it

It also pulls the front gear and the sprocket

I guess you did not get one with your kit?
 
Last edited:
i think i did but i lost it long ago
that sucks :devilish:
cause you really need it.....

I have a whole box of them but that won't do you a lot of good

If you buy a new motor you will get one :giggle:

OK, Good luck!
Let us know what happens.....
 
Last edited:
that sucks :devilish:
cause you really need it.....

I have a whole box of them but that won't do you a lot of good

If you buy a new motor you will get one :giggle:

naw like i said my buddie brett has access to the biggest shop! they have every kind of puller imaginable. he pulled them once before
 
Back
Top