Honda GXH50 Kit - failure of gearbox, with photos, warranty claim in progress

[Sketch]

Here's the good news though: I'm very happy with the bike and I have a bunch of questions unrelated to this gearbox problem. I'll start a different thread for that.

 

[Kline's Kustoms]

Same Problem

This same thing just happened to me last week. My gearbox failed previously. The bell housing got chewed up. I called Jeremy at bicycle-engines.com and he supplied me with the correct replacement parts. There are some pictures below.

As for the gearbox housing mine blew a hole in the same exact spot. I don't know what could cause this. Were all the bolts that attach the gearbox to the the motor still there? I noticed when I opened mine up, I was missing the right bottom bolt. I am going to call Jeremy back to get the housing replaced. I will post pictures of this when I get home from Seatlle.

I haven't had much luck with the grubee. I ordered a EZ Q- Matic off Neil in Anaheim. It's supposed to be here this week. Hopefully this will be better than the **** grubee I got stuck with.

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[HoughMade]

Wow. I've got me Stage 2 gearbox apart right now with 2 years of use. I'll post pics....and you guys will swear that the thing has never been run. That wear is incredible.

 

[Sketch]

Wow!

I originally talked to Jeremy about not sending in the centrifugal clutch (just everything else), but then I double checked and I have some chewed up edges on the gear that's attached to the outer housing. I'm still waiting for a reply about getting the whole thing replaced (including the clutch)

 

[Sketch]

Just got some cool news from bicycle-engines (Jeremy) - he's going to send me an entire new gearbox (sent out today) without having me have to send back the old one - since he already saw how it's messed up via pics. I'm stoked! This means I'll be up and running again pretty soon.

Needless to say, I'm going to take great care with the installation of the new one. Whatever I can do to help prevent a repeat...

 

[Danny3xd]

Klien and Sketch, just wondering what, if any grease you used? I had that happen 2ce. Used white lithium.

Jeremy and bicycle-engines.com are great. Really good service.

 

[HoughMade]

OK, here is my clutch bell and intermediate gear. The brown stuff is old grease I have not cleaned off yet- like I said- brand new. Doesn't even look like anything has touched the bell itself. Those marks on your clutch bell are very odd.

 

[Sketch]

You run it dry?

 

[Sketch]

I greased up before assembly (can't recall the exact grease...it was general purpose gear grease). Then I filled with 50 to 80cc's gear oil as instructed. (again, I don't have the stuff in front of me so I can't tell you what exactly it was). I didn't have any synthetic lube to use.

 

[HoughMade]

I have run my gearbox with grease, with 50-50 gear oil and stop smoke, and auto trans fluid.

In other words, I doubt lubrication had anything to do with you troubles. As for Kline and that chewed up clutch bell, I really don't understand that. I understand that soft metal will result in the teeth getting chewed up, but I am referring to curved gouges on the bell itself. As you can see from the pics of my bell, nothing has ever touched it. Even with good metal, if there was contact, there would be a mark of some sort. That really looks odd.