my first catastrophical failure!

Discussion in '2-Stroke Engines' started by linnix13, Apr 26, 2009.

  1. linnix13

    linnix13 Banned

    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
     

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  2. MotorBicycleRacing

    MotorBicycleRacing Well-Known Member

    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: Apr 26, 2009
  3. linnix13

    linnix13 Banned

    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?
     
  4. MotorBicycleRacing

    MotorBicycleRacing Well-Known Member

    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: Apr 26, 2009
  5. linnix13

    linnix13 Banned

    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
     
  6. linnix13

    linnix13 Banned

    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
     
  7. MotorBicycleRacing

    MotorBicycleRacing Well-Known Member

    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: Apr 26, 2009
  8. linnix13

    linnix13 Banned

    i think i did but i lost it long ago
     
  9. MotorBicycleRacing

    MotorBicycleRacing Well-Known Member

    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 :jester:

    OK, Good luck!
    Let us know what happens.....
     
    Last edited: Apr 26, 2009
  10. linnix13

    linnix13 Banned

    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
     
  11. BoltsMissing

    BoltsMissing Active Member

    linnix13,
    If it not too much hassle can you post a pic of the tool/s your friend actually uses to remove those gears please ?
    I don't mind buying some multi fit pullers of higher quality cos then ya buy them once. The kit's pullers seem hopelesly engineered and just wear out after a few uses.

    Thanks.
     
  12. linnix13

    linnix13 Banned

    im not sure of what he used because its in his huge shop in Mississauga
     
  13. BoltsMissing

    BoltsMissing Active Member


    Thanks
     
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