Need help on how to install small gear in the clutch gear box...

Discussion in 'Frame Mounted Engines' started by NunnSon, Jun 27, 2011.

  1. NunnSon

    NunnSon New Member

    My small gear broke on my Skyhawk and I bought a new one but I have no idea how to get it on. I'm afraid of breaking it if I hammer on it too much. I've tried WD-40. I've searched the forum for plenty of threads about removing the small gear but not any help on putting it on. Can anyone give me any clues? I'm getting pretty frustrated at this point. I just want to ride!
     

  2. Al.Fisherman

    Al.Fisherman Active Member

  3. NunnSon

    NunnSon New Member

  4. Al.Fisherman

    Al.Fisherman Active Member

    Goes back on in the reverse of removing it. May want to put some heat to expand the hole. Is that the same one you took off? If not mike the shaft hole. They may be different.
     
  5. NunnSon

    NunnSon New Member

    I broke the original. This is a new part. How do I put heat on it? I tried putting it in the oven for a bit but that didn't seem to help. I don't have a blow torch or anything like that.
     
  6. Stan4d

    Stan4d Banned

    bake at 450 for 1 hour. if that doesnt do it then you might consider following Al's advice.
     
  7. NunnSon

    NunnSon New Member

    I tried putting it in the oven for an hour and it still won't go on. I can usually only tap it about halfway but it never gets all the way back flush. How do you "mike the shaft hole"? What does that mean?
     
  8. BoltsMissing

    BoltsMissing Active Member

    Keep tapping it on, not directly hitting it with hammer, use a pice of wood, or better still, a special hammer that has a non metal surface.
    http://hammernet.com/vaughan/pages/products/soft-face-hammers-mallets.php
    It's a press fit, if you remember how the old gear came off, how tight it was, then it's the same, or ought to be the same tightness.
    However, there might be slightly different sizes.
    "mike" means, micrometer.
    Some examples
    https://www.alltools.com.au/shop/index.php/344/1142_Sidchrome_0_-_75mm_3pce_Micrometer_Set

    Therefore, go to a machine shop, ask if they can look at it, they will know from expereince.
     
    Last edited: Jun 27, 2011
  9. Al.Fisherman

    Al.Fisherman Active Member

    Last edited: Jun 27, 2011
  10. NunnSon

    NunnSon New Member

    I figured out that I lost my woodruff key so I'm going to have to order another one. I found an ATV repair place that will help me put the gear one once I have it.

    I also lost the screw that secures the flower nut on the clutch. Any ideas on how I could replace that without bringing the motor inside a hardware store and randomly trying screws?
     
  11. Stan4d

    Stan4d Banned

    Well......the screw will be metric, which is common on ATV's also. You might tell them that your missing a screw and see if they have one that will fit. (I never had a problem carrying the motor into Home Depot or Lowes.......the people that help me find what I am looking for think that its cool.....another MBer born with each visit)
     
  12. motorpsycho

    motorpsycho Active Member

    small plastic cups come in handy for throwing screws in while dissassembling something.
    That way, nothing gets lost, unless you lose the whole cup.

    A simple solution would be to unscrew the flower nut and pull the pressure plate off the engine. (the pressure plate will slide right off after the flower nut is removed. beware tho because the clutch pads may fall out...don't panic, they just get placed right back into their holes.
    Then you can take just the plate to the hardware store to get the right screw.
    However...
    The bad part is that when you put the pressure plate and flower nut back on, you have to know how to re-adjust the clutch with the flower nut.
    You will have to know where to set the flower nut because you can't just tighten it down until it won't turn anymore.
    You have to know when to stop tightening it for the clutch to work right. You can adjust the clutch by tightening / loosening the flower nut. If it's set too loose, the clutch won't engauge, if it's set too tight, the clutch won't disengage....there is a happy medium, and every clutch has it's own happy medium.
    This is why it has the locking screw, because the flower not will not be all the way tight when the clutch is adjusted right...the locking screw keeps the flower nut from loosening up by itself.
    I supposed that you could try to count the number of turns that it takes to remove the flower nut, and then when you screw it back on, tighten it the same number of turns and then install the locking screw.
     
    Last edited: Jul 6, 2011
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