can't get the crankshaft out - Solved By Doug in San Diego (Read 1,511 times)

[Doug in San Diego]

Hello all

I am in the process of splitting the case and putting in a new crank

Question.. How do I get the gear that is right behind the variator off? That is the last thing holding the crank into the case.

Side question, what about the timing chain? When do I take that off or how ?

[Bashan]

Off comes the variator:

And I pull the whole assembly off to reveal the gear in question:

That puppy is NOT moving, any suggestions out there? Rich

[Cruiser]

Here's what the special tool looks like to remove this gear. There really is no description so without dimensions, there is no guarantee it would fit.

HIGH RPM RACER GEAR PULLER

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I have also read where some people use a small 3 leg gear puller and grind the ends down so that it will fit behind the gear. They then use plastic cable ties (zip ties) to hold the jaws together while tightening the center bolt.

[Cruiser]

The tool I displayed a link for is the same type as shown on page 7 of the GY6 manual:

The modified gear puller set up I described was used successfully by a member of the Ruckus forum. If you can use either of the above methods, the seal should be reusable.

[Doug in San Diego]

Got it off

I used a torch and banged the S*#@ out of it.

I think the many variator changes (with subsequent re-tightening of the nut) really pushed that gear onto the shaft

Good Times!


In retrospect, I think some sort of a puller would be the way to go.


P.S. I love it when even my 70 year old neighbor lady is asking me "Didn't you
just buy that scooter?"

[Bashan]

What would be wrong with replacing that with a spacer so you would never have to mess with that again? I never use my kickstarter anymore, it's just in the way. Also, I found this tool, expensive but it might work. Rich

APEX TOOL HYDRAULIC GEAR PULLER

[Cruiser]

Good point, Rich. If you have confidence in your charging system and battery, then you really don't need a kick starter. I think the electric start may be more reliable than the kick start in any case. All the bigger scoots don't have the kick start.

[Doug in San Diego]

I personally don't ever want to have to deal with it again.

I see new engines on Ebay for $200! For that, I should just throw this engine away!

After new tools (flywheel puller) gaskets, and crankshaft, I'm up to $100 already and Im not even sure this will work when I put it back together!

However, I do feel pretty proud that I've gotten this far.

I have filmed the entire process, so one day I'll have a YouTube video up

[Bashan]

Good for you Doug! I'd love to see it when your done. You conquered that little SOB. I was going to start heating and hammering and then I thought "nah, I want to go for a ride tomorrow!" Rich