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Replace cross shaft w/o splitting cases?


Discussion at Motorized Bicycle Engine Kit Forum in the 2 Stroke Bicycle Engines & Kits forum. After a lot of tinkering on my 48cc 2stroke, I have determined that the cross shaft, that connects the clutch ...
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Old 09-27-2009, 06:07 PM
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Default Replace cross shaft w/o splitting cases?

After a lot of tinkering on my 48cc 2stroke, I have determined that the cross shaft, that connects the clutch to the chain sprocket (through the motor) is bent. It manifested as a clutch that wouldn't release, a lot of crankcase racket and increase in visible wobble in the chain sprocket AND the clutch assembly.

Can I replace the shaft assembly without splitting the cases?

If not, I may purchase a new motor and repair the engine with the bent shaft as time allows.

I read thru Norm's teardown and buildup and it seems to indicate that the cases will need to be cleaved to repair this.

Any advice is appreciated.
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Old 09-28-2009, 01:19 PM
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Default Re: Replace cross shaft w/o splitting cases?

Quote:
Originally Posted by wheelbender6 View Post
After a lot of tinkering on my 48cc 2stroke, I have determined that the cross shaft, that connects the clutch to the chain sprocket (through the motor) is bent. It manifested as a clutch that wouldn't release, a lot of crankcase racket and increase in visible wobble in the chain sprocket AND the clutch assembly.

Can I replace the shaft assembly without splitting the cases?

If not, I may purchase a new motor and repair the engine with the bent shaft as time allows.

I read thru Norm's teardown and buildup and it seems to indicate that the cases will need to be cleaved to repair this.

Any advice is appreciated.
The case does not have to be split to remove the clutch shaft. You just knock it out after removing the small sprocket. I'd be amazed if that was really "bent" though.
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Old 09-28-2009, 03:04 PM
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Default Re: Replace cross shaft w/o splitting cases?

I guess any part between the sprocket and pressure plate could be bent. The wobble is most visible on the chain sprocket.
The clutch diagrams show some keys and a pin that appear to pass thru the cross shaft. Why dont they prevent the removal of the shaft?
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Old 09-30-2009, 04:26 AM
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Default Re: Replace cross shaft w/o splitting cases?

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Originally Posted by wheelbender6 View Post
I guess any part between the sprocket and pressure plate could be bent. The wobble is most visible on the chain sprocket.
The clutch diagrams show some keys and a pin that appear to pass thru the cross shaft. Why dont they prevent the removal of the shaft?

Unless it was bent prior to assembly I don't see what would cause that to happen.

After popping the drive sprocket my entire clutch could be knocked out the other end. In any event it is not necessary to split the case.
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