gear problem on my dio

diomike · Post by **diomike** » Sat May 12, 2007 5:10 pm

iam trying to put my new gears on but i cant split the case after i removed the bolts http://houseofmotorcycles.bikebandit.co ... +SR%29.asp

hrnytrtlsgsxr · Post by **hrnytrtlsgsxr** » Sat May 12, 2007 6:12 pm

after you take out the #13 & #14 screws you need to pry the plate off with a large screw driver. There is a gap on the front side of the plate. Install screw driver in between the plate and the case and turn the screw driver so it is lifting the plate away from the case. Dp it on the top and the bottom side of the plate nearest the case on the front side. Then it should give enough gap around the whole plate to keep working a smaller screwdriver prying evenly while rotating to all sides of the plate.

diomike · Post by **diomike** » Sun May 13, 2007 12:53 pm

kk i will try, when i install the gears do i need a new gasket ?

Kenny_McCormic · Post by **Kenny_McCormic** » Sun May 13, 2007 5:48 pm

it would be best to whizzy wheel it and put in a new gasket

diomike · Post by **diomike** » Sun May 13, 2007 7:36 pm

i was wondering if i need a press to get the #7 off so i can put the new one on.
http://houseofmotorcycles.bikebandit.co ... +SR%29.asp

W/C · Post by **W/C** » Mon May 14, 2007 11:27 pm

Yes you need to use a press or something similar, if you use a 2 jaw puller ,your gonna have to use it to put the new gear on press is a 2 minute 2 deal

diomike · Post by **diomike** » Tue May 15, 2007 9:46 am

is there anyway i can do it my self at home? cuz the machine shop is like a half hr away.

islandbayy · Post by **islandbayy** » Tue May 15, 2007 11:25 am

Nope. 20 ton hydrolic press at my shoppe barely got mine apart, and even then, it was straining. Ended up squashing one side of the axle, had to hone it down so it would fit back in the bearing by turning it on the lathe.

Putting the gear on is easy though, just put some motor oil in a coffee can, and put it on the stove. Drop the gear in the oil, and put the axle in the freezer. Keep the gear in their until when you spit on the oil, it beed's and dances, then remove the axle from the freezer, take out the gear, and drop it on to the axle. Should drop right on nice and loose. Let er cool so you can touch it without gloves and pliers, clean off the motoroil, and your set ^_^

Just once again, the little problem of getting the orignal gear off in the first place....

diomike · Post by **diomike** » Tue May 15, 2007 11:17 pm

kk thnx man my friend is bringing it to a machine shop t omorrow for me

stillspeeding · Post by **stillspeeding** » Mon May 21, 2007 12:55 am

Do it right the first time

diomike · Post by **diomike** » Thu Jun 14, 2007 10:44 pm

ok i got my new gear pressed on but now i m trying to put the case back on and it wont go on *?

jeremydde · Post by **jeremydde** » Thu Jun 14, 2007 10:48 pm

diomike wrote:ok i got my new gear pressed on but now i m trying to put the case back on and it wont go on *?

Is it binding with the rear shaft into the aluminum cover? Did you mushroom the shaft a little bit?

diomike · Post by **diomike** » Sun Jun 17, 2007 5:33 pm

ithinki mushroomed it Grrrrrrrrrrrrrr......
iamuseing sand paper

jeremydde · Post by **jeremydde** » Mon Jun 18, 2007 9:45 am

diomike wrote:ithinki mushroomed it Grrrrrrrrrrrrrr......
iamuseing sand paper

I accidently mushroomed mine before. I barely tapped on it either that's the thing. I ended up chamfering the edge of the rod with the dremel and it popped back in. I didn't have to take much off at all.