Need help with gearbox!

wisebeuy · Nova Slayer Joined: 02 Aug 2003 Karma :

After a tantalizing 8 months, including replace HT coil, twice rewound stator coil, replaced conrod, piston, big and small end, and main bearings, I have yet another problem.

After rebuilding the engine this weekend, i put the engine into the frame, and put it into gear and pushed the bike forward, to make sure it was turning the enginge right, it seemed to be going fine, and i went through the gears, and then heard a crunch, and the engine stopped dead.

After taking the engine apart again, i the 3rd gear cog has a broken tooth. Bugger. I do have a spare engine and gearbox, and have got the correct cog handy, but am having trouble taking the gearbox out of the "working" engine, as i need to remove the clutch from the other side, yet i can't see a way to do this, any advice? The bike is an aprilia AF1 50cc

priller · Brolly Dolly Joined: 26 Jan 2004 Karma :

Engine shouldn't really turn over with the bike in gear just by pushing it.

Is it the clutch basket your stuck on.

You could try posting here www.apriliaforum.com, there's a few people there who race rs50's and know lots about aprilia's.

Luke_Retrofly · Silly Lesbian Joined: 05 Jul 2003 Karma :

Hi
WTF yes it should if the clutch is in, and if it was me id get a new bike.

Luke
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craigT19 · Jolly Green Giant Joined: 09 Feb 2002 Karma :

yeah on a 50cc, you could easily push it in gear, it doesnt have the compression to lock the wheel, so the engine would turn over
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priller · Brolly Dolly Joined: 26 Jan 2004 Karma :

wisebeuy · Nova Slayer Joined: 02 Aug 2003 Karma :

Yeah, luke, a new bike would be nice, but (a) I'm 16 and can't afford and (b) 50cc bikes are hard to come by in Orkney. This bike is really good when it goes, but like i say, i just need to get the clutch basket off to change the cog, i spoke to the bike guy in town, and he said about taking all the cogs off individually, or taking the clutch basket off, so gonna try that tomorrow.

WheelieKing · Borekit Bruiser Joined: 09 Sep 2003 Karma :

Get yourself a clutch tool/holder. I'm in the middle of replacing the clutch basket of my YZ125 and I wish I had one. Just remember where everything goes.
Mr. Green

wisebeuy · Nova Slayer Joined: 02 Aug 2003 Karma :

yeah, this guy says that its a case of removing the four screws round the edge and working from there, so i think i will give that a go tomorrow, as the individual cogs ain't coming off easy.
Thanks a lot guys
Wise