HS3540 freewheel removal/tear down to 5spd

[crusoe]

Update: just purchased the freewheel removal tool from ebikes.ca. I'm in Canada so it should be here soon!Thanks for the tip Nicobie

In regards to friction vs indexed: All very good points brought up. I'm probably going to try to get the 9spd indexed shifter I have now working first.
I know the spacing between the sprockets is different between 3spd and 7spd freewheels, but shouldn't the 9spd shifter still work? Maybe just take one or two clicks to get it to switch gears? Though, if the indexed route fails, I'll definitely go the friction route.

[Chalo]

In regards to friction vs indexed: All very good points brought up. I'm probably going to try to get the 9spd indexed shifter I have now working first.
I know the spacing between the sprockets is different between 3spd and 7spd freewheels, but shouldn't the 9spd shifter still work? Maybe just take one or two clicks to get it to switch gears?

7-speed is usually 5mm between sprockets, 9-speed is 4.34mm. 3-speed is most likely somewhere in the range of 5.3 to 6.3mm. So, one click probably won't do it and two definitely won't. I'm curious to see what your actual results are, though.

Chalo

[crusoe]

I will keep you updated. Just wondering why two clicks definitely wouldn't do it? Isn't the throw of two clicks 4.34x2 = 8.68mm ?

[Chalo]

I will keep you updated. Just wondering why two clicks definitely wouldn't do it? Isn't the throw of two clicks 4.34x2 = 8.68mm ?

That's right, 8.7 is not equal to 6 (or whatever spacing the 3sp freewheel has). I suppose you could use it more or less like a front triple, where the inner and outer sprockets are governed by the derailleur limits, and the center sprocket is governed by the middle click out of five usable clicks. Sounds hokey to me, but it might work. Most inner limit screws on modern derailleurs won't do up that far to the right, though.

Anyway, the cure is simple and cheap, if one is needed.
http://www.amazon.com/Pyramid-Thumb-Shifter-Right-Black/dp/B000AO5JTS

[crusoe]

Here is the final update:

1. the 3 speed I bought from Hong Kong was nearly as wide as the original 7 speed cluster - confirmed Chalo's advice
2. the 9 speed indexed shifter did not work to shift gears at all - confirmed Chalo's advice
3. in order to avoid chain rub completely I've had to go back to the single speed, 16t in the rear 42t up front. It seems pretty useless at anything over 25km/h, but it may help, who knows!