Today found the mangled retainer ring in the blob of grease inside the housing. Will have to find replacements for it, the spring, and probably the cover washer. Still looks under-engineered in the harsh light of day, but I think I've figured out the orientation of the sprag teeth. Did you ever pop your sprag clutch apart to see why it didn't work? Maybe it was incorrectly assembled, as I fear mine may have been. If your sprag parts are in good shape, the ones I mention above, would you be willing to put them in a letter, if you've done what you said you were going to do with Cyclone? The thing looks like it should work if it was put together correctly. The output cog is CW drive, CCW freewheel, but you must know that by now.
That looks like one messed up little gear box!
Yes I did pull my sprag apart completely. It looked absolutely perfect. And I put it back together and it seemed to work at probably about 50% of what it's meant to do, for about 1 km, and then it started slipping again. I spoke to a bike shop mechanic here that use to assemble these kits on to bikes for Elation. His experience of Elation sprag failures in the chain ring was that you could not see any evidence of damage when you pulled them apart. But when you put it back together it just wouldn't work. So he confirmed what I found with mine (although in the gearbox). He told me to assume it is the sprag because that is the most likely point of failure.
So to answer your other qn, yes I can send the sprag to you if I get to the point of fusing the final stage gear onto the out put shaft (which is still in process - awaiting the local engineering shop to get on to it - my motor is sitting in his workshop), but I don't believe it will solve your problem - as my sprag doesn't work either. I don't think mine was assembled incorrectly - it just doesn't seem to work. I even tried it in both directions (it's a hassle to re-assemble and get it onto the shaft - believe me!).
The workshop has got the Cyclone sprocket. If the new shaft and cyclone sprocket makes my kit work then it would confirm the sprag is the problem. I'll post the dimensions of the new shaft for you or anyone else to copy (to get a machinist to turn for you). But realistically the machinist should just have the motor to work from. Hopefully I want have to wait too much longer.
Thanks for posting.
elation kit V3m Mk 1, 48V 7Ahr LiFePO4, finally got it working (Aug 2012) after owning it for 14 months . . .but will it last???