Cyclone gearbox rebuild

[jk1]

Does anyone know the procedure for pulling apart and rebuilding a cyclone gearbox ?

I just pulled my noisy gearbox apart and i can see inside the grease has gone all dry and it looks like the planetary gears have warn down a bit ?

I compared the planetary gears to a brand new gearbox and they look a lot thinner so i think i need to pull it down clean it and have a good look at it and maybe change the planetary gears

How do i pull the gearbox apart ? I can see their is some circlips i removed it, now what ? do i need to push the keyway off somehow ?

Also their is 3 allen key screws on the other side i removed, now nothing seems to move do i need to press it off next ?

 

[darkone040]

i did this the other day.. yep the Allen head screws and then a flat head screwdriver just work your way around the big circle thing prying it off.. takes a while but gently does it.. then the same with the gears..
if i were you tho, id give the dry grease a clean out put some new stuff in there and keep using the old gears till they completely shit themselves.. at $36 plus expensive postage a pop and mine only lasted 2000kms you might as well wring every little bit out of it as you can..

when i pieced mine together i couldnt turn the motor by hand.. not sure if this is supposed to happen or not.. but when hooked up to the bike it worked.. takes a bit of amps, i think it needs to run itself in a bit.. i would like to know more about that..

cheers adrian.

 

[Ricky_nz]

Don't go overboard on replacement grease. It is possible to put too much and the losses go up.

Mine got noisey and the first time i just scraped the original grease back into places where it became usable and it helped. The next time i put in some fresh stuff and a splash of oil which partly leaked out due to no seals but its been quieter for longer.

I'm tempted to pull mine apart using the info in this thread so I can drill and tap a hole in the front that I can use to put oil in. I would then silicon the gearbox onto the motor and squirt in some thing like diff oil. Probably better at the higher RPMS I have my motor doing.

As to turning the output when attached to the motor the cogging force of the motor is multiplied by the gearbox ratio so trying to turn it with the minimal leverage on the output sprocket is very hard.

 

[darkone040]

oh sorry what i meant was

"when i pieced mine together i couldnt turn the motor by hand, but now that it has been run in a bit (wheel in the air run in) i can"

i havnt done a proper ride with it yet, bit hesitant not sure how i should run it in.. ill probable run it for 35ks (one round trip to work and back) after an easy run in, then pull the front off of it to see if ive put too much grease in there and put some diff oil in, and use some gasket glue to seal it up..

 

[jk1]

Ahh ok the 3 Allen Keys 1st and then pry it off with a flat head, it seems tight and nothing moving but i will try it again as you say.

On replacing the gears , yeah they look warn but maybe they still have some 50% life left, so yeah ill put them back in hopefuly. These gears have done about 3,000 km's so far so not bad

How do i clean all the grease off ? their is a rubber seal under the circlip which i would like to get off before i dunk the whole thing in mineral turps but i dont know how to get that seal off ? or turps wont kill the rubber seal ?

I can take the circlip off but then what as it does not budge ? orafter i take of the planettary gears then the other side will slide out ?

What type of grease do you guys replace this with ? The standard stuff is some molubdenum dysulfide stuff ? Do you think running an oil rather then grease would be better for high rpm 36v ? my grease seems too have gotten hot and then dried out ?

Would car diff oil be best ? or car Transmission oil ? or car geabrox oil ? mmm what do these type of planetary gears need

 

[Ricky_nz]

"when i pieced mine together i couldnt turn the motor by hand, but now that it has been run in a bit (wheel in the air run in) i can"

I don't think i tried turning mine by hand after the grease change.
Ok, seems to fit with my experience that the first time i put too much grease and the motor wasn't too happy spinning up no load. After I took a bit out it worked but amps were a little high but after running it a few minutes it seemed to settle down. I guess it spat out any excess grease :lol:.
To be safe just keep an eye on the motor temperature during the first run of two..

 

[AFT]

For cleaning the grease off with chemicals preferably you need to remove the rubber seal first