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Bicycle engine clutch gear replacement (Part 2: Gear removal)

Getting to the clutch gear

Tools: small flat-head screwdriver

  1. Disengage the clutch and lock it.
  2. Remove the gearbox cover by removing the five Phillips screws.
  3. Remove the flower-but retaining screw with the small flat-head screwdriver.
  4. Remove the flower nut by hand.
  5. Remove the pressure plate and return spring

Removing the clutch gear

Tools: 2 socket wrenches, 14mm socket, two 19mm socket, Super Magic Tool (SMT)

  1. Remove the clutch-lever cover by removing the three Phillips screws.
  2. Remove the 14mm nuts at the gearbox end by using two socket wrenches simultaneously, one on the gearbox end and another on the clutch level end. This will prevent and strong forces from being applied to the chain.
  3. Install the large end of SMT into the clutch gear assembly.
    Installing SMT
  4. Using a 14mm socket, turn the small half of SMT into the large half. It acts as a gear-puller to remove the gear assembly.
    Gear assembly removal
  5. Find the Woodruff key before it is lost, and put it in the magnetic part tray.

Pro tip: If your gearbox exploded like mine did, and the Woodruff key is missing like mine was, the two may have something in common.

Removing the Drive Gear

Tools: Big-ass flat-head screwdriver, SMT, magnetic part tray

  1. Remove the retaining screw with bag-ass screwdriver.
  2. Install the medium size end of SMT into the gear,
    SMT installation in drive gear
  3. Using a 14mm socket, turn the small half of SMT into the large half. It acts as a gear-puller to remove the gear assembly.
  4. Find the Woodruff key before it is lost, and put it in the magnetic part tray.
    Woodruff key

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