Parts and equipment for motorcycles, quads, scooters and bicycles
Gearbox bearings Replacement (MOTOR DERBI EURO 3)
Ce tutorial aims at you help change the gearbox bearings of a type engine Derbi Euro 3 on your box 50cc thanks to pics and explanations associated. This tutorial is quite complicated, you have to be patient and rigorous! It is in two parts: Disassembly then assembly.
Like changing the crankshaft, replacing its gearbox bearings is the most complicated operation on an 50cc with gearbox. We advise you to do both at the same time. Discover all of the box bearings suitable for your gearbox 50cc with motor Derbi Euro 3.
Difficulty :
Temps necessary:
1 hour 30
Necessary material:
1 part: Disassembly of the gearbox bearings on the engine Derbi Euro 3
HOW TO REMOVE YOUR BEARINGSTS BOITE OF SPEEDS DERBI EURO 3
1) Start par take your motor out of the frame and drain it. For this, consult this tutorial.
2) Remove the candle.
3) Put a piston lock instead. Screw the good.
4) Remove the nut on the ignition rotor.
5) Remove the washer located behind this nut.
6) Use the Flywheel puller to remove the ignition rotor, use a pipe wrench.
7) Remove the 3 screws from the ignition stator.
8) Move the stator to the side to access the bottom part.
9) Remove the 3 screws located on the ignition plate.
11) Remove the ignition plate and the stator.
11) Remove the 4 screws from the flaps (the screws are of different types).
11) Remove the valves using a screwdriver and a hammer.
11) Remove the clutch housing (8 screws).
11) Use a mallet to pull out the clutch housing.
11) Remove the 5 screws and springs from the presser plate.
11) Remove all clutch disks.
11) Unfold the nut retainer washer with a screwdriver and hammer.
11) Then remove the clutch nut. Help yourself with the clutch key.
11) Still using the clutch key, remove the crank sprocket nut.
11) Remove the clutch bell (pay attention to the washer underneath).
11) Also remove this washer.
11) Remove the crankshaft gear.
11) Remove the circlip from the kick drive sprocket.
11) Remove the kick sprocket (pay attention to the washer underneath).
11) Remove the selector shaft.
11) Remove the kicker shaft. Remove the spring with pliers (pay attention to the washer underneath).
11) Remove the barrel star (1 screw).
11) Push with a screwdriver the room to the right of the star to better remove it.
11) Remove the piston block.
11) Remove the 5 screws located on the cylinder head, then the cylinder head.
11) Now remove the cylinder head (4 screw) and the cylinder head gasket.
11) You can remove the cylinder.
11) Remove the piston pin clip.
11) Remove the piston pin, piston and needle cage by pushing with a screwdriver.
11) Remove the base gasket.
11) Remove the 12 screws from the crankcase.
11) Put the nut on the crankshaft.
11) Tap on it with a hammer to pull the crankcase.
11) Remove the nut.
11) Remove the crankcase.
11) Put the washers in the gearbox part that could have fallen off by removing the cover.
11) Remove the 2 gearbox axles.
11) Then remove the 2 forks (one of them is under the barrel)
11) Remove the barrel (Put the washer on the bottom on the barrel so as not to forget it).
11) Put the nut on the gearbox shaft.
11) Tap on it to pop out the gear shafts.
11) Put the gears back in the right order (Help yourself with the video tutorial).
11) Put the nut on the crankshaft.
11) Tap on the nut to pull out the crankshaft.
11) Remove the nut and crankshaft.
11) Remove the crankshaft oil seals (located under the bearings on the two parts of the crankcase).
11) Remove the crankcase gasket.
11) Remove the engine oil seals.
11) Remove the gearbox and crankshaft bearings (use an axle and a hammer).
11) For one of the 3 bearings in the other part of the housing, you must unscrew this part to remove it.
11) Also remove this small box bearing on each side of the housing.
2 part: Reassembly of new gearbox bearings on engine Derbi Euro 3
HOW TO WIND UP BEARINGSTS BOITE OF SPEEDS DERBI EURO 3
1) Fit the new crankshaft bearings. Drive them in well with a hammer.
2) Tip: Put a wrench in the crankshaft when you tap it to prevent the masses from approaching.
3) Install the new 4 gearbox bearings, grease them. Help yourself with a fairly thick shaft and a hammer to drive them.
5) Grease the washer located under the thickest gearbox shaft.
6) Replace the transmission shafts.
7) Replace the first gearbox fork.
8) Then the second.
9) And the third fork.
10) Grease the barrel washer then position it on the barrel.
11) Insert the barrel into its location.
12) Grease the upper part of the barrel and put the washer on top.
13) Replace the fork pin. Tip: Grab the bottom fork with pliers and hold it to put the axle.
14) Repeat the operation for the second axis.
15) Heat the casing with a torch or a heat gun.
16) When the crankcase is hot, place your new crankshaft.
17) Put the crankcase gasket with a few grease points.
18) Heat the other crankcase.
19) Install the housing. Trick: Tapoput on it with a mallet.
20) Replace the 12 crankcase screws. Tighten them well.
21) Cut the seal at the cylinder.
22) Put the nut on the crankshaft.
23) Tap the nut with a hammer.
24) Rotate the crankshaft to make sure it goes up faster. Remove the nut.
25) Replace the selector shaft. Tip: use a wedge.
26) Replace the kick pin. Be careful to put the rod in the space made for it. Do not forget the washer below, grease it.
27) Tension the kick by pulling on the spring which comes to be put in its notch.
28) Check the correct operation by turning the axle with pliers. Everything must go up and down.
29) Replace the kick drive sprocket washer.
30) Then install the kick sprocket.
31) Put the washer on top, then the circlip.
32) Put back the crankshaft pinion then the nut.
33) Replace the washer, then the clutch bell spacer (tip: put engine oil on the spacer).
34) Place the clutch bell.
35) Then the clutch bell washer.
36) Replace the clutch nut.
37) Replace the nut retaining washer, then the nut.
38) Install the clutch key and tighten the two nuts.
39) Bend the nut retaining washer using pliers.
40) Pour engine oil on the clutch nut.
41) Replace the clutch discs by adding oil after each disc. Alternate filled disc and smooth disc.
42) Turn everything well.
43) Replace the pressure plate (5 screws with springs).
44) Replace the clutch housing gasket.
45) Replace the clutch cover. Help yourself with a mallet.
46) Replace the 8 clutch housing screws. Tighten them well.
47) Cut the seal at the valves.
48) Replace the valve seal and then the valves.
49) Install a new gasket on the valves then screw the cover (4 screw).
Here is the crankshaft key.
51) Place it in the crankshaft and press it down with pliers.
52) Replace the ignition plate (3 screw).
53) Attention: Align the mark on the plate with that on the housing.
54) Replace the ignition stator (3 screw).
55) Replace the ignition rotor. Rotate it to check that it is working properly.
56) Put the washer, then the flywheel puller. Tighten the ignition rotor securely.
57) Replace the base gasket and remove the tie on the crankshaft.
58) Put oil on the needle cage and put it back in its place.
59) Replace the piston with the shaft.
60) Then put back the piston pin clip.
61) Install the cylinder. Caution: Check before the piston rings are properly fitted.
62) Put the gasket and the cylinder head stud (4 screw).
63) Tighten to 18 nm using the torque wrench.
64) Replace the cylinder head (5 screw). Tighten well.
65) You can now reset your engine with the help of this tutorial.
VIDEO: PART 1 - DISASSEMBLING BEARINGSTS BOITE 50CC ENGINE DERBI EURO 3
VIDEO: PART 2TH - RAISING BEARINGSTS BOITE 50CC ENGINE DERBI EURO 3
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