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  1. #31
    motodevo's Avatar
    motodevo is online now Miniriders OG Master Spanner Spinner
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    From what I've read, if its still got the gear indicator switch on the end of the shift drum then ditch it and when you put the bolt in shim it up with washers to make sure it has no movement. Loctite that bolt and the shift star bolt/screw on the other end. Make sure once the cases are back together the is no play in the shift drum from side to side. Some guys have deleted the centre case gasket, will close it up 0.4 - 0.5 mm and just used a smear of liquid gasket(like permatex aviation sealer). Me, I'd get a couple of centre gaskets from pit bike shop (my local shop sell them for about 8 bucks for a full set. Put it together, shift drum bolt in and torqued, and check it for side play. I clamp the cases to the bench and check it with a dial guage, if it had more than about 0.01"/0.25mm side i would buy a shim 0.05"/0.125mm to 0.01"/0.25mm thinner than the play. Most bearing shop, Enginering suppliers/specialty bolt shop sell shims in 0.05" increments, just measure the shaft diameter and get a shim with the same internal diameter. In saying that, if both the drive and driven countershafts had the same amount of excess play too i would just delete the centre gasket.
    Obviously run it through all the gears by hand and confirm all is ok before going any further.
    It seems that a lot of the zonger g box problem are down to that shift fork (which only affects 2nd), if theres play or wear it doesnt fully engage and when it skips ypu can hear it clicking, sounds like the chain is skipping on the sprocket.
    Like i said, never opened up a big zonger but seeing your pics, your shift fork wear explains why 2nd is not engaging. Before digging too far into it, get you new fork or complete shift drum, make sure that fork is tight on the shift drum, if its not tight on the shift drum no amount of shimming will fix it at all. If it is all good, bolt the cases back together and go from there.
    Last edited by motodevo; 27-07-2017 at 10:04 PM.
    Too many zeds in the shed

  2. #32

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    for those in the know, which gear is 2nd gear??, which is the one that usually fails?, might get it hardened before I put it back together.
    001.JPG
    cheers
    Last edited by AntNZ; 31-07-2017 at 03:21 PM.

  3. #33

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    ......???????

  4. #34

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    Quote Originally Posted by AntNZ View Post
    for those in the know, which gear is 2nd gear??, which is the one that usually fails?, might get it hardened before I put it back together.

    cheers
    Please.....somebody????

  5. #35
    motodevo's Avatar
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    I dont know off the top of my head(only usually replace a whole gearbox, otherwise i need to work it through all the gears to get my head around it) i usually just put the gearsets in the left case (on its side) with the shift drum and spin through the gears on the shift drum and see which one engages in each position if i need to work it out, it will be the one next to your worn shift fork and the corresponding gear on the other shaft
    Last edited by motodevo; 10-08-2017 at 11:39 PM.
    Too many zeds in the shed

  6. #36

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    Cheers mate, tried to work it out like you said but not easy, hard to know which gears are free spinning and which are driven.
    Its a spare engine so have just bent the fork back straight and got it sitting flat against the gear now, was on an angle before.
    It shifts through the 4 gears smoothly so might just bolt her back together and see if it works......
    Oh, and I did damage my flywheel with the 3 jaw pullers like you said
    any idea where I can get a flywheel from without the stator??

    cheers

  7. #37

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    Is it too damaged to use again if I can flatten the bubbles out??
    has these in 3 places...
    001.JPG

  8. #38

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    I have a adjustable timing stator if you want to upgrade the stock one..

    Sent from my ALCATEL_4034A using Tapatalk

  9. #39

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    Quote Originally Posted by gottagetacheaperhobby View Post
    I have a adjustable timing stator if you want to upgrade the stock one..

    Sent from my ALCATEL_4034A using Tapatalk
    cheers stu, I already have a new stator, whats your opinion on the state of the flywheel I posted pics of???

    Thought you would chime in earlier as I know you have had a lot to do with these engines....
    As I said, I just bent the shift fork straight again....is that just a waste of time or not???
    Do you know which gears in the earlier pics are the ones that fail??
    struggling to work out which 2 gears mesh to create 2nd gear??
    Think I got it sorted but doesn't seem to matter what I do the 2 I think are 2nd never seem to fully engage each other....

  10. #40

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    I would replace it if it was me.
    Shift fork I would replace as well as once something's bent it usually bends again.. You have it apart so better to sort it now IMO..
    I'm not sure on which two gears mesh for second gear sorry, why not harden the whole box, shafts included?

    Sent from my ALCATEL_4034A using Tapatalk

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