Mechanical Roketa 250cc help By newscooterer (Read 1,584 times)

[newscooterer]

So today while changin my gear oil I was tightening my drain nut & it snapped into two pieces (bummer I know) I then went and bought a left handed drill bit, and a bolt extracter... That don't work at all it broke at a very awkward angle.

So now my questions are if I remove my clutch bell & back tire if needed will I be able to take off that piece ( with the drain hole ) and be able to tackle that bolt from behind? Or have a better chance at retrieving that broken bolt? If not what is my best option?

I was on "ScooterDawg" forum before this and wasn't getting much help besides from one, or two guys and they directed me towards this forum.

All help is much appreciated!

Thanks

Ian

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[alleyoop]

Welcome Ian,
Good to see you on the forum I am the one that sent you here from the ODER forum

I have emailed JR and gave him some background on your problem. I am sure when he gets on he will jump right in as well as some of the other 250 guys.
Alleyoop

[JR]

Welcome to the forum. From what I understand and by your picture you've got the drain bolt still in there and need to get it all the way out and then clean up the threads and put a new bolt in.

I've not tackled the moto version on this engine but in this manual, the Helix shop manual in the Honda manual tech section on page 100 it shows that if you remove the clutch bell you can then unbolt this cover plate and pull it off and then repair the broken drain bolt. Try to be careful with the gasket and even then I would put some silicone gasket maker on it when putting it back on.

thescooterprofessor.proboards.com/index.cgi?board=ncmanuals&action=display&thread=415

From what I see there will be no need to remove the wheel. Some of the other guys here can chime in that have worked on this engine and varify this for me. It's done this way to access the tranny gears, some people like to change ratios and their speeds.

We're here to help. Keep us informed, I've got family down but I'll check back later.

JR

[richardthescooter3]

newscooterer, Glad to see you make it to our forum, let us know how your making out

[newscooterer]

Thanks a lot for your help!!! That manual shows a lot!

I will be tackling this project tomorrow,so hopefully it will go smoothly.

Also on cleaning up the threads... Any suggestion?

[alleyoop]

Here is a picture of what I was talking about taking that plate off from behind the Clutch to make it easier to get that broken stud out.

As far as cleaning the threads if you did not mess them up You could go to the hardware store and get a AMERICAN bolt the same size and they are just a HAIR bigger and thread that in.
Or you can get a tap the same size you are going to put in there and rethread the hole.

Those bolts do not have to be tight just enough so they do not leak, you also may want to get a rubber o-ring or a copper thin washer and just snuge it up but do not CRANK on it just nice and tight.
Alleyoop

[newscooterer]

Thanks for all the help guys! I've been super busy with work due to the holidays & hopefully will be tackling this project the day after Christmas! With your help & some videos I've watched on re-threading I think it will be fairly easy, or so I hope. I will keep you posted!

Thanks again!

[alleyoop]

Very Cool, You and your family have a GREAT HOLIDAY and a very Prosperous New Year.
Alleyoop

[fflintstone]

We lcome newscooter,bummer ,the broken bolt is usually caused by starting it in a little crooked so pay particular attention to to this when you get ready to put it back in...I know,personal experiance..good luck,and Merry Christmas..fflintstone

[newscooterer]

Okay so I got the main bolt off of my clutch bell with a chain vise grip wrench but it won't budge off at all... I've hit it with a rubber Mallet still nothing? Any suggestions

[richardthescooter3]

Use some WD40, then put bolt back on and try hitting the bolt a couple good hits, there should be a washer on there too, then try to move it again.

[newscooterer]

There was no washer on there.. I tried puttin the bolt back on and hitting it a couple times still nothing there was a clear & white coat of something on the bolt it was real hard I put goof off & WD40 on and then hit it the coating came off but still nothing wih the bell..

[richardthescooter3]

Your saying the bell part of the clutch won't come off, (right?) have you tried squeezing the pulley to remove the belt? That way you could get your hands on the whole clutch to pull on it.

[alleyoop]

The bell should slip off as well as the clutch and pulley which is one unit. But you do have to take the belt off to get the Clutch out which also just slips right off the shaft. SO you are going to have to take the Variator off to get the belt loose pull on the Clutch pulley it should slip right off.
Alleyoop

[skyrider]

On mine I use a BIG screwdriver, insert it to the bottom of the pulley and spread it apart as far as it will go, then push the belt all of the way down at one point to keep it spread. That gives enough slack to remove the pulley/clutch off without removing the variator.