gonsped69

My Feedback: (6)

I'm trying to remove the flywheel from the Zenoah G230RC engine and couldn't use the simple twin M6 gear mount screws method used to remove the clutch as the flywheel spacing to the engine is much deeper.

I don't recall ever seeing an M6 screw that long and spending U$50 for a tool that I will only use once sounds like a bad idea - not to mention the waiting time for it to arrive.

I don't own a self taper nor a bench drill system - is there any other quick way(s) to remove the flywheel? [&:]

avery4jc

My Feedback: (10)

I just pulled really really hard on my G260RC and it came off. Not like that will help you much but it can be done...if need be and your VERY careful you could use a flat head screwdriver to pop it off.

gonsped69

My Feedback: (6)

I like to keep 100% of my flesh in my hands thank you

But my earlier assumption was incorrect - they do have screws long enough to do pop off the flywheel. I obtained a pair of 6mm diameter screws, 75mm long with a 10mm bolt head.

gonsped69

My Feedback: (6)

Unfortunately removing the flywheel reveals another conundrum - how to remove the key on the crankcase? (#28 in the Zenoah manual exploded diagram)

Do I hammer it out? I've tried pliers and that doesn't seem to work [&:]

gonsped69

My Feedback: (6)

Lol - I seem to be answering my own questions rather quickly so I thought I'd share my method that worked.

I used a small chisel and positioned it so as the picture below and tap it with a hammer and voila! The key popped out. There were access holes on the side of the key so I used a small jeweller's screwdriver with perpedicular to the shaft tapping action and no luck. You have to tap with force inline with the shaft to remove the Woodruff key off the shaft

JRexA

I used some Hex IKEA style furniture screws, they are M6 and long enough.

Good to have lots of screws laying around......

avery4jc

My Feedback: (10)

lol, hey whatever floats your boat...I don't mind giving up a little flesh for r.c.! If I use something else it might hurt the parts so this way I know as long as I can take the pain the parts can easily hold up to it vs using metal on metal.

pozze

This thread really helped me out, but now I'm stuck again. Can't get the piston into the cylinder, been struggling for an hour now... Is there a trick to it, or should I just keep struggling???

-v-

radio_controlled_mad

you need a fg multi tool which is a fly wheel and clutch puller amongst other things,your not supposed to use bolts and turn them against the crank case as that will crack it as its only cast.

http://www.rossendalemodels.co.uk/in...3bc6889bcb19d8

radio_controlled_mad

compress the piston ring between with your fingers and slide the head over - the gap in the ring should fit between the small pin on te back of the piston,look round you will see it - should only take a few secs - make sure you have oiled inside the cylinder head 1st.

Oneill Brothers Racing

If the gap on piston ring does not close on the pin you will never get the head on. If the head does not slide on easily don't force it.

pozze

I found out in the end, hope I didn't damage anything.

radio_controlled_mad

only way to find out is to start it up and see if it goes bang

MrMikeG

Steering wheel puller works for the flywheel.
Getting the piston in, you position your fingers in the transfer ports while holding the ring in, don't turn the cylinder though or the ring end will pop out, slide the cylinder straight down.

pozze

Think I was a bit brute trying to get the piston in, I noticed that the engine had ledd compression after my "operation". Btw I was mounting a sikk 29 cc kit (ca484 at davesmotors.com) in a 260RC.

radio_controlled_mad

the head should just go over the piston fairly easy once the ring is compressed,if you have less compression after adding a new 29cc kit sounds like you may have scored inside the cylinder when assembling or the head is not fully tightened onto the crankcase - may be sucking air in past the gasket.

pozze

It's not a loose head, it's the kit on the picture above...

radio_controlled_mad

if you have less compression on a new 29cc head,ring and piston that isnt even broke in then something is wrong - if you struggled and forced the head over the ring when fitting it you may of scored inside the cylinder,only way to find out is to remove the head check if there is any marks,lines ect inside.if you mean you have a lack of power when throttling you may also need to re-adjust the carb settings.

MrMikeG

When you do get it going, make sure it is a resistor plug. Gopeds don't need resitor plugs so I'm not sure which type they put in their kit.

pozze

I think maybe the piston ring or the piston may be broken, just ordered a new piston, it's only 26 $.. Didn't see any scratches in the head...
Tried starting the engine, but it did not fire... It got both spark and gas...

Oneill Brothers Racing

Did you check the head to see if it was scored? If the head is damaged and you put a new piston and ring in it will damage the new piston.