Final Drive Gear Installation How-Tos

[90GTVert]

Gear Swap Using A 3-Jaw Puller
by larryhobman

Malossi Primary Gear Installation For Minarelli/Jog/1E40QMB 2T
by 190mech

Gear Install Using A 2-Jaw Puller
by PIG

Yamaha Zuma Gear Installation Tutorial PDF
by kevin55950

[larryhobman]

I just wanted to share my method on gear upgrades.  I have look at forums and I could not find much help.  Everyone says take it to a shop to be PRESS IN.  I took out my 3 jaw puller and was able to press out the gear easily.  Next I turned it around and pressed the gear back in.  I put it in a vise to hold it easier









Took it out half way just to show everyone.

[90GTVert]

This information was provided by 190mech.

Got something in the mail today;



Got the gears installed,turned out to be a tough job..First I pressed off the old primary idler gear,pretty hard to come off;


After removal I measured the old gear bore and the Malossi gear bore,Heck!The Malossi is a full .002" smaller!Knew that would make starting the gear on the shaft would be very difficult,tried it cold first,NO GO,tried to heat the gear bore with a torch,NO GO,Put the idler shaft in the lathe and ground a shallow taper on the end of the shaft with a Dremel and cut off wheel,Hey!It started!Man,was it tough to press it all the way on,but finally got it there;




Cleaned everything up and reinstalled the gears in the case,it all fit(Whew!)

[90GTVert]

Jun 9, 2017 17:26:03 GMT -5 PIG said:

I figured I'd show a super cheap and easy alternative to using a press. I think I paid like $10 for it