Scooter Clutch & Prop

2. While holding the variable pitch knob(66) to prevent turning, use a Phillips screwdriver to loosen in a counter clockwise direction and remove the knob screw(65).

3. Pull the knob(66) slowly away from the outer hub(70), taking care not to lose the knob ball(68) and spring(69). Thoroughly clean the knob removing any sand or residue, and inspect for any signs of damage. If found, discard and DO NOT reuse.

4. While holding the propeller blades to prevent turning, use a Phillips screwdriver to loosen in a counter clockwise direction and remove the three outer hub screws(67).

5. Carefully pull the outer hub(70) straight off the inner hub(77). Holding the outer hub(70) with the fingers of one hand, positioned with the hub down and the blades up, lift the three blade assembly up and away from the inner hub(77) with the fingers of the other hand. (Fig. 23)

(Fig. 23)

6. Gently pull the propeller blades(78) off the blade yoke(72), and unthread the yoke shaft(71) from the yoke(72) by turning-counter clockwise.

7. Thoroughly clean the outer hub, blades, yoke and shaft removing any sand or residue, and inspect for cracks or any signs of damage. If found, discard and DO NOT reuse.

8. Holding the inner hub(77) firmly to prevent turning, use a Phillips screwdriver to loosen in a counter clockwise direction and remove the clutch screw(73) and washer(74). Remove the nine clutch spring washers(75) and metal clutch ring(76). (Fig-. 24) Clean and inspect all parts for corrosion or deterioration. lf found, discard and DO NOT reuse

(Fig. 24)

9. Pull, or using two flat bladed screwdrivers very carefully pry, the clutch plate(79) off the motor shaft. (Fig.-25) Thoroughly clean the plate removing any sand or residue, and inspect for cracks or any signs of damage. If found, discard and DO NOT reuse.

10. While supporting the motor shaft, carefully press or pull the drive pin(80) out of the shaft.

NOTE : Tapping or pounding could deform the pin hindering its removal.

(Fig.25)

(Fig. 26)

12. Using two flat bladed screwdrivers very carefully pry the rotating outer shaft seal(B2) off the motor shaft. (Fig. 27)

CAUTION : Care must be taken not to scratch the outer seal and shaft sealing surfaces.

13. Using a magnifier and good lighting, examine the seal(82) and shaft seating surfaces for any scratches or mardng. If found, discard and DO NOT reuse.

NOTE: The rubber, metal and plastic components of the seal(86-3) are a molded unit which can not be disassembled.

(Fig. 27)

14. Place both thumbs inside the inner seal cup(84) and gently pull the cup(84) with inner shaft seai(82) and cup retaining ring(83) straight off the motor- shaft and out of the tail cone(37). (Fig. 28)

15. Remove the inner shaft seal(82) and cup retaining ring(83) from the inner seal cup(84).

CAUTION: Care must be taken not to scratch the inner seal and shaft sealing surfaces.

16. Clean and inspect the seal, cup and ring for any damage, tears or scratches. If found, discard and DO NOT reuse.

17. Remove the inner seal washer(85)and examine for deterioration or damage. If found, discard and DO NOT reuse.

(Fig. 28)

CAUTION: Verify that the battery is not installed or the battery and motor leads are disconnected prior to commencing reassembly of the propeller, seal and clutch.

1 . Place the vehicle, or aft housing assembly, horizontally on a soft, clean surface with the tail cone(37) and motor shaft facing you.

2. Position the inner seal washer(85) with the flat side out and .carefully slide it over the motor shaft into the recessed cavity of the tail cone(37). (Fig. 29)

3. Insert the inner shaft seal(82) into the recessed cavity and the cup retaining ring(83) into the inner groove within the inner seal cup(84).

4. Place both thumbs inside the inner seal cup(B4) with inner shaft seal (82) and cup retaining ring (83) and push it straight onto the motor shaft and into the seal cavity of the tail cone (37). (fig 28)

5. Holding the rotary seal (82) by the smaller hex shaped end push it firmly onto the motor shaft until it seats against the inner seal (82).

(Fig. 29)

6. Carefully install the rotary seal sprng(82) over the motor shaft and onto the hex shaped end of the rotary shaft seal(82).

7. Place the spring cap(82) over the motor shaft and onto the end of the spring(82) with the concave side toward the spring. While pressing on the cap(82) to compress the spring, use external circlip pliers to install the rotary seal clip(81). (Fig. 30) Ensure it is seated into the groove in the motor shaft before releasing the spring.

(Fig. 30)

8. Insert the drive pin(80) into the hole through the motor shaft so that it protrudes equally from both sides of the shaft.

9. Slide the clutch plate(79) onto the motor shaft with the pin recess facing inward and turn it slowly until it engages onto the drive pin(80).

10. Slide the inner hub(77) onto the motor shaft with the support posts facing out and turn It slowly until It engages into the clutch plate(79). (Fig. 31)

(Fig. 31)

11. Install the metal clutch ring(76) over the motor shaft and onto the edge of the inner hub(77).

12. Install the first of nine clutch spring washers(75) onto the motor shaft oriented so it bows outward. Install the remaining eight spnng washers(75) in alternate directions to each other and secure by inserting the clutch screw(73) through the concave side of the clutch washer(74) and into the end of the motor shaft. (Fig. 32)

(Fig. 32)

13. Holding the inner hub(77) to prevent turning, use a Phillips screwdriver to tighten the clutch screw(73) by turning clockwise until secure. DO NOT overtighten.

14. Holding the yoke shaft(71) by the squared end, thread the shaft clockwise into the small opening end of the blade yoke(72) until the threads are engaged. DO NOT tighten.

15. Place the outer hub(70) on a clean flat surface with the blade guide notches facing up and lower the squared end of the yoke shaft down into the center hole until it is just contacting the flat surface below. (Fig. 33)

(Fig. 33)

(Fig. 34)

17. Using care to prevent the blades from failing off the yoke stems, lift the complete outer hub, assembly off the flat surface and gently push the blades and yoke together until fully engaged into the hub. (Fig. 35)

(Fig. 35)

18. Holding the complete propeller/hub assembly together with both hands and oriented with the square end of the yoke shaft facing out, slide the assembly onto the inner hub(77) rotating as necessary to achieve proper alignment and full engagement. (Fig. 36) There should not be any space between the inner(77) and outer(70) hubs.

1 9. Holding the outer hub(70) to prevent turning, install the three outer hub screws(67) and use a Phillips screwdriver to tighten in a clockwise direction until snug. DO NOT overtighten.

20. Turn the shaft clockwise with your fingers while twisting the propeller blades so the base of each is flush with the outer hub(70) and the yoke shaft(71) has 1/4 turn of play. Turn the shaft(71) so a flat side faces the pitch mark "9"

(Fig. 36)

NOTE: If two flat sides of the shaft align. in this position, choose the one that makes the circular portion of the shaft flush with the top of the hub.

CAUTION: Use only your fingers to turn the shaft, DO NOT use any tools.

21. Place the variable knob(66) onto the yoke shaft(71) with the notch aligned to pitch mark "9", rotate counter clockwise to pitch mark "1", and remove the knob(66).

22. lnsert the knob spring(69) into the small spring hole located at the edge of the outer hub(70) between the pitch marks '1' and '9', and place the knob ball (68) on top of the knob spring(69).

23. With the notch of the variable knob(66) aligned with pitch mark '9', guide the knob(66) onto the shaft(71), taking care not to dislodge the knob ball (68) and knob spring(69).

NOTE: The ball and spring can be hold in place with a thin piece of metal or plastic.

24. Holding the variable knob(66) to prevent turning, install the knob screw(65) and use a Phillips screwdriver to tighten in a clockwise direction until snug. DO NOT overtighten.

25. Turn the variable knob (66) in both directions to verfify smooth operation and propeller blade pitch change.

 

Dia.No.	Part	Description
65	712863	Screw - Knob
66	712857.01	Knob - Variable Pitch
67	712932	Screw - Outer Hub (3)
68	712902	Ball - Knob
69	712903	Spring - Knob
70	712860	Hub - outer
71.	712861	Shaft - yoke
72	712862	Yoke - Propeller Blade
73	712856	Screw - Clutch
74	712864	Washer - Clutch
75	712865	Washer - Clutch Spring (9)
76	712901	Ring - Clutch
77	712866	Hub - Inner
78	712759	Blade - Propeller (3)
79	712867	Plate - Clutch
80	712868	Pin - Drive
81	712909	Clip - Stop
82	712879	Assembly - rotary Seal
(includes - washer,  spring, seal & seat.)
83	713773	Ring - Cup Reataining
84	713772	Cup - Inner Seal

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