Gears gone

Shame, the trike is off the road again. The rear cassette is very loose. It is quite a big job to fix. The suspension needs to be loosened and the differential disconnected to allow tightening. It was fitted by the dealer a few hundred miles back. This was to replace the original which had teeth stripped. The teeth stripping was as a result of the design of the tandem coupling catching.

The dealer did not want to replace the cassette, but after a few emails Hase agreed to its replacement and fitting. I think this would have cost around £150 to do. Ouch!

 

Removing the differential and replacing the cassette
The differential requires no maintenance and must only be removed
when replacing the cassette.
1. Unscrew the two M6 locknuts (1) on the sway-bar mounting
plate.
2. Unscrew the M8 locknut (2) on the rear-shock mount using a
13mm wrench (spanner).
3. Loosen the Allen bolt (3) on the axle clamp using a 5mm
Allen key.
4. Slide the rubber bellows (4) to the left, away from the differential
case.
5. Pull the left axle assembly (5) approx. 10 cm (4”) out of the
frame tube and the differential. There is a 10mm hexagon
socket in the side of the differential.
6. Bracing the right wheel, insert a 10mm Allen key in the hexagon
socket of the differential (6, in diagram on next page), and
unscrew the differential with the cassette from the right drive
shaft by turning the differential clockwise (attention: left-hand
thread).
Note:
Upon reassembly, the differential must be tightened with a
torque of 80 Nm (59 ft-lbs). Use assembly grease on the
threads.
7. Remove the differential with the cassette. Then you can
detach the cassette.
8. Brace the cassette with a chain whip, and unscrew the sprocket
bolt using a freewheel remover.
9. Pull the cassette off the freewheel.
10. Attach a new cassette by following these steps in the reverse
order.
Note:
When installing the new cassette, make sure that the shim
(7) is lying flat and not wedged at an angle beneath the twopart
bearing seat (8).
Note:
Lubricate the contact surfaces in the differential (6) with a
solid lubricant before you insert the left axle assembly into
the hexagon socket.
11. Slide the rubber bellows (4) back onto the end of the left axle
assembly. Align the rectangular socket in the side of the differential
with the slot nuts on the end of the left axle assembly.
Then slide the left axle assembly as far as it will go into the
axle tube, while guiding the slot nuts into the rectangular slot
of the differential.
12. Tighten the M6 Allen bolt (3) with a torque of 9 Nm (6.6 ftlbs).
Replace and tighten the M8 locknut (2) on the rear-shock
mount with a torque of 23 Nm (17 ft-lbs).
Attention!
It is essential that the M6 bolts (3) of the axle clamp be
tightened with a torque of 9 Nm (6.6 ft-lbs).
13. Replace and tighten the two M6 locknuts (1) on the sway-bar
mounting plate..

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