How To Assembly Fatboy Ss Mini Gear Drive Repair Guide

Difficulty

Moderate

Steps

Time Required

                          1 - 2 hours

Sections

How to assembly FatBoy SS Mini Gear Drive
14 steps

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What you need

Step 1

              Assembly Hanger Mounting hub

Install 4 x M3 grub screws to the hanger hub.
Don’t forget to use Loctite on grub screw thread

Install 4 x M3 grub screws to the hanger hub.

Don’t forget to use Loctite on grub screw thread

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Step 2

              Attach hanger hub to the baseplate

Install 4 x M2.5 bolts through the baseplate to hanger hub.
Don’t forget to use Loctite on threads

Install 4 x M2.5 bolts through the baseplate to hanger hub.

Don’t forget to use Loctite on threads

Step 3

              Mount the assembly on hanger

Tighten grub screws to lock assembly in place.
Make sure the assemblies are parallel to the wheel.

Tighten grub screws to lock assembly in place.

Make sure the assemblies are parallel to the wheel.

Step 4

              Shorten motor shaft for motor gear mounting

Cut the motor axle to the 20mm length from the baseplate.
Make sure to cover motor, motor wholes and whole motor with something to prevent metal dust getting into the motor. Magnets easily attracts metal particles inside and can cause shortening.

Cut the motor axle to the 20mm length from the baseplate.

Make sure to cover motor, motor wholes and whole motor with something to prevent metal dust getting into the motor. Magnets easily attracts metal particles inside and can cause shortening.

Step 5

              Install Key way

Apply this step only if motor has keyway
Apply retaining compound like (Loctite 648) to keyway and install in the keyway

Apply this step only if motor has keyway

Apply retaining compound like (Loctite 648) to keyway and install in the keyway

Step 6

              If required attach stainless steel plate to the motor

It is only useful when motor has open areas in the baseplate it minimize grease getting into the motor.
Attach stainless steel plate to the motor

It is only useful when motor has open areas in the baseplate it minimize grease getting into the motor.

Attach stainless steel plate to the motor

Step 7

              Install Motor Keyway to the motor axle

Tighten M2 grub screws on motor gear to secure motor gear on axle.
Don’t forget to use Loctite on grub screw thread

Tighten M2 grub screws on motor gear to secure motor gear on axle.

Step 8

              Attach motor to baseplate

Use 3xM3 bolts to attach motor to the baseplate
Don’t forget to use Loctite on threads

Use 3xM3 bolts to attach motor to the baseplate

Step 9

              Attach wheel gear to wheel hub

Attach wheel gear using 5xM3 bolts to wheel hub for meshing gears
This is only pre-fitment Loctite is not yet required.

Attach wheel gear using 5xM3 bolts to wheel hub for meshing gears

This is only pre-fitment Loctite is not yet required.

Step 10

              Prepare gears for meshing

Baseplate should be parallel to the wheel otherwise wheels will mesh on angle and will cause negative effects.
Add brass washer to axle before mounting wheel hub.
Attach wheel hub to the hanger and lower down motor to prepare gear meshing.
Motor gear and Wheel gear should be always parallel to each in all wheel position. If gears not parallel and at angle it can cause negative effects and product more noise than necessary.
Loosen up motor bolts so that motor gear would press wheel gear.
Use sheet of paper to drive it through wheel gear and motor gear. Spin wheel to push paper through the gears
After meshing is good tighten motor bolts

Baseplate should be parallel to the wheel otherwise wheels will mesh on angle and will cause negative effects.

Add brass washer to axle before mounting wheel hub.

Attach wheel hub to the hanger and lower down motor to prepare gear meshing.

Motor gear and Wheel gear should be always parallel to each in all wheel position. If gears not parallel and at angle it can cause negative effects and product more noise than necessary.

Loosen up motor bolts so that motor gear would press wheel gear.

Use sheet of paper to drive it through wheel gear and motor gear. Spin wheel to push paper through the gears

After meshing is good tighten motor bolts

Step 11

              Prepare final assembly

Remove wheel gear from wheel hub
Put wheel gear into the cover and attach V-ring on the wheel gear.
Use some grease on v-ring to make it easier to slide on the cover.
It is good time to apply grease to the gears
Use 6xM2.5 bolts to attach motor cover to baseplate

Remove wheel gear from wheel hub

Put wheel gear into the cover and attach V-ring on the wheel gear.

Use some grease on v-ring to make it easier to slide on the cover.

It is good time to apply grease to the gears

Use 6xM2.5 bolts to attach motor cover to baseplate

Step 12

              Attach Wheel Hub

Check that everything looks okay
Put wheel hub on the axle again
Use 5xM3 bolts to attach wheel hub back to wheel gear.
Don’t forget to use Loctite on threads

Check that everything looks okay

Put wheel hub on the axle again

Use 5xM3 bolts to attach wheel hub back to wheel gear.

Step 13

              Repeat same for other side

Use same instructions for assembling another side

Use same instructions for assembling another side

Step 14

              Test spin

Do a test spin on the bench to make sure everything is fine and sounds okay
On the first test ride start by slowly accelerating and slowly braking to make sure everything is working fine.
If there is some minor vibration happening at specific RPM it can be some misbalance in wheel/gears which should disappear after gears sit down in their place.

Do a test spin on the bench to make sure everything is fine and sounds okay

On the first test ride start by slowly accelerating and slowly braking to make sure everything is working fine.

If there is some minor vibration happening at specific RPM it can be some misbalance in wheel/gears which should disappear after gears sit down in their place.

To disassembly gear drive, follow these instructions in reverse order.

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                    Aurimas Niekis

Member since: 11/26/2018

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