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[ADVENTURESonZERO]

I'll try to explain,
At 7:40 on the video, the bearing is pressed (hammered) into the plate until it rests against the shoulder of the plate. The bearing is sandwiched and held in place by the shoulder that is inside of the hole and the snap ring.
At 8:30 on the video, I placed boards in between the plate and the top of the rig.
As I tightened the bolt, the force of the rig is on to the plate, which transfers the force to the bearing with the above mentioned "shoulder". The legitimate concern is that the shoulder could break.

Ryan is suggesting to instead use a sleeve (pipe) in between the bearing itself and the top of the rig. The sleeve needs to be the same size as the inner race of the bearing and allow room on the inside for the motor shaft. Looking at the old bearing, which is 30mm ID, so the sleeve needs to be 32mm ID.

Thanks again Ryan. I'll edit this into the video one day soon. I hope this helps. Sometimes things are easier done than said.
Best luck with the project. Go slow and work on a very clean bench away from metal shavings.

Ride On, Red Clay

Ah gotcha. I really appreciate you posting the video. As I type this, my motor sits in my basement disassembled with the front bearing out, waiting on the replacement to come in the mail in 3 days - followed your video step by step (although with a thrown together gantry of plywood, not steele tubing). I'm concerned about getting it back in based on that comment above - I have a 2500 mile trip in less than two weeks that I've spent months planning, I'm down to the wire on getting this bike up and running.

Did you replace the other motor bearing as well? I'm thinking that I probably should just for the sake of it since the motor is already taken apart. Thoughts?

[Red Clay]

Hello ADVENTURESonZERO,

Congratulations on being half way there. The re-assembly is not too difficult, granted though a little nerve wracking the first time through. Notice in the video, after 8:30, that I twisted the allthread bolt after each tightening. The twist caused the pressure to release with a popping sound, not audible in the video. A little at a time and the bearing pressed on without too much force.

I have not replaced the rear bearing on a motor yet. It is more involved than the front bearing, with pieces that have to be realigned perfectly. The only information that I have found on this subject is in the unofficial service manual and a post by travis kimbrell.

https://zeromanual.com/wiki/Motor_Bearing_Replacement

https://electricmotorcycleforum.com/boards/index.php?topic=8813.msg78554#msg78554

I do not understand the part about loctite 648. My question is: "If it is put back together with loctite...then how did he get it apart?"

Like you, I had a deadline to meet, therefor I did not look at the inner bearing parts and process while the motor was dis-assembled. I spun it. It seemed solid and moved on to the outer bearing, replaced because it had been compromised by dirt intrusion through the seal.
Post some pictures of the rig that you built.
If you replace the inner bearing, please take pictures and share.

Best of luck.

Excuse me, I can't resist.....HELLO ZEROMOTORCYCLES!! You build an awesome motorcycle BUT there are too many mysteries. Wish you offered your customers a real SERVICE MANUAL like every other motorcycle company!!.....done.

Ride On, red clay

 

[Auriga]

Off topic, but I don't think most motorcycle service manuals are produced by the manufacturer
EDIT: Apparently they are more common than I thought.
.
Even if they did produce one, bearing replacement is not something Zero recommends(even for dealers) and would not be included.

I actually saw them building motors a while back at their plant, and it looked like fairly delicate work.

[Richard230]

Off topic, but I don't think most motorcycle service manuals are produced by the manufacturder.
And even if they did produce one, bearing replacement is not something Zero recommends(even for dealers) and would not be included.

I actually saw them building motors a while back at their plant, and it looked like fairly delicate work.

BMW makes wonderful factory DVD service manuals for each of their models that can be updated over the internet. They are the best service manuals that I have ever seen. Very clear and organized with step by step instructions and diagrams showing how each step is performed for every task you can think of. The dealers can order the DVD for the bike's owner for around $110 in NA.

[Crissa]

The service manual I have for my spouse's Ducati is from Ducati...

-Crissa

[ADVENTURESonZERO]

So my bearing replacement did not succeed. After replacing both bearings with two Timken 6006 2rs bearings, I conducted a test ride after getting the motor put back in (after waiting 24 hours for locktite to cure).

After about 15 miles of absolute silence, the knocking sounds came back. There is no play or axial movement at the pulley or drive shaft, so I'm a bit perplexed at the moment. I've ordered some OEM bearings (NSK 6006DU 2rs), which will be here in a few days, hopefully that rectifies the issue.

I will say that the knocking sounds are reduced a bit, as are the vibrations from the first time this problem came up - so there's that

Will update when I have replaced the other bearings...again. 3 times I've removed the motor in two weeks 

[Red Clay]

Thanks for the update and sorry to hear that there are still issues with the motor.

I too am perplexed and have the standard questions: Are you sure the sound is coming from the motor/bearings? Do you hear the knocking sound when you run the motor without the belt? Is the sound more loud on one side?

Two of our six brand new FX motorcycles had sounds coming from the motor, a clicking/popping sound that matched the rpms. Seemingly, bad bearings from the factory. The motors were replaced by Zero and I did not ask for an explanation for the source of the sound.

The bearings that were replaced in the video were making a grinding sound from obvious dirt intrusion.

How was the process of getting to the inner bearing? Were there any issues with the disassembly? Pictures? Video?

On a positive note: the motor sure is easy to remove!! especially compared to my, now sold, Honda XR650R.

keep on striving on so we can Ride On, red clay