ZA50 Breakdown Videos

My Puch Sport MKII’s ZA50 had a loose 1st gear nut and after pulling away from a stoplight, it blew the bearing ring out through the clutch case cover.  Here is the breakdown and reassembly I had to do to get it running again.

This was the first time I ever took apart my motor, so please excuse the fact that I may have used the wrong terminologies at times…however, I feel SO much closer and more in tune with my bike now that it’s running again.  Hopefully these videos will help some people know what to expect when they open up their case and not have to experience some of the trials and tribulations that I faced going in.

VIDEOS AFTER THE JUMP.

ZA50 First Opening

Looking at the 1st Gear and Clutch Bell

** I forgot to turn the video camera on when I took off the 1st and 2nd gear clutches, but the only thing to note is the lock washer, which I explain later in retrospect while reassembling the clutches.

The 2nd Gear

Removing 2nd Gear Loctite Threadlocked Screws

Melted Puck Showcase…this was to be expected

Cleaning 2nd Gear After Torching the Screws is Easy

Breakdown of the Disassembled 2nd Gear

Scraping Melted Shift Dampeners;  or Puck You, Melted Plastic

Assembling 2nd Gear and Installing New Pucks

Threadlocking 101 – Loctite Blue

Installing 2nd Gear

2nd Gear Clutch Install

1st Gear Clutch Install

Clutch Lock Washer and Nut – As far as I can tell, this is the only video on the net that actually shows what’s up with this thing…

1st Gear Install

1st Gear Bearings

WEWT.  All done.  My bike is running, and I think I’ll go for a ride now.

1/2W for life.

UPDATE:

Case Cover Bearings Removal – Disregard the part where I mention knocking the post all the way into the case, it was early in the morning and there is no way to do that since they are set into a stop to keep them from going too far in…that said, still make sure they’ve been removed because it won’t work if they’re in the case cover.

Case Cover Bearings Installation