Gearbox Modification - adding Drain / Fill Plug

This modification is required to allow a filling plug for the replacement of gear oil.


Note: The gearbox cover must be removed from the scooter before this modification is started. For removal of the gearbox cover, Refer to Gearbox Cover Replacement.
1. Clean any oils or dirt from the cover.
2. Select one of the brake rotor bolt holes (2) that is across from a gearbox cover boss (1)

3. Remove brake rotor screw in location (2), clean all old Loctite from screw and thread in cover.

4. Install gearbox cover in press drill or milling machine.

5. Using 7mm drill make hole trough - be careful to not damage tread



6. Drill spot (max. depth 1.5mm) at outer boss to mark fill screw hole location for future reference.




7. Clean ALL metal chips and debris from inside and out, particularly in and around bearing and inside of hole. Lubricate shaft seal, using gear oil, before installing cover


8. Reinstall cover. Take extra care to ensure the o-ring seal is correctly positioned in the o-ring groove, and fill with 88cc gear oil per service manual (brake disc was removed for clarity. Normally, it is not necessary to remove disc unless changing entire assembly)


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You can use a steal guide or Bushing for protect the tread and drill at a good place.

Hi. Mine has done 25 000 km, made in 2008. Have never changed gear oil. Gear is rather noisy, but maybe it just sounds like that...
Would it be wise to do modification / replace oil?
Should I also replace sealings around axle, and around the gear housing?
brg, Johan

Hello, mine has done 108 000km, made in 2009, have changed oil at 12 000 km and added 5 ml of warm up gold formula anti-frictions, and after that you can forget all noise from your gearbox.


Best Rg,


Armand


Thanks Armand. 108 000 Km(!) - and no major breakdowns?
I just ordered gearbox sealing, O-ring and oil from Vectrix parts.
Warm-up Gold does not seem to be available in Norway, but I might find it at Ebay. Or maybe some other "anti friction" gear additive will do the same..? - Would really like the gearbox to be more or less quiet :)

Thanks once again, Johan

Hi Johan, with only 5ml of Warmup added in my oil I have forget the noise from my gearbox, you can found warmup on Amazon, I have replaced one ESD Charger with a Runke, and one little fuse on Motor controller and all Nimh battery from Lithium at 32000km and nothing else


Best regards

Thanks, I will try that. Godd to know they can go so far. - I have also replaced charger like you. Had some troubles with T-sensors on NIMH-battery, With Leaf Lithium it is all good. - Planning to replace shock absorbers though.

How many Km you can expect with leaf battery, and have you 54A or 65A?

I believe it is 65 Ah.. I got my modules from a 2015 Leaf. I have done 140 Km once, mostly at 60-70 Km/h. I would say 110-120 is normal. 2016-model seem to have 82 Ah.

+1

the leaf
batteries were made for the vectrix, and I would like to install them
instead of my winston at the end of their life, they currently have 80
000km and start to be less efficient than at the beginning.

I must found it at the best price.


Best regards


Armand

I was busy with my academic papers writing work so I missed your post on Gearbox Modification - adding Drain / Fill Plug. But I will read this late for sure as soon as I am done.