Driver Sprocket Replacement

Getting ready

It is advised to wear suitable protective personal equipment (PPE) and be in safe working environment. Before starting this maintenance process, below tasks must be completed:

• Disconnect the battery/power supply to prevent the risk of electrical issue or hazard
• Housing Removal

Tools required

5mm Allen Key
Circlip Plier

Parts required

You will need to prepare the listed parts for this maintenance procedure.

Replacement Driver Sprocket  x 1 unit
Replacement 35 mm Circlip  x 1 unit (if needed)

Steps to follow

Step 1 Kickstand Removal

For this step, Kindly refer the Kickstand removal by clicking the link below.

Kickstand Removal

Step 2 Housing Removal

For this step, Kindly refer the Housing removal by clicking the link below.

Housing Removal

Step 3 Removing chain tensioner & chain

3.1 Using an 5mm Alley Key, loosen up the Chain Tensioner’s screw. Remove the shoulder screw & set aside.
3.2 Carefully release the Chain Tensioner and remove it from the chain.
3.3 Now the chain is loose, carefully unhook the chain from the driven sprocket.

Step 4 Removing old driver sprocket

4.1 Using a circlip plier, remove the 35mm circlip.
4.2 Once the circlip is removed, gently slide the driven sprocket out along with its keyway.

Step 5 Installing new driver sprocket

5.1 Take the replacement driven sprocket along with its keyway and align it into the shaft.
5.2 Insert the sprocket until it is fully flushed & ensure the keyway is aligned.
5.3 Re-install the 35mm circlip into its designated groove to secure the sprocket.

Step 6 Reinstalling & aligning chain 

6.1 Re-install the chain by wrapping the chain around the driver sprocket.  Ensure that all gear teeth are fully hooked.
6.2 Continue to wrap the chain around the driven sprocket.  Ensure that all gear teeth are fully hooked.
6.3 Make sure that the top part of the chain is tensioned and at the tightest point.

Step 7 Reinstalling chain tensioner 

7.1 Re-install the chain tensioner by aligning to its screw hole.  Make sure that the spring is slotted into its designated slot.
7.2 Push the tensioner down to compress and hook the chain to the tensioner.
7.3 Once the chain is fully hooked, secure the tensioner by screwing in the shoulder screw. Firmly tighten the screw.

Step 8 Testing the new driver sprocket

8.1 Visually inspect the installed sprocket and ensure that all gear teeth are hooked perfectly.
8.2 Spin the rear wheel and ensure that the installed sprocket is rotating smoothly.
8.3 Finally, twist the throttle or rotate the crank. Make sure that the sprocket is rotating smoothly without any further issue.

Step 9 Re-installing Housing

For this step, Kindly refer the Housing Installation by clicking the link below.

Housing Installation

Step 10 Re-installing Kickstand

For this step, Kindly refer the Kickstand installation by clicking the link below.

Kickstand Installation

End of article