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Replacing E-4 Drive Gear Track Cog
Tools Needed:
- 4-prong freewheel removing tool
- good solid bench-vise or long “breaker bar” socket driver and 15/16” socket,
- extra-long chain whip tool
- long pipe or old handlebar to act as“cheater bar” for chain whip tool’s handle
- large channel lock,
- 6mm allen wrench
- old toothbrush to clean the threads
- grease
- the replacement cog (standard is 14T)
Procedure: (Click here for helpful drawings.)
- Hold the big washer with the channel locks, if needed.
- Use the 6mm allen wrench to loosen the hold-down bolt at the end of the drive shaft.
- Either remove the motor/drive/mount assembly from the bike
- Firmly mount the freewheel removing tool in the bench vise with prongs facing up.
- Place the four slots of the freewheel over the 4-prongs of the freewheel removing tool.
- OR keep the assembly on the bike
- Wrap the chain whip tool around the rear cog clockwise, “Righty-Tightey” and tie it down or otherwise secure it so it won't move.
- Insert the 4-prong freewheel removing tool into the 15/16” socket mounted on the breaker bar.
- Use that 3-part tool to turn the freewheel counter-clockwise, “Lefty-Loosey”.
- This might take several tries to finally break the freewheel loose! Once loose, it should spin off easily.
It may help to spray WD-40® or other penetrating lubricant the threads. (Be sure to keep WD-40® out of the freewheel bearings.)
Do this off the bike for better aim, then put back on the bike (or vise).
- Remove the track cog. If it doesn’t come off easily,
- Mount the motor/drive/mount assembly back on the bike;
- Re-attach the washers and hold-down bolt to act as an anchor;
- Reverse the chain whip on the track cog, “Lefty-Loosey” this time;
- Use the 6mm allen wrench pushing clockwise to release the cog.
- Once the track cog is loose, grab the large washer with the channel locks,
and use the 6mm allen wrench to remove the hold-down bolt and washers.
- Clean the threads.
- Grease the threads.
- Install the new track cog until snug but not tight.
- Re-grease the threads, and
- Re-install the freewheel PRONG-SIDE OUT (so the freewheel removing tool can remove it again when necessary) and tighten.
- Re-mount the washers and hold-down bolt.
- Tighten the hold-down bolt.
- Check your work for forgotten steps.
- Test-ride the bike.
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