Subject: ETX125PE Dec lock 'flop' problem. Sent: Thursday, March 10, 2011 14:25:24 From: Brian (email@example.com) I promised a follow-up on the floppy tube syndrome of my ETX. Grand news. My engineering company produced the goods. In essence, they cut off the stub axle where the clutch washer is/was bonded to the shoulder and replaced it with a stainless steel stub. They cut straight through the plastic and the steel tube liner, leaving the steel tube in the right tube adaptor which they drilled from the tube side to take a through bolt and lock washer. The stub was exactly the same dimensions as the plastic stub, tapped to take the Dec lock knob bolt in the outer end and an M5x25mm bolt at the inner, tube end. This bolt went through the right tube adaptor and into the end of the new steel stub, both of which I fixed in place with Loctite on the threads and epoxy on the faces of the shoulder and the end of the stub and also on the washer and bolt head. It was very fiddly to get the remaining parts assembled correctly. First I had to clean and de-grease the lock stop / clutch components and coat the inner face (tube end) of the previously bonded clutch plate washer with epoxy. These were then inserted into the compartment behind the large bearing which was then pressed in place*. The right tube adaptor was then inserted through the epoxy'd washer, the worm wheel and the lock stop plate. The small, outer, bearing was then slipped in place and the whole lot tightened down lightly with the Dec knob and assorted washers in place. It was at this point, as I was tidying up, that I discovered a spare plastic part lying around; yup, you guessed it, the right fork arm inner cover plate. Off with the dec knob and out with right tube adaptor, drift out the large bearing and retrieve the cleaned and epoxy'd parts. Clean everything and start again, this time making sure the cover was in place before assembly. Once (correctly) assembled I left everything to cure for 24 hours. I have to say, the final result is very satisfying to use. It has the feel of a quality engineered part about it, almost as if it had been designed to lock the parts together snugly. My tube has never been so firmly held. *Had my large bearing been as sloppy a fit as the small one, I could have assembled everything prior to insertion but it was a tap in / drift out fit and I was loathe to ream out the casting to make it a sliding fit. I think if I was to do this again, I would loosen the fit and assemble the whole thing out of situ and then just slide it all in. Had the bonded washer been a lug fit into the plastic, of even into the new steel axle, then it would have been a lot easier to assemble and it wouldn't have needed to be epoxy'd in place at all. C'est la vie. I have included some photo's (usual rubbish quality) to show the stub axle in place and the locking bolt through the right tube adaptor from the inside. I would have taken some shots of the axle prior to assembly but the battery on the camera went down at the wrong moment. It looks exactly like the original, except that the part of the stub axle from the shoulder outward is steel instead of plastic; easy to visualise I guess. Typically it is now a lovely clear night but I am too tired to take advantage of the sky, so it's off to bed to dream of my lovely new clutch action. Ooooohhhhh! Brian Martindale
Go back to the Tech Tips page.
Go back to the ETX Home Page.