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[Rod Irl]

After 60,000 I failed to check battery, weak spark and bang same prob sprag jamed very tight,have removed the chain case,but can not free up sprag to get at circlip to remove from houseing, have any of you lads got any bright thoughts on this, money is tight so won't be getting any gear, thanks for any help. Rod Irl

[Norm]

Rod need a bit more info, how far do you have it stripped down? What have you been able to remove? Electra or Cast Iron?

[Leon Novello]

Rod: As suggested above, a drive tooth must be partially turned over, or completely turned over. If you can find which one it is you might be able to tap it back into position with a screwdriver, but I don`t think you will have much luck. Maybe rocking the crankshaft back and forth will pop it back if nothing else looks broken. From what I hear about these things, once they go BANG, it`s too late.

[Rod Irl]

Hi Norm it is 2003 4speed Iron, I have removed the idler gear from the chain case, and it is looking at me from the bench with glee, gotcha. Rod Irl

[Norm]

Leon this is a different situation, from what I'm reading the sprag bearing has siezed and they are a pig of a thing when this happens because the gears won't line up so you can remove the engine sprocket and this is a 2 man job to do but at this stage it is hard to tell until he posts some more information.

[Rod Irl]

Hi Norm can you tell me what a two man job entails to remove this sprag thanks. Rod Irl

[papasmurf]

I have no idea if this video is of any use:-
Removed Broken Sprag Clutch of Royal Enfield Motorcycle

https://www.youtube.com/watch?v=ckiQN_i-buE

[Norm]

Rod it becomes a 2 man job if the starter gears have locked up on the shaft, at this stage you haven't given a lot of info so I can only assume this is what has happened. You have to remove the starter motor and one person has to get in there from that side with a big screwdriver to jamb/lock the inner gear, and another person with a cold chisel and hammer to hammer away at the outer gear from the primary side till the gears line up so you can slide the engine sprocket out. Then you have to get the three countersunk screws out of the primary and that can be a feat on its own and cause a lot of stress. What bike is it?

[Rod Irl]

Hi Norm thanks for reply, as stated above I have the chain case on the bench with idler gear removed, what you are saying would reqire reasemble of chain case putting idler gear back and jamb it etc, am I correct?,if so what about circlip. Thanks Rod Irl

[Norm]

Rod I'm doing this from memory, been a while since I pulled the last sprag apart, Only circlip I can remember is the one holding the sprag together and I use circlip pliers to remove it. Not sure if this is what you are talking about. In a couple of cases with a spindle I was having grief removing I welded a piece of threaded rod to the spindle so I could use it as a puller.Removing the spindle means you don't have to get the circlip out. I assume you are not replacing the sprag and if so, and removing the sprag gears is a problem to you, then the other option is to cut the sprag gear off the engine sprocket with a grinder and ignore the rest of the bits