02-03 EV Rear Wheel Cush Drive Snap-Ring Repair

[guzzied]

Has anyone done the cush drive snap ring repair for the 2002 and early 2003 California EV rear wheel? The snap ring fits loose on my early 03 EV and I wanted to fix it before it gets too far gone. Guzziology states that there is a repair but it is kinda confusing on what is done, is the snap ring totally removed or is there a new style snap ring and added retainer plates? Says only one hole needs to be drilled and tapped yet they add 3 more retainer plates....

Your help will be welcomed!

Thanks, Mike

[Markcarovilli]

That ring is supposed to be loose and not be tight…

Guess I don’t understand.

Mark

[guzzied]

The groove for the snap ring is only about 1/32" deep 180 degrees from the ring retainer/bolt. With the loose snap ring, it has worn away the the lip and is about to come loose somewhere down the road. Guzzi's late 2003 fix was to add a retainer 180 degrees from the one shown in the picture but Dave Richardson suggest adding two more at the 90 degree locations. But, that won't work cause the spoke bosses are at that location...Doh! I might be able to put 2 at 60 degrees from the original snap ring retainer but I thought I would pick your minds first...

[Kiwi_Roy]

That wheel looks somewhat similar to the one on my 76 Convert but the ring grove in that is much deeper, I can't see it ever breaking out.
I would think 3 small flat plates (or even a 6mm screw with flat washer) 120 degrees apart pressing on the circlip would do the trick.
I don't believe there is much strain on the circlip in fact you might be able to take it out and the plate would stay in place.
Note: I'm not suggesting you actually do away with the circlip.
Dave Richardson was probably not expecting you to take his 90 degrees literally, just put them on the flat area between the spoke bulges.

[Wayne Orwig]

I cleaned up the ring, and the slots in the wheel, and I glued the ring in place using simple RTV. So it is easy to remove if I need to. That stopped the wear.

BUT, the UNDERSIDE of the snap ring, against the plate, I lube so the plate can freely move.

The problem, as you may understand, is if the rings moves, it will eat away the aluminum wheel real fast. The ring should NOT move. I did see one wheel where the owner had drilled and tapped the aluminum in a few spots, and run screws into the aluminum where the large screw head caught and held down the snap ring. That is a good fix if done right.

[kingoffleece]

Please indulge a question-thx.  I purchased some tubeless spoke rims off what I thought was a late 90's Guzzi to install on my 2001 Jackal-which went flawlessly.  I was not aware any plate was needed so 1) do I need one for my bike, 2) are the issues the same for late 90's wheels vs 2002-03 wheels, and3) if needed are they available anywhere?

THX in advance.

[John A]

Just make sure any fasteners in that area won’t easily come out. I had the short screw I put in come out and went out through the gap between the wheel and the bevel box. I was going about 30 mph and heard and felt it. Since I didn’t know what had happened I called for a flatbed to take it home, not wanting to risk bad things happening. It made a gouge in the aluminum but luckily that’s all. I had done the 180 degree added fastener but didn’t use a strong enough loctite.

[John A]

Please indulge a question-thx.  I purchased some tubeless spoke rims off what I thought was a late 90's Guzzi to install on my 2001 Jackal-which went flawlessly.  I was not aware any plate was needed so 1) do I need one for my bike, 2) are the issues the same for late 90's wheels vs 2002-03 wheels, and3) if needed are they available anywhere?

THX in advance.

No, the older wheel is fine

[pehayes]

It is possible to have a similar failure on the earlier EV.  98?
The snapring is NOT a simple ring.  The underside has a band of friction material glued in place.  That band acts like a slip clutch to allow motion of the plate but only after a certain level of force.
I was doing a cross-country on my 98EV about 2005.
I was unaware that most of my friction band had been worn away and the snapring/plate interface was now metal/metal.
I drove through a full day of rain in Colorado and then rested in a motel.
While I was sleeping, the plate rusted itself to the inner face of the snapring.  At this point, all of the cush rotational force was now transferred directly to the snapring.
The ring moves easily within its groove and is only restrained from rotation by the little "Z" metal tab and one screw.
At the Continental Divide in Wyoming I heard and felt a hideous noise from the rear.  I slowed to drive cautiously and the noise was gone.  It re-appeared in several small spurts before I got to Jackson Hole.
Upon inspection at night, I discovered that the "Z" had been sheered completely in half by the now mostly-free snapring.  The sheared piece had bounced around and damaged the interior face of the hub and wheel.  Eventually the sheared piece lodged on a bit of level webbing on the drive face.
Easy enough with a vice and hammer to duplicate a new "Z" tab.
I have been religious about greasing the contact face of the plate and snapring ever since.

https://i.postimg.cc/3W5MmHRJ/MVC-249L.jpg



https://i.postimg.cc/W3ycpZcZ/MVC-250L.jpg



Patrick Hayes
Fremont CA

[Dilliw]

Mine failed years ago and Mark, a Guzzi Guy that at the time had a shop in Columbia, did the "repair."  It adds clips to retain the ring, and at the the time the clips were available from MG. 

I think I have a picture on my computer at home.

[guzzied]

A new snap ring for a 2003 EV is over $200. through Harper's, thank god the friction material on mine is in good shape. I did order six 03632770 plates to repair the two rear wheels on my 02 and 03 EV's. I will have to drill and tap some holes but it should be a solid fix afterwards.

Number 25 is the plate needed to repair the 2002 and early 2003 rear wheels. This parts picture is of a 2003-2004 EV which the wheel was updated.

[Dilliw]

Yep that's what they look like.  Be careful on your drill depth as there's not a whole lot of thickness between the lugs.  One of mine came through just a tad but you have to remove the grime to see it :)

  I think I have 6 of them total in my '03 rear. 

[Dilliw]