My knuckles are bleeding!

[cave weta]

Ive been in the shed doing a 'love job' for a local farmer...
Im trying to replace the cush drives in the rear hub of his HondaXLR125 farmbike. They are rubber bonded steel sleeves that are pressed into the hub.
Theres 5 of them and ive spent two hours trying to mangle the first one out of its hole the holes are blind so I cant knock em through, Im just in there with a small chisel trying to collapse them inward.

they just wont budge

IDEAS PLEASE?

[B0000M]

ill put in one of those useless road rider comments--


replace the bike with a new one!

[Pedrostt500]

I take it that they have rusted them selves into the holes?, maybe a soaking over night with CRC

[cs363]

Can you take a piccy Stu so we can get a better idea?

(By the way, are you sure your knuckles aren't bleeding from dragging on the ground?! lol)

[cs363]

failing a pic...do you have a gas plant or blow torch that you could perhaps burn the rubber out and then just deform/cut the sleeve with your much abused cold chisel and remove it? (Am I even on the right track here? can't say I'm familiar with these things)

[barty5]

http://www.cmsnl.com/honda-xl125s-19...ist/F++11.html

try this link is the part you are talkin about NO: 3

if they are just rubber hows about a nice sharp drill wont be able to use them again we do this with cars sometime when the bushes wount come out or there is the gas option no good for the ozone but you have to do what yah gota do just dont get the hub to hot.

[FROSTY:Me]

Mate are you sure there arent rubber locating pins sticking out the back of the hub?
they might be well hidden in years of gunge

[Motu]

You use a muffler chisel....

[cs363]

You use a muffler chisel....

I could be wrong but I don't think he has air tools, or do you Stu?

[cave weta]

I take it that they have rusted them selves into the holes?, maybe a soaking over night with CRC

Ive done that- its now next morning........

http://www.cmsnl.com/honda-xl125s-19...ist/F++11.html

try this link is the part you are talkin about NO: 3



if they are just rubber hows about a nice sharp drill wont be able to use them again we do this with cars sometime when the bushes wount come out or there is the gas option no good for the ozone but you have to do what yah gota do just dont get the hub to hot.

Yes- thems the bits- they are in a blind hole and the old rubber was just absorbing the chisel blows.

Mate are you sure there arent rubber locating pins sticking out the back of the hub?
they might be well hidden in years of gunge

Nope blind holes- ive been out here 4 hours now

You use a muffler chisel....

Whats a muffler chisel? I imagaine a splitting chisel for opening the slits on exhaust joints?- Im using a tiny 6mm wide chisel and hook that ive bent out of a flat blade screw driver.

I could be wrong but I don't think he has air tools, or do you Stu?

Ive got tools for africa! tubing benders to drill press to mig and even brake cylinder hones. -

****UPDATE***** its 8.30 am and the jobs done- I drilled the rubber out with a 16mm drill then I used the 3lb hammer from a Harley Davidson carburettor adjusting tool kit to mash them inwards with that tiny chisel again!
Now ive fitted new ones and a shiney new sprocket and chain. - it can go back out into the cowpoos again till next springtime.

Thanks guys!

[cs363]

Ive done that- its now next morning........


Yes- thems the bits- they are in a blind hole and the old rubber was just absorbing the chisel blows.


Nope blind holes- ive been out here 4 hours now



Whats a muffler chisel? I imagaine a splitting chisel for opening the slits on exhaust joints?- Im using a tiny 6mm wide chisel and hook that ive bent out of a flat blade screw driver.



Ive got tools for africa! tubing benders to drill press to mig and even brake cylinder hones. -

****UPDATE***** its 8.30 am and the jobs done- I drilled the rubber out with a 16mm drill then I used the 3lb hammer from a Harley Davidson carburettor adjusting tool kit to mash them inwards with that tiny chisel again!
Now ive fitted new ones and a shiney new sprocket and chain. - it can go back out into the cowpoos again till next springtime.

Thanks guys!

Cool, glad you've got it sorted! A muffler chisel for future reference is one of these (attached)
Wondered where all my tools went....ha ha

[cave weta]

Cool, glad you've got it sorted! A muffler chisel for future reference is one of these (attached)
Wondered where all my tools went....ha ha

Thanks Baldrick- bring your CRF up here next time you come, we need to see if you still stick your knee out in the dirt an d I want you to have a go on that Christini AWD version! - that will be featured in this months DRDmagazine. Power, Birch and Mc Donald all love it!

[cs363]

Thanks Baldrick- bring your CRF up here next time you come, we need to see if you still stick your knee out in the dirt and I want you to have a go on that Christini AWD version! - that will be featured in this months DRDmagazine. Power, Birch and Mc Donald all love it!

Nah, stopped doing that a few years ago - I was bashing my knee on the tree stumps at Woodhill, that learned (!) me pretty quick, lol (smartarse )
Yeah I'm keen to have a bash on the Christini, just getting over your way is such a pain from Eastern Australia...
Hopefully will have some time over summer, pretty sure even if it's dry you'll be able to find some mud for us!!

[Motu]

I could be wrong but I don't think he has air tools, or do you Stu?

Not an air chisel,a muffler chisel....for use with a hammer.It will cut exhaust tubing inside and outside.I use mine to cut steel sleeved rubber bushes,same as on the Honda.I've done plenty of Honda rear wheel bushes,and that is the tool I use.....unless the bushes are so flogged out they go through the outer sleeve and into the alloy hub.I had some nylon bushes I used to fit instead of the rubber things,you could also use urethane....but it makes them a bit snatchy.

[cs363]

Not an air chisel,a muffler chisel....for use with a hammer.It will cut exhaust tubing inside and outside.I use mine to cut steel sleeved rubber bushes,same as on the Honda.I've done plenty of Honda rear wheel bushes,and that is the tool I use.....unless the bushes are so flogged out they go through the outer sleeve and into the alloy hub.I had some nylon bushes I used to fit instead of the rubber things,you could also use urethane....but it makes them a bit snatchy.

Yep with you now, that pic is of an ir chisel bit designed for that same job - hence the confusion.
Talked to the local guy today who has done a few of those XLR's and he said they used the drill or gas torch on the rubber then attack the sleeve with a muffler chisel (air or hand! ) as per your description above.
Interesting to know as I've never seen a cush drive like that, they've all been the conventional rubber insert type.