HELICOPTER ENGINES

Zenoah G230 (A300): $219.00 

NGK Plug (A305): $8:13  

 
Spark Plug Wrench Nickel Plated (A305-1): $8.95

Choke Lever (A332): $3.95

 
    Body Assembly Air Purge for Walbro (A333): $4.98 

petrol
     
Petrol Tank (328): $15.48 

   

    
Petrol Felt Clunk (A331): $12.84

 

   
Petrol Clunk (A334): $2.95    

           
            Clutch Bell 22-tooth incl. clutch lining  incl. 2 bearings (A210): $ 85.60  

We recommend that any time you work on your helicopter or any parts that you wear as set of ANSI approved safety glasses. Also observe al safety precautions regarding sharp tools, fuel and other hazards.

Clutch Shaft Bearing Removal and Replacement

Replacing the clutch shaft bearing requires the removal of the clutch and the clutch assembly.

Removal

1.      Loosen the four motor mount screws and slide the motor rearward to loosen the primary belt drive. Remove the primary belt.

2.      Remove the clutch by using the clutch wrench (2 Pins) to hold the clutch and loosen and remove the center screw. Pull the clutch assembly off the shaft.

3.      The clutch, clutch bell, brass bushing  and the drive pulley will come off as a unit.

4.      Remove the C clip from the brass bushing. The clutch and bushing should slide downward from the clutch assembly. It may require some gentle pressure to remove the bushing from the bearings.

5.      Remove the top bearing from the drive pulley with a blade screw driver from the bottom of the clutch. It may require gentle even pressure so that the bearing moves evenly and is not cocked.

6.      Remove the lower bearing from the bottom of the pulley by pushing down from the top. Note: if this is difficult, gently heat the outside of the clutch pulley to expand the pulley. This will soften any locktite. The bearings must be removed in the correct direction as there is a separation and seating ring in the center of the pulley.

7.      Once the bearings are removed, clean the internal surface of the clutch pulley completely.

8.      Separate the brass bushing from the clutch.

1.      Examine all parts for cracks, wear or excessive play. Cherck the bearings for nicks I cracks on the sides, rotate the  inner and outer races to check for any roughness , flat spots or loose areas.  Check the clearance between the clutch facing and the clutch. If the clearance is more than 0.04 replace it. Replace any questionable parts.

2.      Remove the clutch liner with an exacto knife. Remove the residue with 200 grip sand paper, clean with alcohol. Replace the liner with an Airstar liner kit only $3.95. The directions are on the kit.

3.      Apply a thing film of JP Weld to the clutch bell housing interior sides and the exterior of the clutch liner material. Carefully press the liner onto the bell.

4.      Wrap five turns of standard note paper around the clutch as a spacer. Press the clutch  with the spacer into the clutch bell to provide suitable pressure to the clutch material. Let dry.

5.      Remove the clutch and remove the paper spacer. The clutch is now ready to assemble. 

Assembly 

1.      Apply a small amount of locktite on the internal surface and on the outside of the bearing races. Be sure to that there is no excess locktite. Be sure that no locktite gets any where near the bearings.

2.      Press the first bearing in from below until it contacts the clutch pulley bearing seat. Note: We recommend a thin film of locktite be applied to both outer beating races to ensure a solid seal to the bearing seat. This counteracts the micro vibrations from the engine.

3.      Press the second bearing in from the top until it contacts the clutch pulley bearing seat.

4.      Insert the brass bushing from the bottom of the clutch and seat in the pulley bearings.

5.      Slide the C clip into the bushing slot. Make sure it is seated properly.

6.      Push the clutch onto the brass bushing from below.

7.      Slide the clutch assembly onto the engine drive shaft. Check to make sure all parts are aligned.

8.      Apply locktite to the engine drive shaft screw hole and to the clutch screw and insert the screw into the drive shaft. Use the clutch spanner and the driver to tighten the assembly. The brash bushing is designed with as tapered hole for the engine shaft and a tapered shaft for the clutch hole.

9.         Tighten the engine shaft bolt fully.

10.  Place the primary drive belt over the clutch housing and the drive shaft. Check that everything moves freely with no binding.

11.  Slide the motor mount forward until the drive belt is tight. Note. Firm side pressure on the drive belt should per less than one quarter inch of movement.

12.  We recommend that you remove each mounting screw individually and reapply locktite and tighten. Doing this one at a time will maintain the proper alignment.

13.  Check for smoothness and freedom from binding.  This completes the procedure.

14.  You are ready for a test

   
Clutch Bell Bearing15x24x5 (A212): $7.50

 
 Clutch split taper Colet/Clutch Bell Sleeve (A221): $11.95

            

                              m        
               Throttle Lever (A317): $9.95 

AirStar International
13006 E. Vista Park Dr.
Moorpark, CA 93021

Phone: 805-553-9996
Fax:     805-553-9888

E-mail: airstar@sbcglobal.net