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General Category >> Technical >> Replacing Blue Gear in Tongsheng TSDZ2 Drive
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Message started by jayg on Feb 20^th, 2023, 5:45pm

Title: Replacing Blue Gear in Tongsheng TSDZ2 Drive
Post by jayg on Feb 20^th, 2023, 5:45pm

Bob M experienced a loss of assist while riding his E-700. He could hear the motor running, so the problem could have been a defective blue nylon drive gear/Sprague bearing combo in the motor housing. I ordered a new gear a couple of days ago and received it this afternoon. Spent several hours replacing the old gear and greasing the new gear and the big drive gear on the right side of the drive. Seems to be operating normally now.

http://i.imgur.com/yPEx6Ji.jpg (https://imgur.com/yPEx6Ji) http://i.imgur.com/nZ9KK6R.jpg (https://imgur.com/nZ9KK6R)

Drive installed on Catrike 700 Left housing cover removed, revealing motor and controller

http://i.imgur.com/S0U6mFS.jpg (https://imgur.com/S0U6mFS) http://i.imgur.com/zTMp3Zs.jpg (https://imgur.com/zTMp3Zs)

Motor removed, revealing blue nylon drive gear Motor

http://i.imgur.com/vaBa4Bn.jpg (https://imgur.com/vaBa4Bn) http://i.imgur.com/yKPe58H.jpg (https://imgur.com/yKPe58H)

Motor and blue gear removed No obvious damage to gear, but grease around gear contained rust

http://i.imgur.com/vKSJg6B.jpg (https://imgur.com/vKSJg6B) http://i.imgur.com/qjbEk9E.jpg (https://imgur.com/qjbEk9E)

Blue gear lubricating grease recommended by ECO Cycles Sprocket and main drive gear cover

http://i.imgur.com/c4VeccL.jpg (https://imgur.com/c4VeccL) http://i.imgur.com/2vyAaR5.jpg (https://imgur.com/2vyAaR5)

Sprocket and main drive gear cover removed, revealing gear and large Sprague clutch bearing in gear center Main drive gear lubricant recommended by ECO Cycles

Title: Re: Replacing Blue Gear in Tongsheng TSDZ2 Drive
Post by Tiger_Mike on Feb 22^nd, 2023, 5:37am

Nice work!

Title: Re: Replacing Blue Gear in Tongsheng TSDZ2 Drive
Post by jayg on Feb 22^nd, 2023, 4:44pm

Thanks, Mike.

Title: Re: Replacing Blue Gear in Tongsheng TSDZ2 Drive
Post by TonyWard on Feb 25^th, 2023, 8:45pm

Agreed - good work and writeup as always! Hope you are doing well.

Title: Re: Replacing Blue Gear in Tongsheng TSDZ2 Drive
Post by jayg on Feb 26^th, 2023, 5:03pm

TonyWard wrote:

Agreed - good work and writeup as always! Hope you are doing well.

Thanks, Tony. Still doing well.

The TSDZ2 Tongsheng drive is perfect for the DIYer, because all the individual drive components are readily available online (Amazon, Ebay, and AliExpress).