Group 32 Gate 2
Gate 2: Preliminary Project Review
Our work and management proposals were successful with a couple conflicts along the way. The challenges in the disassembly were limited to removing the centrifugal clutch. This required an enormous amount torque. To do this we used a vice grip to lock up the crankshaft. Also, we had to use a metal rod to extend our moment arm. This challenge in disassembly was not predicted and caught us off guard.
Following our management proposal we had left time in our disassembly process to handle any situations like the clutch removal. However, our initial plan to meet twice a week was found to be unnecessary. The full disassembly was done in two meetings, and a trip to the lab to remove the clutch. After the Request for the Proposal was due, Andrew went to the lab and signed out the chainsaw. He then took it with him and did a quick analysis disassembly. By removing the three outer covers over the flywheel, clutch and intake, a secondary analysis for tools and challenges was done. This took him 25 minutes at most. This is where we found the clutch removal problem. Our list of tools required was confirmed.
Our next meeting was at Cam’s apartment, where everyone gathered on October 15th at 5pm. For two hours we worked on the disassembly. During the disassembly we took photos of the whole step process and recorded our progress in an Excel document (see attached). At the end of the two hours we had removed everything from the main component up to the intake (see Chart 1 for details). Next we met October 20th at the same place and time (Cam’s apartment @ 5pm). During this time we finished our disassembly. The next day we went to the lab to remove the clutch. Overall, we have to say our disassembly was a success and we plan on continuing our management proposal into the next gates.
Disassembly Process
| Step | Tool Used | Part Removed | Location on Product | Time it Took | Ease Rating 1-5 | Directions |
|---|---|---|---|---|---|---|
| 1 | Straight Blade Screw Driver | Intake Cover | Exterior | 5 sec | 2 | Turn the bolt 90 degrees and pull plastic cover off. |
| 2 | Straight Blade Screw Driver | Intake Cover Locking | Underneath the intake cover | 5 sec | 2 | Remove the bolt. |
| 3 | 14 mm Socket & 1/4" Drive | Clutch Cover | Exterior | 30 sec | 2 | Remove both nuts and washers, and slide the cover off of the protruding bolts. |
| 4 | None | Chain Bar | In between clutch and body | 1 sec | 1 | Slide it off of protruding bolts that hold it in place. |
| 5 | Straight Blade Screw Driver | Handle | Exterior | 1 min | 2 | Remove all four bolts holding it in place. |
| 6 | Straight Blade Screw Driver | Flywheel Cover | Exterior | 1 min | 2 | Remove all 3 bolts. |
| 7 | Straight Blade Screw Driver | Bottom Exterior Cover | Bottom | 1 min | 2 | Remove all 4 bolts. |
| 8 | crescent wrench | On/Off Switch | Attached to the bottom cover | 5 sec | 2 | Remove the thin nut holding it in place. |
| 9 | Straight Blade Screw Driver | Muffler/Exhaust Cover | On the side, next to the clutch | 30 sec | 2 | Remove all 3 bolts attaching it. |
| 10 | Straight Blade Screw Driver | Exhaust Header | Under the muffler/exhaust Cover | 30 sec | 2 | Remove all 3 bolts holding it in place. |
| 11 | Spark Plug Wrench | Spark Plug | At the top of the cylinder | 30 sec | 4 | Remove the spark plug by twisting it. |
| 12 | 14 mm Socket & 1/4" Drive | Fly Wheel | Under the flywheel cover | 30 sec | 3 | Remove the bolt holding it onto the shaft protruding through the center of it. |
| 13 | Straight Blade Screw Driver | Magneto and Spark Plug Wire | Beside the flywheel | 15 sec | 2 | Remove the 2 bolts holding it in place. |
| 14 | Straight Blade Screw Driver | Spark Plug Timing Mechanism | Above the timing mechanism | 3 sec | 2 | Remove the clip/lock and pull plastic cover off. |
| 15 | Straight Blade Screw Driver | Choke | Connected to the intake | 15 sec | 3 | Slide the choke out from intake. |
| 16 | Straight Blade Screw Driver | Intake | On the top under the intake cover | 10 sec | 2 | Remove the bolt holding it in place and slide out. |
| 17 | 14 mm Crescent Wrench | Cylinder | Surrounding the piston and connecting rod, beneath the intake | 5 min | 3 | Remove all 4 of bolts and nuts.Then slide it off. |
| 18 | Straight Blade Screw Driver | Battery | Next to the crankshaft, under the flywheel | 10 sec | 2 | Remove the 2 bolts holding it in place. |
| 19 | None | Plastic Holder | Next to the crankshaft | .5 sec | 1 | Pull it out. |
| 20 | Straight Blade Screw Driver | Timing Mechanism | Surrounding the crankshaft outside of the crankcase. | 5 sec | 2 | Remove the bolt. |
| 21 | Straight Blade Screw Driver | Left Half of Casing | Exterior | 5 min | 2 | Remove all 7 bolts attaching it to the other half of the body casing. |
| 22 | None | Throttle and Cable | Inside the handle part of the external casing | 1 sec | 1 | Lift it out of place. |
| 23 | Vice Grips, 15/16" Crescent Wrench, and Leverage Bar | Clutch Assembly | Attached to the crankshaft on the opposite side of the casing from the piston and connecting rod. | 5 min | 5 | Clamp the vice grips to the crank case in a position that will prevent the counter balance to pass it therefore keeping the crank shaft from spinning freely. Put the open end of the crescent wrench in the slots on the clutch and using a leverage bar in the other end of the wrench, twist in the direction of the arrow (reverse threaded) and pry it off. |
| 24 | None | Crank Shaft, Piston, and Rod | Inside the crankcase and protruding from both sides | 30 sec | 3 | Twist and pull it out of place. |
The Difficulty Scale is rated accordingly:
- 1 = No tool required
- 2 = One tool required with little force required
- 3 = One tool required with a large force required or an awkward positioning
- 4 = Multiple or specialized tools required with little force required
- 5 = Multiple or specialized tools required with a large force required
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