Rebuilding a Vittorazi Atom80 reduction redrive, bearings, gaskets, gears & seals

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This is a step by step rebuilding process of a MY19 Atom80 gearbox. It’s boring, but hopefully will assist you with fixing yours.
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UPDATE:
Look at this video before rebuilding.
• UPDATE: Atom80 Gearbox...
After rebuilding a handful of these on MY19 and older gearboxes, I’ve realized that it’s better to “lift” the lid of the gearbox (when splitting the case) rather than “jack” it up as shown in this video. This can be accomplished by using a flat plate over the output shaft gear with holes that correspond to the lid retaining bolt holes. Then using bolts to reach through the plate in order to lift the lid. On MY20 and newer gearboxes, it’s easier to simply jack up the lid using the (2) 4mm nuts in the front case and jack up the front cover.
Check out the UPDATE video listed above to help better understand.
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There’s definitely a few things that make this job much easier.
1. Making a wood box out of 1”x2”(really .75”x1.5”) that will fit around the clutch drum.
2. Splitting the cases would’ve been much easier than shown in the video if I would’ve used 6 longer bolts to “jack up” the top cover.
3. Making a wood block with a countersunk hole in it for pressing the cases back together and the prop hub back on.
4. If I would’ve just heated each case with both bearings in, they would’ve dropped right out on their own (slightly tapping on them while sitting on the wood box/crib) without needing any tools at all.
5. Securing 4 small 1”x2” blocks during reassembly.
I sourced the bearings from a local bearing shop. See pic in video for the bearing numbers.
I sourced the gaskets and seals (and all other Vittorazi parts) from skysportsusa.net
I bought the Vittorazi multi puller tool from skysportsusa.net/multifunctio...
I bought the blind bearing puller from smile.amazon.com/8MILELAKE-Bl...

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Опубликовано:

27 ноя 2020

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Комментарии : 45

@dkumpula001 2 дня назад

Thank you for making this excellent video. I've been putting off my reduction drive rebuild for a while as there were no warning signs of failure. At 300 hours however, I saw some metal flakes in the oil and knew the time for rebuilding had arrived. Turns out my drive was eating ball bearings like they were PEZ and upon splitting open the drive, the faulty bearing fell completely apart. I found your rebuild video easy to follow and preferable to the approach that the Vittorazi manual describes. I really appreciate your time.

@wednesdaykartingflyingclub8164 2 дня назад

Thanks for the kind words. Glad that you found it helpful. I do have a playlist on my channel with other atom80 repair videos.

@flierbill Год назад

Thank you ! I'll rewatch while I'm rebuilding mine.

@wednesdaykartingflyingclub8164 Год назад

I’ve rebuilt a few Atom80 gearboxes since I made this video. The newer gearboxes are much easier to split the cases making the job much easier. I’ve also found that heating the the bearings will simply fall out by heating the case halves to the correct temp, no need for special tools. But I’d only heat them if you’re planning on replacing the seals too. Check out this video for the update on splitting the cases. Good luck with the rebuild, let me know if you have any questions. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-Ht8ENpR8htA.html

@douglasson1 3 года назад

Amazing. So helpful and very nicely done! Thank you.

@wednesdaykartingflyingclub8164 3 года назад

Thanks for the kind comment Doug.

@matthewpesce765 3 года назад

Very well done video Dennis. My guess is I will be doing this at some point.

@577buttfan Год назад

oh gosh the horrible death rattle.Mine needs a rebuild bro.Thanks for video!!

@wednesdaykartingflyingclub8164 Год назад

Oh no. That’s too bad. I’m curious, What’s it doing exactly?

@577buttfan Год назад

@@wednesdaykartingflyingclub8164 Mine has been developing a high pitched whine but it started really slow and would only make the noise for 2-3 seconds on and 2-3 off.Now its louder and more constant plus if I spin the prop CCW it grumbles pretty good. How exactly did you split the cases.I dont understand how putting bolts back in there will jack the covers apart? Thats the only step thats confusing me so far lol :)

@wednesdaykartingflyingclub8164 Год назад

@@577buttfan what year is your gearbox? The my20 and newer ones have two threaded spots in the case cover to split the case. However, all model year outer covers have oversized threads on the case cover. There’s a link in the description to an update to this video with pics of a better way to split the case. Hope it makes sense.

@wednesdaykartingflyingclub8164 Год назад

@@577buttfan Look at this video before rebuilding. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-2CnCr7I9oes.html After rebuilding a handful of these I’ve realized that it’s better to “lift” the lid of the gearbox (when splitting the case) rather than “jack” it up as shown in this video. This can be accomplished by using a flat plate over the output shaft gear with holes that correspond to the lid retaining bolt holes. Then using bolts to reach through the plate in order to lift the lid.

@577buttfan Год назад

@@wednesdaykartingflyingclub8164 Its a 2019 I think.Thanks brother Ill let ya know how it turns out when I tear into it!! Huge help!!!

@scotthall6518 2 года назад

Very impressive. You have skills. 👍

@wednesdaykartingflyingclub8164 2 года назад

Thanks Scott. I put this video together after I rebuilt one for the first time. I’ve rebuilt a few since then and have found a few easier and/or better ways to do it. Just hoping that it helps a few people out in the process. But thanks again for the kind words.

@mikehawkins3263 3 года назад

Very informative with lots of detail. Well done. Thank you.

@wednesdaykartingflyingclub8164 3 года назад

Thanks. Hopefully it helps you if you ever need to rebuild one.

@mikehawkins3263 3 года назад

@@wednesdaykartingflyingclub8164 Dennis, just took delivery of a new MY20 Parajet Maverick/ Atom 80. I'm a machinist/toolmaker 46 years on now and I do find videos like these extremely valuable. You did it right and it shows folks how not to force things and to be deliberate on their approach to repairing these machines.

@wednesdaykartingflyingclub8164 3 года назад

@@mikehawkins3263 wow, thanks for the compliment. Trust me when I say that I tried many different techniques on several of the steps. The video only shows what I found worked the best for me. The rebuild and video took me a couple of weeks to complete. I’ve since rebuilt another one in a matter of only a couple of hours. So I really hope that it’ll help save somebody else some time and frustration. Btw, I’m also putting together a rebuild video on the exhaust and top end of the Atom80. Should be out soon. Thanks again for the kind words. I’m just glad that somebody else is interested in what makes these things tic too. 😁 Have fun with your Maverick hope to see you in the sky.

@mikehawkins3263 3 года назад

@@wednesdaykartingflyingclub8164 That's great that you want to do more videos on the Atom 80. Exhaust and top end rebuild are two areas that will help both experienced and inexperienced folks tremendously. I'll be watching for them. Thanks again.

@WillFly 3 года назад

Superb video, thank you! Question: I'm curious as to why you put the gear and bearings in the freezer?

@wednesdaykartingflyingclub8164 3 года назад

Putting those parts in the freezer and heating the cases helps with assembly. The heat expands the cases and cooling shrinks the gears and bearings. It’s not by much, but makes them fit together easier since the tolerances are so close.

@WillFly 3 года назад

@@wednesdaykartingflyingclub8164 that makes sense. I'm always learning something new. Thanks for contributing!

@nickpa8871 2 года назад

@@WillFly it called Interference fit.

@muratilgar1519 7 месяцев назад

Hi Dennis, great video with a lot of details.. I have a MY20 that needs a rebuild but its a bit beyond my skills,, so do you build for a fee for others??

@wednesdaykartingflyingclub8164 7 месяцев назад

Thanks for the kind words. I have rebuilt one or two for other pilots. Usually they’re local though to avoid the shipping costs. Are you on Facebook? If so, we could exchange phone numbers and discuss options on getting yours fixed up.

@577buttfan Год назад

Jeez dude just watched it again your cases looked BLACK and real nasty inside haha. My large gear stayed on the other case cover so i have to make a tool using a slide hammer to get it off tommorow. Everything is going smooth i did bugger up the original case threads slightly on the top jacking the cover up(MY19)I was not in the mood to make a plate lol.I just ran a tap through them and filed the case flat again.The drive side of both my gears are hammered and 2 of the bearings are grumbling.One on the outer side of small gear and one on the outer prop hub shaft.

@wednesdaykartingflyingclub8164 Год назад

Yeah. The little bearings take a beating in there. The slide hammer will work. Another option is to heat the case up a bit with a heat gun or a few minutes in an oven and the cases will expand and the bearings will simply drop out. Same in reverse, heat the cases and freeze the bearings and the bearings will simply drop in. Anyway, keep at it. Glad to hear that you’re getting it done. 👍🏽

@577buttfan Год назад

@@wednesdaykartingflyingclub8164 Dude Im just waiting for my parts now its all apart. I have two more questions.1.Can all the bearings go in anyway or do the letters always go down.I noticed on one of the gear bearings(larger one with less balls)there are no markings.2.Would it be better to stick the cases back in the oven with the new bearings in them and heat them up before tapping cold gears into cold bearings.Especially when we have to beat on the INNER race to instal which is the weakest part of the bearing?

@wednesdaykartingflyingclub8164 Год назад

@@577buttfan I haven’t personally paid any attention to the direction of the bearings. I did notice on the engine main case bearings that Vittorazi does now have a recommendation for bearing direction on those. But not on the gearbox. The easiest way to assemble would actually be to heat the bearings and cool the gears. Then assemble the bearings onto the gears (they should slide right on). Then heat the clutch side case, cool the bearings (with gears now attached) and drop the gears into the clutch side case (might take a slight tap with a block of wood and a mallet). Next, install the Oring, case seal and clutch drum which will finish that side. Then, I’d cool that entire assembly and heat the prop side case. The prop side case should then fit onto the gears with a slight tap of a mallet and block of wood. Then don’t forget to put the thin oring, case seal, prop bushing then finally the prop hub back on. That’s the order of how I’d do it now after a few rebuilds. Check out Vittorazi’s manual. They now break it down too. vittorazi.com/manuali/Maintenance_manual_Atom80_Eng_022.pdf?fbclid=IwAR3Q-giff3-l5xb9oVDGjdLas3HvJzciFITj2-omuz2YC-93aW-U9LPxfHM Also, I’ve found that replacing the bearings will eliminate the grinding noise of the gearbox (provided that there’s no major damage to the gears). But the only way to get rid of the high pitched whine during high rpm’s (if yours is making that noise) is by replacing the gears too. So, if you’re replacing the gears, make sure with your parts supplier that they send a main gear with a psi relief valve built in, or order one to be installed when you get it.

@577buttfan Год назад

@@wednesdaykartingflyingclub8164 Yeah mine had that high pitched whine and I ordered both gears and all 4 bearings.Not sure if the gear is going to be updated with PSi relief I hope so. Thanks again man!!

@matthewpesce765 3 года назад

What size sockets did you use to press in the bearings? Is that generic bearing grease you apply at 15:09?

@wednesdaykartingflyingclub8164 3 года назад

I’m pretty sure the socket that I used is 3/4”. However, when pressing bearings, I try to use a socket size that will put the pressure on the outer “race” of the bearing. But obviously it has to also be smaller than the outer diameter of the bearing. The socket that I used has almost a flat surface of the driver side. So it spread out the force on most of the bearing. Yes, any standard grease should work.

@onecircuit 2 года назад

How did you split the case using those bolts without stripping the internal threads? Once the bolts bottomed out etc.

@wednesdaykartingflyingclub8164 2 года назад

You’re right, this is without question the simplest way, requiring less tools, to get the job done on a MY18 or MY19 gearbox. This is only one way to get the job done. In fact I’ve used this and one other method where I used a plate to lift the outer case rather than “jack” it up with bolts. (See the video description for a follow up link to this video). Also, the MY20 gearbox does have two threaded holes on the case cover specifically designed to jack it up. Jacking the cover up there would reduce the risk of destroying any threads in the lower case.

@wednesdaykartingflyingclub8164 2 года назад

Check out Vittorazi’s website for their new maintenance manual. It shows in great detail the breakdown of the gearbox as well using the MY20 or newer gearbox and the two jacking bolts. vittorazi.com/manuali/Maintenance_manual_Atom80_Eng_022.pdf?fbclid=IwAR3Q-giff3-l5xb9oVDGjdLas3HvJzciFITj2-omuz2YC-93aW-U9LPxfHM

@matthewpesce765 3 года назад

What did you torque the clutch bell to @ 16:09

@wednesdaykartingflyingclub8164 3 года назад

I was going to torque it to 25NM. But it hit 25NM pretty quick and really didn’t seem to be tight yet. So I kept going a little further. It shouldn’t ever come loose though because the rotation of the engine should be tightening it, not trying to loosen it.

@snakevera 2 года назад

Did you use any specific grease for packing the bearings?

@wednesdaykartingflyingclub8164 2 года назад

Vittorazi lubes the gearbox with 30cc of their specific blend of oil. I leave the grease that comes with the bearings on them. But it washes out after the first fluid change anyway and is lubricated by the gearbox oil.

@snakevera 2 года назад

Hey thanks! And is splitting the case really as easy as getting 6 longer bolts same thread and evenly torqueing them? Great video!

@wednesdaykartingflyingclub8164 2 года назад

@@snakevera the bolts that I used are 6mm x 30mm long. They thread into the outer case and push down onto inner case. The case bolts are 5mm. So you have to be cautious not to force the bigger 6mm bolts into the 5mm threaded inner case. Keep in mind that there are several ways to split the case. The way shown here is just one. After this video, I’ve found a few better ways to get this job done. Especially in splitting the case. Doing it this way is effective, but does bugger up the original bolt holes slightly.

@snakevera 2 года назад

What would be one of the better ways you found as an alternative?

@wednesdaykartingflyingclub8164 2 года назад

@@snakevera I made a metal plate that I drilled 6 holes into. The holes line up with the 6 case bolt holes. I then set the plate on the prop output shaft and put (6) 6mm bolts into the threads on the outer case. These bolts need to be long enough to thread into the outer case, but not too long causing them to hit the inner case. Then the outer cover can be pulled away from the inner case. I also learned that the bearings will simply fall out of the cases if heated to the correct temperature (no tools required) and a new one can be put in at the same time if the new bearings are already in the freezer.