I tried to get a side cover from ebikes.ca (who supplied the motor originally) however they were a bit slow to my requests to get one sent (unusual for them but later found out some emails fell through the cracks with staff on leave - it happens!). Being keen to be back on the road as soon as possible I decided to contact Ezee direct and within an hour of my email to them I was told to contact Glowworm Cycles in nearby Sydney who are now an Australian dealer for Ezee gear. They were great and when I explained the situation they offered to remove a side cover from one of their motors and send it to me express post for only $55 and I had it within a few days of contacting them! They even gave me some pointers on how to remove my cover and replace it with the new one.
The side cover was attached with 9 small phillips head screws secured with Loctite. Most were OK to remove with a bit of firm pressure but one needed a hair dryer to melt the Loctite before it would come off. I replaced the 9 original phillips head screws with ones that used an allen key - much better in my view as the head of the screws is less prone to being wrecked when removing or tightening.
It was interesting to take the motor apart and check out the insides -
|Drive side of the motor|
|Internal gear assembly|
My first ride with the new freewheel was going well until I went on to the 34T cog and it all seized up! Looks like I needed a slightly longer chain to use the very low gear. I adjusted the low stop point on the derailleur to lock out the 34T cog until this was installed a few days later. I may also look at changing the current 7 speed trigger shifter to a 6 speed twist. Now that my handlebars come apart in the middle a twist shifter can be installed very easily.
So after all that I am now back on the road and it is all going very well!