Thanks for your reply Doug, Is there any chance of getting one of these clutch operating/thrust items? Thanks Bruce

Clutch thrust required, thrust cam, thrust bearing?

Meanwhile, perhaps these posts might answer your question:

https://www.douglasmotorcycles.net/index.php?msg=27033

https://www.douglasmotorcycles.net/index.php?msg=29202

https://www.douglasmotorcycles.net/index.php?msg=18532

-Doug

Hi Biellestanche,

Yes the gears and bearings can be tricky to remove from the bearing recesses in the casing, in particular the blind ones. My description following is what I do is for the gear and bearing in the blind recesses;

Heat the casing with a propane torch. You don't need to heat it to an extreme temperature, just enough gentle heat to make the casing expand more than the bearing and the gear will (usually) literally just fall out.

I place the casing with the gasket face downwards. i.e. the gear on the inside facing down and heat the outside of the casing

The bearing and gear will often just drop out with gravity. If not, then I hold onto the casing (wearing suitable heat proof gloves to prevent burnt fingers obviously!) and tap the gasket face onto a flat piece of scrap wood (not hard enough to damage the gasket face but hard enough to displace the gear). It might take  a couple of cycles, i.e. let the casing cool down, re-heat and tap the casing again.

I have found you don't really need a lot of heat and have even used just very hot water successfully on the outside of the case for one gearbox I disassembled. I guess you could use a hot air gun to do the same job but have not tried this method.

I have attached a cross section drawing  of the  4HP 3 speed.

If you have the gear out of the bearing in the blind recess in your gearbox case and the bearing is still stuck in the case after trying the heat method, then you will probably have to resort to a blind hole bearing puller tool to remove the bearing - hopefully you won't.

Hope this helps

Hutch

Good evening, I am writing from Italy and I am asking for help because I cannot disassemble the gear connected to the clutch bell of a Douglas 4 HP gearbox. Is there a drawing to understand how they are fixed together? The bearing mounted in the middle is damaged and needs to be replaced. From the drawings published in the spare parts, the matter is not clear, but now I have to find the solution. Thanks to everyone and have a good evening

Can anybody help with information on the clutch thrust for a Douglas Aero

Many thanks. 

Thats a Mark V engine - not Dragonfly. 

 doug good post, very interesting, thank you Jim

??

Here is one post on that subject, though the paint code is now ten years old:

https://www.douglasmotorcycles.net/index.php?msg=20345

-Doug