MOPED ARMY

Rear axle is probably sealed on an 81 Newport but front is not unless someone modded it.

Just remember to tighten everything back down to torque specs on reassembly and check the spacing using plastigauge.

Some other very helpful tools to have around:

Manual impact driver with large flat head tip and hammer (to remove bolts that house pucks and sometimes the tranny cover bolts as well if it's the first time)

Red loctite for reassembly of the above (just the pucks part, not the cover bolts)

Wooden work bench or stool with a hole in it (to rest the gear with the pucks on so the shaft protrudes through the hole and you have a flat surface to work with)

Breaker bar for that pesky reverse-thread nut

Deep 15mm and deep 24mm sockets

New tranny cover gasket (oem preferred)

And of course, if you have access to the ZA50 clutch holder tool it makes life a hell of a lot easier (edited)

Holding the rest of the starter assemble in place with a wrench, carefully remove the top securing nut that holds the cable in place.

https://www.treatland.tv/puch-ZA50-starter-securing-nut-p/puch-za50-starter-nut-00087.htm

All disassembled, without incident. I'm just waiting for an impact driver to get the puck retainer screws out. Should be here Friday. I hate waiting.

In the meantime, since I am planning on flipping second gear clutch, which side should face out originally? I don't think anybody was in here yet, but maybe. I want to be sure to put it together with second gear clutch flipped.. I read a thread on this once, but I can't find it now. Here is a picture of the guts, in order, with the outside surfaces facing up, as disassembled.

You just did it right by researching thoroughly first. It's not hard with the right tools and know-how. Although to be fair I once encountered a late-model ZA with the reverse nut so tight that a pneumatic impact drill couldn't even budge it. I had to clamp the cases in a vice and use a 4 foot steel bar attached to the breaker bar to get it off, so sometimes it's not so easy.

Congrats!

Anyone have a measurement of the shift picks? I'd like to try and cut my own for my Newport.

I have a few sticks of delrin from work and can get more. Its less the money and more curiosity. If it blows up, its just another thing to fix.

Oh Puck!

Really? That doesn’t sound right to me, but I could be way off I guess. Been awhile since I’ve opened up my za50 cases now.

But on that note, it's all back together with new pucks, second gear clutch flipped, and end play float mics out good. Sprocket turns nice front and back. All seems well. I'll throw the engine back on the bike and put some oil in it tomorrow, and then it's test ride time. That was way easier than I expected, thanks to the awesome information and help on this site.

Nice! Did this on mine too. Definitely a different machine after the flip. Drill your intake out, add a pipe and tune. Peppy stock engine.