I am in the process of having gears manufactured of another material, before sales start on tindie, I don't know when this will be finished.

Yamaha PW X2 broken gear repair
Yamaha PW X2 broken gear repair

See the article here.

The nylon gear is a weak part of the Yamaha PW-X / PW-X2 motor. When the motor is broken, it will just be exchanged by Yamaha. Outside the warranty period, this will cost around $750. This is a big problem because, when the gear will be overloaded again, you can keep going this way.
I cannot have the gears injection molded because the numbers are too small, which unfortunately makes production expensive.

Remove the broken gear and glue the new one in place. Use common one or two component polyurethane adhesive (used for wood).
The gearwheel has a few tenths of a millimeter of play on the bearing, this is required for the adhesive. To ensure that the clearance is equal over the entire circumference, you need to apply 4 narrow strips of adhesive tape before gluing. This will remove the clearance.

Yamaha PW-X and PW-X2 broken gear repair
Yamaha PW-X and PW-X2 broken gear repair

Yamaha PW-X and PW-X2 broken gear repair
Yamaha PW-X and PW-X2 broken gear repair

Yamaha PW-X and PW-X2 broken gear
Yamaha PW-X and PW-X2 broken gear

Removing the broken gearwheel
Removing the broken gearwheel

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