If you don't need that gear, just use a Dremel if you have one and grind it out. One of my Aveox came with a gear box and when I took the gear box out it had a 32 pitch pinion glued to the shaft. I did everything to try and get it out, but my Dremel needed some action . After your done just sand the shaft a bit with fine grit sand paper.
If it is running without the set screws, it is on there pretty good. I think heat and a gear puller is the best answer - any hardware store will likely have a small gear puller that would work. Next time, you may go a little lighter on the threadlock (only a little dab on the set screw is needed - blue loctitie). :)
I have had a pinion stuck on a shaft without using any threadlock
Yeah. If I manage to get this pinion off, I'll be at least removing a little bit of material on the inside of the pinion. I haven't had a try at prying it off yet, as I'm still disassembling and cleaning my Revo. It probably won't happen until the weekend.