P3 Motor : Opening the Motor
I've got a lot of detail here about opening the motor. There is more information than is really need, but for people who may not have much mechanical experience here are all the steps involved.
The motor has two different sides. The side with the wires coming out is the
side the cluster goes on. It has quite a wide thread and the side plate has no
screws and is part of the hub.
The other side of the hub has 8 screws which hold the side plate in position
on the hub. It is the side which has a narrow thread for a brake ( band type or
disc type).
The picture below shows the two different sides from above.
Remove the 8 screws from the side plate, see below on how to do this without damaging the screws. Leave the axle nuts in position on this side of the motor for the time being.
It is preferable that you use an impact driver to undo the screws the first time. They can be quite tight and its easy to damage the screws if not using the correct size screwdriver.
First make sure the phillips head is the correct size for the screw.
To unloosen the screws the first time I use an impact driver, it is better than using a plain screwdriver as you can hit it with a hammer and it will rotate the screw to make it easier to remove. If you haven't used an impact driver before to unloosen a screw you twist the driver anticlockwise as far as it will, you keep some force in the anticlockwise direction on the screw and then hit the end of the impact driver very firmly with a hammer.
Below shows the side plate screws removed but the axle nuts should remain in position for now.
Next go to the other side of the motor where the wires are located. If your using the 3 speed cluster that comes with the motor you wont need to take off the cluster to remove the axle nuts from this side which is the next step.
To remove the axle nuts hold the axle with a shifting spanner ( or 10mm open ended spanner ) on the flats of the axle. Rotate the large nut close to the hub in an anticlowise direction to remove it.
Once those nuts are removed you will need to remove the circlip located right next to the bearing of the motor. You will need some expanding type circlip pliers to do this ( it can be very difficult to remove circlips without circlip pliers ).
My technique for removing the circlip involves opening the circlip with the
circlip pliers and placing a very thin screwdriver behind the circlip to help
lever it off.
Reason for this is that you have to push the circip pliers towards the motor to
hold it in the holes in the circlip but you want the circlip to come off the
axle in the other direction to what you are pushing, so a screwdriver behind the
circlip allows you to lever it over the lip that the circlip sits in , in the
axle.
Once you have the circlip over the lip you can slide it off the axle, you'll find you may need to keep the circlip expanded to get it off the axle.
Next clean off the thread from any dirt of foreign objects as it needs to slide through the bearing in motor, any dirt will make it more difficult to get the axle through the bearing. A wire brush is probably best thing to use to clean the axle.
Now the motor can be removed from the hub as one complete unit. Heres how to do it. We need to push the axle on the side with the wires coming out, through the bearing in the motor . The end result is shown below but a few tips following on how to do it.
Where the circlip has been in place there may be a slight lip on the edge of the groove where the circlip was sitting. The slightly raised edge may make it a bit difficult to push the axle through the bearing. So below is technique to make a bit easier.
Place an axle nut on the axle where the wires are coming out. Make it flush with the end of the axle.
Place a shifting spanner or other suitable thing over the nut on axle, and give it a bash towards the motor. Be careful not to hit the wires. A few bashes and the axle should slip through the bearing.
You will have to remove the axle nut of course once the axle is moving through the bearing to get the whole motor assembly out as shown below.
Below whole motor out of of the hub as one complete unit.
One thing to take note of. When resting the motor on the ground put something soft under the wire side so that the wires are not damaged.
To Open the Motor Assembly:
Remove axle nuts
Put one nut on end of axle flush with end of the axle. The hit whole motor unit on a hard surface firmly.
When the plate slips down you will see the gears of the motor.
There are two gear sections. There is an all metal gear cluster which sits in the freewheel section which is inside the side plate. The other gear section has a plastic moulded frame in which metal gears are located.
Note there are two brass washers, one sits on top of the platic framed gear section, the other one sits underneath it.
Pic below shows the gear parts sitting on freewheel plate.
While the motor is apart, take time to check all screws are tight. In particular check the ones shown below. If any of those are loose, use some loktite liquid and screw them up very firmly. Use and impact driver if handy to make them tight.
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