3. Replacing Brushes and High Current Wires
Remove the screws from the hub plate. Leave the nuts in position on the axle on the side where the screws are (nuts removed in picture below but best to leave them in place if only changing brushes.
Remove nut from the axle side that has wires coming out of it. Remove the circlip off the axle.
You will be able to remove the whole motor assembly from the hub as shown below. Be careful not to damage the wires if you need to tap on the end of the axle, and not to damage the axle thread if you tap it to remove the motor assembly.
Next remove the brush plate but first mark the position of the plate relative to the two screws that have to be removed.
When plate comes loose make sure the brush springs dont fall into the motor, you can feed some of the high amp wire into the axle to allow the plate to move off the motor.
Below is a closeup showing one brush and how the brush spring sits in position.The brush should slide very freely in its slot the spring providing tension to keep the brush on the commutator. If the brush does not slide freeely you can file a bit off its edges (its very soft material so a very light file only is necessary)
Picture below shows the solder points. Brush 1 has a thin high amp wire which joins it to solder point 3 ( the position of that wire is shown by white arrows), there is a groove in the side of the brush plate where the wire sits. Solder point 2 is where brush2 is soldered to the brush plate.
Note that solder points 2 and 3 above, are very close together as shown below. Be careful that the solder doesn't join these two points together. They are isloated from each other by only a few mm of space.
When puting the new brushes back into the brush plate put the brush spring in position first as shown below, then push the brush into the hole, it must slide very freely in this hole. If it sticks at all in the hole the motor may not function correctly.
The high current wire used in these motors is very thin, but can take very high amps. There is only enough room inside the axle for a thin wire, so this particular type of wire should only be used with this motor. Other wire (of similar current rating )will be too thick to go inside the axle.
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