Novak Brushless Motor: 55-5980-1.C__Manufacturing 3-Up Layout - Manual

END BELL & BEARING REPLACEMENT INSTRUCTIONS:
1. Remove motor from vehicle & brush off any dirt (do not use motor cleaner).
2. Remove the front end bell/can/cap (end section of motor on the same side
as the pinion shaft) using a hex wrench to remove the three long socket
head cap screws, then slide it off the motor.
NOTE: The front bearing is secured in the end bell/end cap with a non-removable
locking agent. Removal of bearing can bend or damage the end bell/can/cap.
3. Remove the rotor by grasping the pinion shaft with pliers and carefully
pulling the rotor out of the motor.
Note: The rotor is the magnet in brushless motors and will attract metallic objects
(wrenches, washers, etc.)--place rotor on a soft cloth or towel to prevent damage.
–Most Novak motors have shim washers on the pinion end (& sometimes on
the back end) of the rotor to adjust free play-- Do Not lose these & re-install
them on the correct side of rotor. Washers may be stuck to the bearing.
–Older SS series motors have brass spacers on both sides of rotor between
magnet & bearings-- Do not lose them & re-install them on the correct sides.
–Check condition of rotor--Careful to not damage electronics inside motor.
4. Clean inside motor using compressed air. (NO solvents or spray cleaners).
5. Note the timing setting of the motor. Newer Novak motors with
adjustable timing have a timing label on the side of the back end cap
and a timing notch machined into the back end bell/ring to indicate the
timing set point. Make note of this to properly set timing during assembly.
6. Remove back end cap from motor using a hex wrench to remove the
3 flat head cap screws. The bearing on older plastic end cap motors is
held between the end cap and the sensor assembly (beneath the power wire
tabs-- Note: Don’t rotate the sensor assembly) --end cap may be slightly stuck due
to excess flux--gently pry end cap off if needed. Bearings on newer metal
end cap motors are pressed in and secured with a non-removable locking
agent--replacement bearing caps come with a factory-installed bearing.
7. On older plastic cap motors, remove rear bearing with small needle nose
pliers. Install new bearing into the recess in the plastic sensor assembly.
8. If your motor had a silicone sensor grommet inside the back bearing end
cap, insert it into the new end cap. Install new back bearing end cap
and re-install the flat head screws. Hold the old end cap above the new
end cap to determine proper timing position. Install new timing label on
the side of end cap with proper timing mark aligned with the timing
notch in end bell/cap. If changing wind type (Wye/Delta) in Ballistic8
motors, install new timing label directly over old label and then rotate
end cap to the other wind position (Y or D).
9. Re-install rotor, with shim washers/brass spacers on correct sides of
rotor (short brass spacer goes on pinion side in SS motors) . Use a rolled-up piece of
a business card inserted down into stator to help align and insert rotor.
10. Remove insulator from old front end bell and insert it into new one.
11. Install new front end bell/can/cap by inserting the 3 long socket cap
screws into the new end bell/can/cap, aligning screws with slots in stator,
and threading into tapped holes in the back end bell/ring-- Check that
rotor spins freely as tightening screws--If binding occurs, disassemble
motor and determine cause. If it turns freely, firmly tighten the screws.
If screws do not have a patch of locking agent on threads, add a small drop to tips.
12. Re-check screw tension after a few runs. Check all 6 main screws.
VULCAN EXPLODED VIEW
BALLISTIC EXPLODED VIEW
BALLISTIC 8 EXPLODED VIEW
END BELL & BEARING REPLACEMENT INSTRUCTIONS:
1. Remove motor from vehicle & brush off any dirt (do not use motor cleaner).
2. Remove the front end bell/can/cap (end section of motor on the same side
as the pinion shaft) using a hex wrench to remove the three long socket
head cap screws, then slide it off the motor.
NOTE: The front bearing is secured in the end bell/end cap with a non-removable
locking agent. Removal of bearing can bend or damage the end bell/can/cap.
3. Remove the rotor by grasping the pinion shaft with pliers and carefully
pulling the rotor out of the motor.
Note: The rotor is the magnet in brushless motors and will attract metallic objects
(wrenches, washers, etc.)--place rotor on a soft cloth or towel to prevent damage.
–Most Novak motors have shim washers on the pinion end (& sometimes on
the back end) of the rotor to adjust free play-- Do Not lose these & re-install
them on the correct side of rotor. Washers may be stuck to the bearing.
–Older SS series motors have brass spacers on both sides of rotor between
magnet & bearings-- Do not lose them & re-install them on the correct sides.
–Check condition of rotor--Careful to not damage electronics inside motor.
4. Clean inside motor using compressed air. (NO solvents or spray cleaners).
5. Note the timing setting of the motor. Newer Novak motors with
adjustable timing have a timing label on the side of the back end cap
and a timing notch machined into the back end bell/ring to indicate the
timing set point. Make note of this to properly set timing during assembly.
6. Remove back end cap from motor using a hex wrench to remove the
3 flat head cap screws. The bearing on older plastic end cap motors is
held between the end cap and the sensor assembly (beneath the power wire
tabs-- Note: Don’t rotate the sensor assembly) --end cap may be slightly stuck due
to excess flux--gently pry end cap off if needed. Bearings on newer metal
end cap motors are pressed in and secured with a non-removable locking
agent--replacement bearing caps come with a factory-installed bearing.
7. On older plastic cap motors, remove rear bearing with small needle nose
pliers. Install new bearing into the recess in the plastic sensor assembly.
8. If your motor had a silicone sensor grommet inside the back bearing end
cap, insert it into the new end cap. Install new back bearing end cap
and re-install the flat head screws. Hold the old end cap above the new
end cap to determine proper timing position. Install new timing label on
the side of end cap with proper timing mark aligned with the timing
notch in end bell/cap. If changing wind type (Wye/Delta) in Ballistic8
motors, install new timing label directly over old label and then rotate
end cap to the other wind position (Y or D).
9. Re-install rotor, with shim washers/brass spacers on correct sides of
rotor (short brass spacer goes on pinion side in SS motors) . Use a rolled-up piece of
a business card inserted down into stator to help align and insert rotor.
10. Remove insulator from old front end bell and insert it into new one.
11. Install new front end bell/can/cap by inserting the 3 long socket cap
screws into the new end bell/can/cap, aligning screws with slots in stator,
and threading into tapped holes in the back end bell/ring-- Check that
rotor spins freely as tightening screws--If binding occurs, disassemble
motor and determine cause. If it turns freely, firmly tighten the screws.
If screws do not have a patch of locking agent on threads, add a small drop to tips.
12. Re-check screw tension after a few runs. Check all 6 main screws.
VULCAN EXPLODED VIEW
BALLISTIC EXPLODED VIEW
BALLISTIC 8 EXPLODED VIEW
END BELL & BEARING REPLACEMENT INSTRUCTIONS:
1. Remove motor from vehicle & brush off any dirt (do not use motor cleaner).
2. Remove the front end bell/can/cap (end section of motor on the same side
as the pinion shaft) using a hex wrench to remove the three long socket
head cap screws, then slide it off the motor.
NOTE: The front bearing is secured in the end bell/end cap with a non-removable
locking agent. Removal of bearing can bend or damage the end bell/can/cap.
3. Remove the rotor by grasping the pinion shaft with pliers and carefully
pulling the rotor out of the motor.
Note: The rotor is the magnet in brushless motors and will attract metallic objects
(wrenches, washers, etc.)--place rotor on a soft cloth or towel to prevent damage.
–Most Novak motors have shim washers on the pinion end (& sometimes on
the back end) of the rotor to adjust free play-- Do Not lose these & re-install
them on the correct side of rotor. Washers may be stuck to the bearing.
–Older SS series motors have brass spacers on both sides of rotor between
magnet & bearings-- Do not lose them & re-install them on the correct sides.
–Check condition of rotor--Careful to not damage electronics inside motor.
4. Clean inside motor using compressed air. (NO solvents or spray cleaners).
5. Note the timing setting of the motor. Newer Novak motors with
adjustable timing have a timing label on the side of the back end cap
and a timing notch machined into the back end bell/ring to indicate the
timing set point. Make note of this to properly set timing during assembly.
6. Remove back end cap from motor using a hex wrench to remove the
3 flat head cap screws. The bearing on older plastic end cap motors is
held between the end cap and the sensor assembly (beneath the power wire
tabs-- Note: Don’t rotate the sensor assembly) --end cap may be slightly stuck due
to excess flux--gently pry end cap off if needed. Bearings on newer metal
end cap motors are pressed in and secured with a non-removable locking
agent--replacement bearing caps come with a factory-installed bearing.
7. On older plastic cap motors, remove rear bearing with small needle nose
pliers. Install new bearing into the recess in the plastic sensor assembly.
8. If your motor had a silicone sensor grommet inside the back bearing end
cap, insert it into the new end cap. Install new back bearing end cap
and re-install the flat head screws. Hold the old end cap above the new
end cap to determine proper timing position. Install new timing label on
the side of end cap with proper timing mark aligned with the timing
notch in end bell/cap. If changing wind type (Wye/Delta) in Ballistic8
motors, install new timing label directly over old label and then rotate
end cap to the other wind position (Y or D).
9. Re-install rotor, with shim washers/brass spacers on correct sides of
rotor (short brass spacer goes on pinion side in SS motors) . Use a rolled-up piece of
a business card inserted down into stator to help align and insert rotor.
10. Remove insulator from old front end bell and insert it into new one.
11. Install new front end bell/can/cap by inserting the 3 long socket cap
screws into the new end bell/can/cap, aligning screws with slots in stator,
and threading into tapped holes in the back end bell/ring-- Check that
rotor spins freely as tightening screws--If binding occurs, disassemble
motor and determine cause. If it turns freely, firmly tighten the screws.
If screws do not have a patch of locking agent on threads, add a small drop to tips.
12. Re-check screw tension after a few runs. Check all 6 main screws.
VULCAN EXPLODED VIEW
BALLISTIC EXPLODED VIEW
BALLISTIC 8 EXPLODED VIEW
Novak End Bell (w/factory-installed bearing)
& Bearing Replacement
Novak End Bell (w/factory-installed bearing)
& Bearing Replacement
Novak End Bell (w/factory-installed bearing)
& Bearing Replacement