Novak Brushless Motor: Brushless Motor Stator Replacement (55-6801-1.D) - Manual

REMOVE STATOR FROM MOTOR:
55-6801-1.D • 1/2014
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. The front end bell/can/cap will then slide off the motor.
3. Remove the back end assembly (end bell/ring, back bearing cap, & timing
assembly) by sliding it back away from the stator/solder tab assembly.
–Keep track of fiberglass insulators between end assembly & solder tabs.
4. Clean inside motor using compressed air. (NO solvents or spray cleaners) .
5. Remove the rotor by grasping the pinion shaft with pliers and carefully
pulling the rotor out of the stator assembly.
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.
–Do Not lose shim washers on pinion (& sometimes back) end of rotor.
–Check condition of rotor--Careful to not damage electronics inside motor.
VULCAN EXPLODED VIEW
BALLISTIC EXPLODED VIEW
BALLISTIC 8 EXPLODED VIEW
Brushless Motor
Stator Replacement
INSTALL NEW STATOR ASSEMBLY:
1. Carefully install rotor into the stator (windings). Be sure to re-install any
shim washers that were removed onto the correct sides of the rotor.
2. Insert the fiberglass insulator into back end bell/end ring.
3. Holding the stator in one hand, gently push the pinion end of rotor
into the stator, extending back end of rotor shaft about 1/2” past stator.
4. Install back end assembly . Locate back bearing onto back end of rotor
shaft and key the end bell/ring over the solder tabs. Remove pressure on the
rotor, allowing back end assembly to slide into place on the stator.
5. Slide aluminum sleeve (on motors w/sleeve) over stator assembly.
6. Insert insulator disc into front end bell.
7. Slide front end bell/cap over pinion shaft and onto stator assembly
and insert the three long socket head cap screws up through the holes in end
bell/cap and guide them into the slots in the stator and sleeve.
8. Seat front & rear end bells/caps onto stator assembly. Stator needs to sit
squarely down into end bell/cap recesses for proper assembly (sleeve may appear
to have extra space). Firmly press ends together to properly seat components.
9. Thread screws into tapped holes in back end bell/ring. Be sure that
rotor spins freely as tightening--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.
10. Re-check screw tension after a few runs. Check all 6 main screws.
PRODUCT WARRANTY
Novak brushless stators are guaranteed to be free from defects in materials or workmanship for a period of
120 days from the original date of purchase (verified by dated, itemized sales receipt). Warranty does not cover
incorrect installation, components worn by use, overheating solder tabs, damage from thermal overload or
operation above 175°F, use of excessive timing or failure from using non-Novak ESCs that have advance
motor timing, damage from disassembling motor, allowing water, moisture, or any other foreign material to
enter motor, short-circuiting of motor by allowing exposed wiring or solder tabs to cross-connect, free-revving
motor, or any damage caused by a crash, flooding, or natural disaster. In no case shall our liability exceed the
product’s original cost. We reserve the right to modify warranty provisions without notice.
Because Novak R/C, Inc. has no control over the connection & use of stator or other related electronics, no liability may be assumed nor
will be accepted for damage resulting from the use of this product. This product is not intended for use by children under 14 years of age
without the strict supervision of an adult. Use of this product in a uncontrolled manner may result in physical damage or injuries. Take
extra care when operating any remote control vehicle. By the act of connecting/operating motor, the user accepts all resulting liability.