Novak 4PHD Motor Replacement Part (55-5956-1) - Manual

It is highly recommended that if you are replacing anything in
the motor, the whole motor should be disassembled, cleaned,
parts replaced, and motor reassembled. Refer to photos on
back for description of parts.
Tools Needed: 1.5mm and 2.0mm hex wrenches
DIS-ASSEMBLE & CLEAN MOTOR
1. Remove motor from vehicle & brush off any dirt.
Do not use solvents or motor cleaners.
2. Clean a space on your workbench so that no unwanted
debris will end up inside your motor. Place a clean work
cloth on table.
3. Note the mounting screw pattern on the front endbell so
it can be placed back in the same position.
4. With a 2mm hex wrench, remove the six M3 button-head
screws on the front endbell.
5. With a 1.5mm hex wrench, remove the three M2 button-
head screws from the back sides of the stator sleeve.
6. Carefully push on the motor output shaft until the back
endbell breaks free from the motor sleeve.
7. Remove back endbell and timing assembly. Remove shims
(if any) on the back of the shaft.
8. Separate the front endbell from the stator sleeve by push-
ing on the back of the rotor and then remove it from the
shaft. Save any shims that might be on the front of the
shaft. Shims also may stick to the bearings.
9. Remove the magnetic rotor by grasping the pinion shaft
with pliers and carefully remove it from the stator. Place
it on the clean soft towel making sure it is far away from
any metal parts that might be attracted to it which could
cause it to be damaged.
10. Clean all parts using compressed air. Do not use solvents
or motor spray cleaners.
REPLACING TIMING ASSEMBLY
If you are going to replace the timing assembly:
1. With a 1.5mm hex wrench, remove the two M2 button-head
screws that hold the old timing assembly to the back endbell.
2. Apply a small amount of thread lock to the screws.
3. Screw in the new timing assembly.
RE-ASSEMBLING MOTOR
1. Carefully put the rotor (new or current) into the stator as-
sembly (new or current).
2. Replace shims (if any).
3. Slide back endbell (new or current) onto rear of rotor shaft.
Be sure timing assembly is installed in back endbell.
4. Snap back endbell into stator assembly aligning the three
M2 screw holes. Place a small amount of thread lock on
the three M2 button-head screws, and screw them into
the three M2 screw holes with a 1.5mm hex wrench.
5. Slide front endbell (new or current) onto the front of the
rotor shaft and snap it in place, realigning it with the six
M3 screw holes. Place a small amount of thread lock on
the six M3 button-head screws and screw them into the
motor using a crisscross pattern to tighten them.
6. Check that rotor turns freely with no scraping or binding.
7. Lubricate bearings with Novak’s Speed Lube (#5860)
8. After a few runs, check screw tensions & re-tighten if needed.
Novak 4PHD Motor Part
Replacement & Maintenance
55-5956-1 • 11/2014
Novak 4PHD Motor Part
Replacement & Maintenance
55-5956-1 • 11/2014
Novak 4PHD Motor Part
Replacement & Maintenance
55-5956-1 • 11/2014
It is highly recommended that if you are replacing anything in
the motor, the whole motor should be disassembled, cleaned,
parts replaced, and motor reassembled. Refer to photos on
back for description of parts.
Tools Needed: 1.5mm and 2.0mm hex wrenches
DIS-ASSEMBLE & CLEAN MOTOR
1. Remove motor from vehicle & brush off any dirt.
Do not use solvents or motor cleaners.
2. Clean a space on your workbench so that no unwanted
debris will end up inside your motor. Place a clean work
cloth on table.
3. Note the mounting screw pattern on the front endbell so
it can be placed back in the same position.
4. With a 2mm hex wrench, remove the six M3 button-head
screws on the front endbell.
5. With a 1.5mm hex wrench, remove the three M2 button-
head screws from the back sides of the stator sleeve.
6. Carefully push on the motor output shaft until the back
endbell breaks free from the motor sleeve.
7. Remove back endbell and timing assembly. Remove shims
(if any) on the back of the shaft.
8. Separate the front endbell from the stator sleeve by push-
ing on the back of the rotor and then remove it from the
shaft. Save any shims that might be on the front of the
shaft. Shims also may stick to the bearings.
9. Remove the magnetic rotor by grasping the pinion shaft
with pliers and carefully remove it from the stator. Place
it on the clean soft towel making sure it is far away from
any metal parts that might be attracted to it which could
cause it to be damaged.
10. Clean all parts using compressed air. Do not use solvents
or motor spray cleaners.
REPLACING TIMING ASSEMBLY
If you are going to replace the timing assembly:
1. With a 1.5mm hex wrench, remove the two M2 button-head
screws that hold the old timing assembly to the back endbell.
2. Apply a small amount of thread lock to the screws.
3. Screw in the new timing assembly.
RE-ASSEMBLING MOTOR
1. Carefully put the rotor (new or current) into the stator as-
sembly (new or current).
2. Replace shims (if any).
3. Slide back endbell (new or current) onto rear of rotor shaft.
Be sure timing assembly is installed in back endbell.
4. Snap back endbell into stator assembly aligning the three
M2 screw holes. Place a small amount of thread lock on
the three M2 button-head screws, and screw them into
the three M2 screw holes with a 1.5mm hex wrench.
5. Slide front endbell (new or current) onto the front of the
rotor shaft and snap it in place, realigning it with the six
M3 screw holes. Place a small amount of thread lock on
the six M3 button-head screws and screw them into the
motor using a crisscross pattern to tighten them.
6. Check that rotor turns freely with no scraping or binding.
7. Lubricate bearings with Novak’s Speed Lube (#5860)
8. After a few runs, check screw tensions & re-tighten if needed.
It is highly recommended that if you are replacing anything in
the motor, the whole motor should be disassembled, cleaned,
parts replaced, and motor reassembled. Refer to photos on
back for description of parts.
Tools Needed: 1.5mm and 2.0mm hex wrenches
DIS-ASSEMBLE & CLEAN MOTOR
1. Remove motor from vehicle & brush off any dirt.
Do not use solvents or motor cleaners.
2. Clean a space on your workbench so that no unwanted
debris will end up inside your motor. Place a clean work
cloth on table.
3. Note the mounting screw pattern on the front endbell so
it can be placed back in the same position.
4. With a 2mm hex wrench, remove the six M3 button-head
screws on the front endbell.
5. With a 1.5mm hex wrench, remove the three M2 button-
head screws from the back sides of the stator sleeve.
6. Carefully push on the motor output shaft until the back
endbell breaks free from the motor sleeve.
7. Remove back endbell and timing assembly. Remove shims
(if any) on the back of the shaft.
8. Separate the front endbell from the stator sleeve by push-
ing on the back of the rotor and then remove it from the
shaft. Save any shims that might be on the front of the
shaft. Shims also may stick to the bearings.
9. Remove the magnetic rotor by grasping the pinion shaft
with pliers and carefully remove it from the stator. Place
it on the clean soft towel making sure it is far away from
any metal parts that might be attracted to it which could
cause it to be damaged.
10. Clean all parts using compressed air. Do not use solvents
or motor spray cleaners.
REPLACING TIMING ASSEMBLY
If you are going to replace the timing assembly:
1. With a 1.5mm hex wrench, remove the two M2 button-head
screws that hold the old timing assembly to the back endbell.
2. Apply a small amount of thread lock to the screws.
3. Screw in the new timing assembly.
RE-ASSEMBLING MOTOR
1. Carefully put the rotor (new or current) into the stator as-
sembly (new or current).
2. Replace shims (if any).
3. Slide back endbell (new or current) onto rear of rotor shaft.
Be sure timing assembly is installed in back endbell.
4. Snap back endbell into stator assembly aligning the three
M2 screw holes. Place a small amount of thread lock on
the three M2 button-head screws, and screw them into
the three M2 screw holes with a 1.5mm hex wrench.
5. Slide front endbell (new or current) onto the front of the
rotor shaft and snap it in place, realigning it with the six
M3 screw holes. Place a small amount of thread lock on
the six M3 button-head screws and screw them into the
motor using a crisscross pattern to tighten them.
6. Check that rotor turns freely with no scraping or binding.
7. Lubricate bearings with Novak’s Speed Lube (#5860)
8. After a few runs, check screw tensions & re-tighten if needed.