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3. Remove the tool from the vise and, while holding the tool
horizontally, carefully unscrew the Gear Case by hand and pull it
away from the Motor Housing.
4. Using snap ring pliers, remove the Gear Retainer (48).
5. For M, N or P ratio, the Rotor Pinion (49) may come out with the
Gear Case, or it may have remained with the Rotor (37) when the
Gear Case was removed. Remove the Rotor Pinion.
6. For M, N, P, Q or R ratio, remove the Gear Head Planet Gear
Assembly (51), Gear Head (50) and Gear Head Spacer (55).
7. Remove the Spindle Planet Gear Assembly (46).
8. Position the Gear Case vertically in an arbor press with the motor
end down. Using a 7/16” (11 mm) diameter brass rod against the
outer rim of the Spindle (43), press the Spindle from the Gear Case.
9. Using snap ring pliers, remove the Spindle Bearing Retainer (62).
10. Tap the externally threaded end of the Gear Case on a workbench
to remove the Spindle Bearing (61) and Grease Shield (59).
11. Remove the Seal Support (44) from the Spindle.
12. If the Grease Shield Retainer (60) must be removed, insert a thin
blade screwdriver under the tab, and using a rotary motion, spiral
the Retainer out of the groove in the Gear Case.
13. For 6WT or 6WRT, spread the ends of the Deflector Retaining
Ring (66) and remove it from the Gear Case.
14. For 6WT or 6WRT, slide the Exhaust Deflector (64) off the Gear
Case and remove the Muffler Element (63) and two Exhaust
Deflector Seals (65).
Disassembly of the Motor and Throttle
1. Using a pin punch and hammer, drive the Throttle Lever Pin (5)
out of the Rear Muffler (14) to release the Throttle Lever (4).
2. Grasp the splined end of the Rotor (37) in leather-covered or
copper-covered vise jaws and pull the assembled motor from the
Motor Housing (1).
3. Remove the Rear End Plate Gasket (33) from the Motor Housing.
4. Using a wrench, unscrew and remove the Rear Rotor Bearing
Retaining Nut (34).
5. Remove the Rotor from the vise and remove the Bearing Thrust
Washer (34A), Rear End Plate (36), Cylinder (39) and Vanes (38).
6. Check the Front Rotor Bearing (42) for damage or roughness.
If replacement is necessary, support the Front End Plate (40)
between two blocks of wood on the table of an arbor press. Press
the Rotor from the Front Rotor Bearing. Using a flat face punch on
the inner ring, tap the Bearing out of the End Plate.
7. Check the Rear Rotor Bearing (35) for damage or roughness. If
replacement is necessary, use a flat face punch on the inner ring
and tap the Bearing out of the End Plate.
8. Being careful not to distort the Housing, grasp the flats on the
Motor Housing in leather-covered or copper-covered vise jaws
with the inlet upward.
9. Using a wrench on the flats, unscrew and remove the Inlet
Bushing (17).
10. Remove the Throttle Valve Spring (11) and the Air Strainer
Screen (18).
11. Remove the Rear Muffler (14), Inlet Bushing Spacer (16), Muffler
Element (15), Exhaust Deflector Seal (13) and the Silencer Seal
Ring (12).
12. Lift out the Throttle Valve (10) and Throttle Plunger Assembly.
13. Remove the Throttle Plunger Seal (7) from the Throttle Plunger (6).
NOTICE
Only remove the Throttle Valve Seat (8) when replacing it or
when the Throttle Plunger Bushing (2) must be replaced.
14. To remove the Throttle Valve Seat, insert a wire hook through the
central hole of the Seat and hooking the underside of the Throttle
Valve Seat Support (9), pull the Support and Seat out of the Motor
Housing.
15. Before removing the Throttle Plunger Bushing (2), all seals and
components must be removed from the Motor Housing.
For 6WRS or 6WRT, remove the Reverse Valve. Refer to the
section Disassembly of the Reverse Valve.
For 6WT or 6WRT, remove the Shutoff Valve. Refer to the section
Disassembly of the Shutoff Valve.
To remove the Throttle Plunger Bushing, proceed as follows:
a. Grasp the rear hub of the Motor Housing in leather-covered or
copper-covered vise jaws with the Throttle Plunger Bushing
upward.
CAUTION
Apply enough heat to warm the Housing, but not enough heat
to distort it.
b. Using a torch, apply heat to the Motor Housing around the
Bushing.
c. For 6WS, thread a 5/16”-18 tap into the Bushing and pull the
Bushing out of the Housing with the tap.
For 6WT, 6WRS or 6WRT, thread a No. 10-32 tap into the
Bushing and pull the Bushing out of the Housing with the tap.
Disassembly of the Reverse Valve (for 6WRS or 6WRT)
1. Using a 3/32” Allen Wrench, remove the Retainer Setscrew (22).
2. Remove the Lock Pin Retainer (20).
NOTICE
Be careful not to lose the Reverse Valve Spring (23) when
removing the Reverse Valve (19).
3. For 6WRS, hold the Motor Housing horizontally with the throttle
plunger hole downward. While applying light inward pressure to
the Reverse Valve, tap the top side of the Housing with a plastic
hammer to dislodge the Reverse Valve Lock Pin (21). Remove the
Reverse Valve Bushing Seal (3A).
For 6WRT, hold the Motor Housing vertically with the motor end
downward. While applying light inward pressure to the Reverse
Valve, tap the inlet end of the Housing with a plastic hammer to
dislodge the Reverse Valve Lock Pin (21).
4. Withdraw the Reverse Valve from the Housing.
Disassembly of the Shutoff Valve (for 6WT or 6WRT)
1. Using a wrench, loosen and remove the Regulator Body (27).
2. With one hand over the Shutoff Valve opening, invert the Motor
Housing and drop the Shutoff Valve (24) and Shutoff Valve
Spring (26) out of the Housing.
3. Using a pointed pick, remove the Regulator Body Seal (32) and
the Shutoff Valve Stop (25) from the Housing.
Assembly
General Instructions
1. Always press on the inner ring of a ball-type bearing when
installing the bearing on a shaft.
2. Always press on the outer ring of a ball-type bearing when
pressing the bearing into a bearing recess.
3. Unless otherwise noted, always press on the stamped end of a
needle bearing when installing the needle bearing in a recess.
4. Always clean every part and wipe every part with a thin film of oil
before installation.
5. Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in a clean, suitable, cleaning solution
and dry with a clean cloth. Sealed or shielded bearings should
not be cleaned. Work grease into every open bearing before
installation.
6. Apply a film of O-ring lubricant to all O-rings before final
assembly.
7. Unless otherwise noted, always press on the stamped end of a
needle bearing when installing a needle bearing into a recess. Use
a bearing inserting tool similar to the one shown in Dwg. TPD488.
