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Maintenance, Service, and Repair
Motor Service
Page 5
REPAIRING THE COMMUTATOR
1. The motor must be removed from the vehicle for
this procedure. Refer to
Transmission Service
section for information on removing the motor.
2. The armature must be removed from the motor
for this procedure. Refer to
Motor Inspection-
Disassembly
section for information on taking
the motor apart.
3. Using a lathe, cut the armature just enough to
remove all grooves, depressions or ridges.
4. Measure the diameter of the commutator. If the
commutator is less than the minimum diameter
specified in
Service Limits
,
then the motor must
be replaced.
5. Thoroughly clean all copper debris from between
the commutator segments.
6. Measure the commutator undercut depth in 5-
places around the commutator. If any one of the
measurements is less than the minimum undercut
depth specified in
Service Limits
, then the
commutator must be undercut.
7. While still in the lathe, smooth the commutator
with fine emery cloth.
Undercutting the commutator
1. Using a small straight cut saw blade, cut the
commutator insulation to the proper depth. Refer
to undercut depth in
Service Limits
.
2. Once all segments have been properly undercut,
mount the armature in a lathe and smooth the
commutator with fine emery cloth.
3. Inspect the armature for shorts. Refer to
Motor
Inspection
section for information on testing the
armature.
NOTE: Copper debris in the undercut area can give
a reading of a shorted armature.
Example of freshly cut commutator
Properly undercut and cleaned
commutator segments
Insulation
Commutator
Incorrect
Hacksaw blade
Correct
Min. OD
Armature
Undercut
Summary of Contents for TT-316-36
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Page 99: ...Sevcon Troubleshooting Page 3 Electrical Troubleshooting Identifying Your Controller...
Page 120: ...TAYLOR DUNN...
Page 134: ...TAYLOR DUNN...
Page 138: ...Illustrated Parts Page 2 Front Fork...
Page 140: ...Illustrated Parts Page 4 Front Brakes...
Page 142: ...Illustrated Parts Page 6 Tilt Steering Column and Gear...
Page 146: ...Illustrated Parts Page 10 Transmission Differential Case Rear Axle...
Page 148: ...Illustrated Parts Page 12 Rear Brakes Master Cylinder 8 Brake Body...
Page 150: ...Illustrated Parts Page 14 Rear Suspension...
Page 152: ...Illustrated Parts Page 16 Motor...
Page 156: ...Illustrated Parts Page 20 Brake Lines...
Page 158: ...Illustrated Parts Page 22 Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 10...
Page 164: ...Illustrated Parts Page 28 Miscellaneous Frame and Body...
Page 168: ...Illustrated Parts Page 32 Decals...
Page 172: ...TAYLOR DUNN...