Join Date: May 2014
Location: Washington State
Na you haven't ruined the brushes. However it might look different to you up close than it does to me on a laptop. I would clean the commutator with a scotch bright pad and degrease it with contact cleaner being sure the residue washed down the shaft not into the windings. Then once reassembled I would turn the motor over by had till the roughness disappeared . Or spin it with a drill at low speed. Once it felt smooth I would reinstall it and charge the battery and run it over several times with no plugs in it. Don't let it get warm just a few simulated starts then let it cool completely, put a full charge on the battery and use it.
As for reassembly I haven't done this particular DC motor but have done others and they are all pretty much the same.
If you can remove the armature from the other endbell it is much easier of course. Gives you room to operate and is less frustrating without the fields housing blocking your view.
You might be able to bend up clips from 1/16 welding rod that catch the face of the brush and the outside of the housing, Like this -> l______l. That is if the brushes are worn enough to push back in their slots far enough so there is room for the clips with the commutator in place. Then remove the clips after the armature is partially in and a portion of the commutator blocks the brushes.
As it says in the Hitchhikers guide to the universe. Don't panic.
They built it once, you can get it back together again. It is important that you don't change the arc on the brush face. It is all about getting as much contact area between the brush and the commutator bars as possible.
presently owned bikes
2014 XC 8 ball that no longer stalls
1993 HD fxrp
1982 HD Sturgis
2009 Honda rebel
1991 gl1500 A w/ Champion Daytona 2+2 sidecar.
"God works both good and evil in a mans' life and you deal with it as best you can" Somebody..
Last edited by Joe_; 04-12-2015 at 06:58 PM.