When the electric motor of an electric vehicle experiences a malfunction and requires disassembly, it’s essential to follow proper procedures to ensure the motor is removed and reinstalled correctly. Here are the steps for disassembling and reassembling an electric vehicle motor:

Disconnecting Wires and Record Connections:

• Before starting the motor disassembly process, disconnect the wires connecting the motor to the controller. It is crucial to record the corresponding connections between the wires to facilitate reinstallation.
• Ensure the workspace is clean before opening the motor cover.

Removing and Inspecting the Motor:

• The radial gap between the motor rotor and stator, known as the air gap, typically ranges between 0.25 to 0.8 mm. After disassembling the motor and addressing any issues, be sure to reassemble it in its original configuration, following any marked indications. This prevents misalignment during reassembly, which could lead to further problems.

Assembling the Motor:

• Before assembling a brushed motor, check the elasticity of the springs inside the brush holder, inspect for any rubbing between the carbon brushes and the brush holder, and ensure that the carbon brushes can reach their maximum travel within the brush holder.
• Pay attention to the proper alignment of the carbon brushes with the commutator to prevent brush or brush holder damage.

Lubricating Gears:

• Apply lubricating grease to all gear surfaces. This lubrication helps reduce the noise generated during motor operation.
• Typically, use No. 3 lubricating grease or the lubricating oil specified by the manufacturer.

In addition to the motor, the controller is another component that can be easily damaged. The controller is the CPU of the vehicle, and when the controller is damaged, all the components of the vehicle will not function. It is important to understand How to Handle Electric Bicycle Controller Damage.

Properly disassembling and reassembling an electric vehicle motor is critical for the vehicle’s functionality. Following these steps ensures that the motor is correctly installed and reduces the risk of issues during operation.