BionX D500 asssembly

[BobG]

I successfully opened my BionX D500 motor to make an internal repair. Now I can't get it back together without the stator making contact with the magnet ring! There's only about 1 mm of clearance when properly centered. The magnetic attraction will always cause contact & rubbing at one location of the magnet circle. Insertion of axle into second motor enclosure half will not center it. Are there any BionX enthusiasts still in the audience with suggestions?

Also, after several attempts at closure one magnet has detached from the ring. What is the proper adhesive for repair? Thanks!

Contact at yellow arrow, gap at white arrow. Plastic milk jug strips will hold it centered while open but, of course, must come out for closure ...

 

[lnanek]

Justin used a dead blow hammer at 16:43 here:

Although he also had both sides off. Maybe he put them together in opposite order?

 

[BobG]

Thanks Inanek. I have no problem popping the enclosure back on and screwing it together. When I do, the stator still makes contact with magnet ring when I turn the wheel manually. I thought the opposing axle bearing would pull the stator concentric. One time I powered it by throttle damaging a Hall Sensor & knocking a magnet loose. Hall Sensor has been replaced, will re-attach magnet when I figure this out.

My D500 has the composite/plastic enclosure. That looks like a P series metal enclosure Justin is working on.

Magnet ring is already glued back into disc brake side. Not sure if adhesive (magnet ring > shell) is required on the cassette side. Not going to ad more making a gooey mess until I figure this out. Copper wire in photos was for jaws of puller when I opened it.