Rusted Crystalyte 409 Advice Sought

[gazzata]

Hi Folks

Got a 409 with busted wiring that I am going to return to repair. Just wanted to check that I can clean motor with toothbrush, contact cleaner and if needs more wet and dry paper and wire brushes?

Thanks

Gary

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[gazzata]

‘repair’ not ‘return to repair’


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[dogman dan]

Just spray down the inner core, DO NOT rub the varnish off the core windings with a wire brush. I would not use much more than a toothbrush on the magnets too.

The side covers you can clean more, but its not really needed. I'd just wet the whole thing, and simply wipe it down with a towel.

The cover screws though, they could use replacement if really rusted, but I'd just clean them with WD 40 if the threads still exist.

The bearings can be removed, and a good bearing shop locally should have a bearing that fits. But if they are still sealed, they are still good.

This motor should rise from the dead just fine. Slightly slower winding, so good for a 20 mph bike.

 

[Chalo]

Wipe it down with a damp cloth and don't clean it more than that. You can do a lot more harm than good. Maybe apply a film of silicone spray before you reassemble, to help prevent further corrosion.

Put new bearings in the hub side covers while you have the hub open. I expect the ones in there now are compromised.

 

[gazzata]

Thanks so much to Dogman Dan and Chalo. Very grateful for advice.


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[spinningmagnets]

This sounds counter-intuitive but...after wiping off the bulk of the rust (no scrubbing)...spray with rust inhibitor as suggested already, and then...

Consider drilling holes in the side plates to let moisture out.

No need to goop the edge sealing surfaces of the side-plates, either. When the motor cools down after a ride, the shrinking internal air volume draws-in a tiny amount of humid air.

Then the humidity condenses inside. It has no way to get out. It's not much, but over time, it builds up.

A single tiny hole can let out the re-heated vapor on the next ride when it warms up, and...several large holes will also vent excessive stator-heat, if you like. Search ES for motor cooling vent holes to see examples.

 

[gazzata]

Thanks Spinning Magnets. Good advice. Just gotta solder all the power cables and Hall sensor wires back together after they snapped!


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