Happijak repair
I had an issue with one of my happijak motors and have a real issue with $60 for a reman exchange. So I opened it up myself, here are the highlights I am sorry I didn't take pictures.
1 using compressed air put a few quick shots through the weep hole in the bottom of the protective motor cover.
2 unbolt the motor from the jack using a 3/8 wrench, then remove the cover from the gearbox using a square drive.
3 Remove the geartrain by pulling up on the center spur gear first then the other drive gear that the motor engages into.
4 Now you will be able to see the 5/16 nuts that hold the motor to the gear drive plate, remove those then, pull the motor straight down. Now you will see 2 more nuts on the motor and flat head screws on the other end. Hold the screw driver end and loosen the nuts. Now you can remove the end caps and see the brushes and bearings. My problem was the lower bearing had seized up solid. I had to break the bearing apart and replace it. Happijak was not at all helpful here but it turns out the bearing is like 4 bucks and turns out to be a very common skateboard wheel bearing part number I used was 608-2RS.
5 Reassembly is pretty straight forward the brushes are a real pain to get back together, but what I did was install the top motor plate and brushes on the armature first and then slide that whole piece into the motor housing. Relube all the gears and reassemble the gear box.
6 When you go to put the motor cover back on be careful to support the gearbox also because it takes a lot of force to slide it back on. I used alittle dish soap as lube and make sure you don't cover the breather hole with your hand as you slide the cover on.
Total cost $4.00 and my time
1 using compressed air put a few quick shots through the weep hole in the bottom of the protective motor cover.
2 unbolt the motor from the jack using a 3/8 wrench, then remove the cover from the gearbox using a square drive.
3 Remove the geartrain by pulling up on the center spur gear first then the other drive gear that the motor engages into.
4 Now you will be able to see the 5/16 nuts that hold the motor to the gear drive plate, remove those then, pull the motor straight down. Now you will see 2 more nuts on the motor and flat head screws on the other end. Hold the screw driver end and loosen the nuts. Now you can remove the end caps and see the brushes and bearings. My problem was the lower bearing had seized up solid. I had to break the bearing apart and replace it. Happijak was not at all helpful here but it turns out the bearing is like 4 bucks and turns out to be a very common skateboard wheel bearing part number I used was 608-2RS.
5 Reassembly is pretty straight forward the brushes are a real pain to get back together, but what I did was install the top motor plate and brushes on the armature first and then slide that whole piece into the motor housing. Relube all the gears and reassemble the gear box.
6 When you go to put the motor cover back on be careful to support the gearbox also because it takes a lot of force to slide it back on. I used alittle dish soap as lube and make sure you don't cover the breather hole with your hand as you slide the cover on.
Total cost $4.00 and my time
