Pinion Install Flat Spot

[mike12779]

I am to the point where I need to install the pinion on the hacker motor, the instructions call for lining up the hole with the flat spot, I see no flat spot on the motor. Has anyone else had this problem?

[vitek]

Unfortunately, Yes. You are the 3rd that I have heard with this problem.

Travis

[ChrisS]

Hi

The flat is easy to put on the shaft, you can do it easily or send it in and we can do it for you. I promise to turn any motors sent in for flats same day.

If you choose to do it yourself, follow these instructions:

1) Install the three shims P/N 101-60 onto the motor shaft
2) Remove the setscrews from the pinion P/N 124-31
3) Place the pinion on the motor shaft
4) Using an "ultra fine" tipped Sharpie marker, mark the motor shaft
through one of the setscrew holes, be sure to push the pinion into the
motor as you do this.
5) Remove the pinion and spacers from the motor
6) Cover the top of the motor with masking tape so as to keep grinding
dust from getting into the bearing.
7) Hold the motor shaft with a vice, vice grips or similar. Be careful not to
marr it, a light grip will do. You could build up the clamp area with tape
to protect it.
8) Using a Dremel with a grinding stone, make a flat where the spot is
you made with the marker. Alternately, a file works well and you can
generally be neater and create a nicer looking flat. The flat only needs
to be deep enough to create a spot big enough for one of the
setscrews to sit on and you only need one flat, not two.

Hope this helps. Again, if it seems too difficult a process, please send us the motor and we will put a flat on the shaft for you.

Chris