Problem inserting motor back in to ABS block (2007 non servo) “On bike”

[Stan H]

Hi all,

I’ve just pulled the abs motor from my 2007 (non servo) GS, to sort out the usual sticking brushes. Sorted the brushes and reassembled the motor without any problems, motor tested and all good.

But on reassembly I”ve hit a snag that’s got me bashing my head against the wall. When I pulled the motor, the dome shaped roller bearing carrier was stuck on the motor output shaft and came with it. This is the carrier that actuates the two plungers in the abs block (see pics). Now it’s out both plungers are extended and spring bock in to place, so I don’t have enough clearance to reinsert the carrier.

Due to another owner doing a mullered go at a previous repair, I was able to detach the motor with the rest of the abs system in situ without bleeding the lines… the motor pretty much fell off.

Any techniques or tool for the job suggestions for how to get this domed sucker back in his home are very welcome….

I’m wondering with the brakes not being bled, this might be the reason for the actuators are popping back, unless of course they’re sprung or held by some magical internal valving within the block.??


….Next job figure out how I’m going to hold the motor securely in place as the last person in here seemed to have used metal eating chipmunks to remove most of the original pillar material

 

[NeilH]

When I connected the motor back onto the body I was worried about it being serviable. I debated if I should tap some holes and make some tabs but because aluminium is soft I didn't want to end up tapping bigger and bigger holes as time goes on.

Aluminium weld might have worked but again applying heat is probably a bad thing, so for now I just used Superglue and baking soda (Watch a few youtube videos) . Not the best perhaps, but it was easy to do, I had supplies at hand and I could file it to make it smooth and neat.

So thats just a cheap quick fix, it will be interesting how long it lasts.

I was lucky regarding the roller bearing carrier, mine staid intact, so can't help there, sorry.

 

[DrFarkoff]

Put the domed bearing on the rear of a drill bit that fits nicely but not really tight, I can;t remember what size the one was that i used

The trick is to twist the bearing and rotate your hand in a spiral as you push it in

Then fit the motor into the bearing and secure it

I did 4 studs into m6 helicoils and half washers in each corner, but that is over kill 2 would be plenty in hindsight

Don;t buff off the raised alloy! that is what stops the motor from spinning out of place, the two studs would just hold it down into and against the square edges

If you are this far on it is a good time to change to a Fiesta Mk9 motor!

 

[Stan H]

Put the domed bearing on the rear of a drill bit that fits nicely but not really tight, I can;t remember what size the one was that i used

The trick is to twist the bearing and rotate your hand in a spiral as you push it in

Then fit the motor into the bearing and secure it

I did 4 studs into m6 helicoils and half washers in each corner, but that is over kill 2 would be plenty in hindsight

Don;t buff off the raised alloy! that is what stops the motor from spinning out of place, the two studs would just hold it down into and against the square edges

If you are this far on it is a good time to change to a Fiesta Mk9 motor!

Outstanding so simple and worked like a charm, thank you!

A 7mm hss drill bit was a nice sliding fit for the job. After a couple of ‘practice goes’…. The technique for me was to get rh plunger as fully compressed as possible, going in as straight as possible with a little back pressure and wiggle action the little sucker popped right in

Thought about the mk7 Fiesta motor mod, but this may not be the only issue with this abs, so I’ll go as is “famous last words”
Did spent the time getting the sides of the brushes ‘like glass’ with some with some 1500 wet dry, and flushed with isopropyl. Then scrapped out a ton of debris between each commutator contact with a jewellers screwdriver. Fingers crossed at least for a while.

Love to do the studs and plates but with the block in the bike drilling would be challenging. Hate to do it, but I’ll probably go with some JB Weld steel stick putty on the pillars that need it. Then snug up a sleeved stainless cable tie around the entire unit as added insurance. Plastic ones were there before so stainless would at least be an upgrade.