How to remove pinion from 12V CC motor shaft

[Lorenzo]

I do beg pardon if this thread is about a square four Suzuki two stroke...







It's the power valve actuator motor of an RG
The pinion does not (understandably) budge; I wonder if it's super-glued on or just press fit.
In any case it offers little leverage.
Any ideas?
Thanks

[Jimroid]

In your top photo,does that back half move away or is it integral? If it moves out of the way you can use a clamshell bearing puller.

[Lorenzo]

Yes Jimroid, it has a little axial movement, about 1,5mm.
But, I do not know if it's clear from the pics, that the motor is very small. we are talking 6,5cm by 3,5.
The extractor must be very small, got any link/pics?
Thanks

[Jimroid]

Can you take one more picture straight at the pionion end?

[Lorenzo]

[Jimroid]

Sorry, just now saw this. You will have to get the big driven gear off first. Is that possible? Just remember , they had to put it together, so it has to come apart. Just reverse order. I' m sure the small pinion is shrunk or pressed on.

[Jimroid]

Ok I see what you did now. I think you will have to make a plate to go behind it and jack screw it off by pushing on the pinion shaft.

[Lorenzo]

The idea of an extractor/micro bearing puller did not occurred to me and looking at robotic and RC sites, some images came up. But ordering and waiting for one is one option.. see what we can do with what lies in the scrap bin...

[Jimroid]

I like how you think, great idea looking at the RC stuff.Good luck, you will get it.

[Lorenzo]

Yes but, sometimes I need some input...

[Lorenzo]

OK, looks like we are on to a winner (so far):

drilling the tip holder (tip is a broken drill);




the extractor itself, pic's self explanatory;




takes some dexterity to hold the pin tip onto the shaft head;




eventually it gave up. The end of the shaft is splined;



...so did the other motor, on which the part of the shaft that goes into the round stay, is slightly bigger, so it will need to be reamed.



Now a micro press must be deviced...

[Jimroid]

Hot damn Lorenzo, thats what I'm talking about!

[Lorenzo]

See what I mean...

[Lorenzo]

Now, the motor turns, both ways, I got a new control unit, the actuator turn the valves fully on at the prescribed revs (7800) but does not return in the closed position below that regime.
So, my last chance is checking and replacing the Hall sensors, for which I am documenting myself about on how to.

https://youtu.be/BhJoi7JaE8o" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;

[Suzsmokeyallan]

With the relatively low cost of used controllers on certain sites its feasible to buy some and experiement. I've restored some already for my RGs and if you look into the end of the shaft you can barely see the splines, that told me it was a splined interface to the gear and shaft.
Heres a photo of one moter unit after I had restored it and some other parts
Perform a test on the motors travel limits to see if the window stops current when its blocking the sensors.


One of the restored motor assembly units after complete dissassembly, cleaning, lubing and rebuild.


One of the cleaned up control units, I lost the decals which I want to have some remade just for originality of them.


Two cleaned up CDI units


Two restored alternator stators with improved phase wires, new sheathing etc.