Remigo

RemigoOne Go&DE2 Drivetrain Service Manual

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FieldValue
Document summaryRemigoOne Go&DE2 Drivetrain Service Manual
Document ID
Version0.2
ProjectRemigoOne Go&DE2
AuthorsJan Rudolf
Release date
Approved by
Approval date
Statusdraft

Revision history

DateVersionDescriptionAuthorStatus
21.6.20260.1Initial draftJan Rudolfdraft
14.7.20260.2Restructured into Disassembly/Check/Reassembly with safety notes, cleaned up parts list, and non-reusable part markersJan Rudolfdraft

Purpose

This document provides service instructions for the RemigoOne Go&DE2 drivetrain. It defines the required disassembly, inspection, assembly, tools, parts, consumables and safety precautions needed to service the drivetrain correctly.

WARNING

Read Safety instructions before starting.

  • Remove the kill switch before starting any service procedure to prevent accidental motor start.
  • Keep the motor shaft free of rotation during service.
  • The rotor contains strong magnets — keep fingers clear of pinch points during removal and installation.
  • The motor controller (PCBA) is ESD-sensitive. Handle it with care.
  • Use thermal gloves when handling the heated bearing.
  • Follow specified torque values for all fasteners.

Required parts

Required consumables

Required custom tools

Required standard tools

Drivetrain disassembly

DT-DIS-001 DISASSEMBLY STEP 1 - Remove anode

Tools:

Removing parts:

Procedure:

  1. Loosen the anode using a 19 mm socket.
  2. Remove the anode from the shaft.
Link to original

DT-DIS-002 DISASSEMBLY STEP 2 - Remove safety nut

Tools:

Removing parts:

Procedure:

  1. Loosen the safety nut using a 19 mm socket.
  2. Remove the safety nut from the shaft.
Link to original

DT-DIS-003 DISASSEMBLY STEP 3 - Remove washer and propeller

Tools:

  • No tools required.

Removing parts:

Procedure:

  1. Remove the washer from the shaft.
  2. Remove the propeller by pulling it from the propeller hub.

CAUTION

Do not pull the propeller by only one fin. Pull evenly to avoid damaging the propeller or shaft.

Link to original

DT-DIS-004 DISASSEMBLY STEP 4 - Remove shear pin and washer

Tools:

Removing parts:

Procedure:

  1. Push the shear pin out of the shaft.
  2. If the shear pin is bent — for example after a sudden propeller stop — it cannot simply be pushed out. In this case, cut the shear pin with a die grinder fitted with a cutting disc instead of forcing it out.
  3. Remove the washer from the shaft.

CAUTION

When cutting a bent shear pin, take great care to protect the shaft. Do not let the cutting disc contact or damage the shaft surface.

Link to original

DT-DIS-005 DISASSEMBLY STEP 5 - Remove housing anode

Tools:

Removing parts:

Procedure:

  1. Unscrew the anode screws using a T20 Torx driver.
  2. Remove the housing anode.
Link to original

DT-DIS-006 DISASSEMBLY STEP 6 - Remove seal cover

Tools:

Removing parts:

Procedure:

  1. Unscrew the three M3 screws using a T10 Torx driver.
  2. Remove the seal cover.
Link to original

DT-DIS-007 DISASSEMBLY STEP 7 - Remove housing lid

Tools:

Removing parts:

Procedure:

  1. Install the motor rear cover remover tool on the housing lid.
  2. Unscrew the housing lid anticlockwise.
  3. Remove the housing lid.

CAUTION

Use only the correct removal tool to avoid damaging the housing lid.

Link to original

DT-DIS-008 DISASSEMBLY STEP 8 - Remove radial shaft seals

Tools:

Removing parts:

Procedure:

  1. Press on the radial shaft seals and push them out of the housing lid.
  2. Clean the housing lid with isopropanol.

CAUTION

🗑 Do not reuse removed radial shaft seals. Always install new radial shaft seals during assembly.

Link to original

DT-DIS-009 DISASSEMBLY STEP 9 - Remove wave spring washer

Tools:

  • No tools required.

Removing parts:

Procedure:

  1. Remove the wave spring washer.
Link to original

DT-DIS-010 DISASSEMBLY STEP 10 - Remove bearing 6202 ZZ

Tools:

Removing parts:

Procedure:

  1. Mount the axial bearing removal tool as shown.
  2. Apply torque on the forcing screw so that the claw legs grip the bearing evenly.
  3. Continue turning the forcing screw until the bearing is removed.

CAUTION

🗑 Do not reuse the removed bearing. Always install a new bearing during assembly.

Link to original

DT-DIS-011 DISASSEMBLY STEP 11 - Disconnect cables and prepare for heat sink removal

Tools:

Removing parts:

  • No parts removed in this step.

Procedure:

  1. Unplug the marked connector.
  2. Unscrew the two nuts.
  3. Tuck the cables inside the housing.
  4. Make sure that the cables do not protrude into the bore.

Correct cable position

Incorrect cable position

WARNING

Cables can be sheared during heat sink removal if they are not tucked completely inside the housing bore.

Link to original

DT-DIS-012 DISASSEMBLY STEP 12 - Remove motor controller

Tools:

Removing parts:

Procedure:

  1. Unscrew the marked screws.
  2. Remove the motor controller.

CAUTION

The motor controller must only be handled in an ESD-protected environment. Use proper ESD protection before disconnecting or removing the controller.

Link to original

DT-DIS-013 DISASSEMBLY STEP 13 - Remove heat sink

Tools:

Removing parts:

Procedure:

  1. Insert the tool base plate into the heat sink.
  2. Screw the mounting screws into the heat sink.
  3. Screw on the second part of the heat sink removal tool.
  4. Carefully rotate the lever clockwise (CW) until the heat sink starts to press out.
  5. Pull the heat sink out.
  6. Clean the thermal paste from the controller and heat sink.
Link to original

DT-DIS-014 DISASSEMBLY STEP 14 - Remove rotor

Tools:

Removing parts:

Procedure:

  1. Assemble the rotor removal tool onto the motor shaft.
  2. Screw the M12 nut onto the tool.
  3. Attach the lever and rotate it clockwise (CW). The tool will slowly lift the rotor out of the motor housing.
  4. Insert a screwdriver through the radial hole in the rotor and use it to pull the rotor the rest of the way out.

WARNING

The rotor contains strong magnets. Keep fingers clear of pinch points during removal.

Link to original

DT-DIS-015 DISASSEMBLY STEP 15 - Clean motor housing

Tools:

  • No tools required.

Removing parts:

  • No parts removed in this step.

Procedure:

  1. Clean the motor housing of any debris.

CAUTION

There may be a shim washer inside the bearing hole. Whether a shim is present is determined at initial manufacturing (based on the housing measurement) — it is not something to add or remove during service. If a shim is present, make sure it does not fall out during disassembly, and reinstall the same shim during assembly (see DT-ASM-002 ASSEMBLY STEP 2 - Install shim washer if required).

Link to original

Check

DT-CHK-001 CHECK STEP 1 - Inspect propeller, shear pin and anode

Tools:

  • No tools required.

Procedure:

  1. Inspect the propeller for bent, cracked or missing blades and check the propeller hub for damage.
  2. Inspect the shaft for visual damage, especially in the area of the propeller and washer seat.
  3. Inspect the anode for wear. Replace if worn beyond the acceptance criteria.

CAUTION

🗑 The Shear pin (901050006) and Safety nut M12 A4 (011020005) must not be reused. The shear pin is designed to fail under overload and the safety nut loses its locking torque once removed — always install new ones.

TODO

Define the anode wear acceptance criteria (e.g. minimum remaining material) and the propeller damage acceptance criteria (nick/bend limits before replacement is required).

Link to original

DT-CHK-002 CHECK STEP 2 - Inspect bearings and radial shaft seals

Tools:

  • No tools required.

Procedure:

  1. Inspect the rotor shaft and bearing seats for scoring, corrosion or damage.
  2. Inspect the wave spring washer for deformation or damage. Replace if damaged.
  3. Inspect the housing lid and O-ring contact surfaces for cuts, scratches or corrosion.

CAUTION

🗑 Do not reuse the removed Bearing 6202 ZZ (013010001) bearings, Radial shaft seal 15x25x5 (017020001) or O-ring 70x4 (017010001). Always install new bearings, seals and O-rings during assembly.

TODO

Define the acceptance criteria for shaft/bearing seat wear (e.g. maximum scoring depth, corrosion limits) and the wave spring washer damage tolerance.

Link to original

DT-CHK-003 CHECK STEP 3 - Inspect motor controller and heat sink

Tools:

  • No tools required.

Procedure:

  1. Inspect the removed motor controller (PCBA) for burn marks, corrosion, damaged connectors or bent pins.
  2. Inspect the heat sink contact surface for damage, corrosion or leftover thermal paste.
  3. Inspect the motor cables and connectors for damage.

CAUTION

The motor controller (PCBA) is ESD-sensitive. Handle it with care and avoid contact with PCB components. See Safety instructions.

TODO

Define the acceptance criteria for motor controller and heat sink surface damage (e.g. corrosion limits, acceptable connector wear) before deciding whether the removed parts can be reused or must be replaced.

Link to original

Drivetrain assembly

DT-ASM-001 ASSEMBLY STEP 1 - Prepare rotor

Tools:

  • No tools required.

Installing parts:

Procedure:

  1. Prepare the new rotor.
Link to original

DT-ASM-002 ASSEMBLY STEP 2 - Install shim washer if required

Installing parts:

  • Shim washer 25x35x0.5 DIN988 (only if one was present at disassembly)

Procedure:

  1. If a shim washer was present at disassembly (see DT-DIS-015 DISASSEMBLY STEP 15 - Clean motor housing), place the same shim washer 25x35x0.5 DIN988 at the bottom of the motor housing bearing seat before inserting the rotor.

NOTE

Whether a unit has a shim washer is decided at initial manufacturing, based on measuring the housing — this is not determined or added during service. Never add a shim washer that was not present at disassembly.

Link to original

DT-ASM-003 ASSEMBLY STEP 3 - Insert rotor into motor housing

Tools:

  • No tools required.

Installing parts:

Procedure:

  1. Insert the rotor into the motor housing.
  2. Make sure the rotor bearing is inserted into the designated hole in the bottom of the housing.
  3. Check the insertion depth.
  4. The top of the rotor magnets must be in line with the steel laminations.

WARNING

The rotor contains strong magnets. Keep fingers clear of pinch points during insertion.

Link to original

DT-ASM-004 ASSEMBLY STEP 4 - Align heat sink

Tools:

  • No tools required.

Installing parts:

Procedure:

  1. Slightly grease the outer diameter with multipurpose grease.
  2. Align the heat sink holes with the phase cables.
Link to original

DT-ASM-005 ASSEMBLY STEP 5 - Press heat sink into motor housing


The dashed line marks the housing edge for rough alignment; L is the depth measured down to the heat sink face.

Tools:

Consumables:

Installing parts:

Procedure:

  1. Apply a thin coat of silicone spray to the outer diameter of the heat sink to ease installation.
  2. Insert the heat sink into the motor housing.
  3. Press the heat sink until it reaches L = 42,3 mm from the top edge of the housing.

CAUTION

Check the heat sink depth with a digital caliper. Adhesive is no longer applied at this step.

Link to original

DT-ASM-006 ASSEMBLY STEP 6 - Apply thermal paste to heat sink

Apply a thin, even layer of thermal paste to the flat contact surface of the heat sink before mounting the motor controller.

Tools:

  • No tools required.

Consumables:

Procedure:

  1. Apply a thin, even layer of thermal paste to the flat contact surface of the heat sink — the surface that will be in direct contact with the motor controller PCB.
  2. Spread the paste evenly to cover the entire contact surface.

CAUTION

Apply thermal paste only to the flat contact surface. Keep paste away from screw holes and connector contacts.

Link to original

DT-ASM-007 ASSEMBLY STEP 7 - Install motor controller

Tools:

Installing parts:

Procedure:

  1. Bolt the phase terminals to the controller using M3x4 screws and washers.
  2. Bolt down the motor controller using M3x5 screws.

Torque specification:

  • M3 screws: 1,3 Nm

CAUTION

Do not overtighten the screws. Follow the specified torque.

Link to original

DT-ASM-008 ASSEMBLY STEP 8 - Connect and secure cables

Tools:

Consumables:

Installing parts:

Procedure:

  1. Bolt down the power cables onto the red cube phase terminals on the motor controller PCB.
  2. Bend each power cable into a loop away from the housing wall (see picture) so it does not touch the motor housing.
  3. Make sure the power cables do not touch the motor housing.
  4. Apply a small amount of Permabond A130 to the nut threads to secure them against vibration.
  5. Plug in the signal cable.
  6. Fix the signal cable to the GND cable using a zip tie.

Torque specification:

  • Red cube (phase terminal), M4 nut: 1,2 Nm

CAUTION

Make sure cables are routed away from sharp edges and moving parts.

Link to original

DT-ASM-009 ASSEMBLY STEP 9 - Apply silicone to motor controller area

Tools:

  • No tools required.

Consumables:

Procedure:

  1. Apply silicone around the electrolytic capacitors.
  2. Fill the smaller connector with silicone.
  3. Secure the signal cables to the connector with silicone.

CAUTION

Do not apply silicone to connector contact surfaces unless specified.

Link to original

DT-ASM-010 ASSEMBLY STEP 10 - Preheat bearing

Bearing 6202 ZZ placed in the heating element set to 110 °C. Preheating expands the bearing for easier installation onto the shaft.

Tools:

Installing parts:

Procedure:

  1. Place the 6202 ZZ bearing into the heating element.
  2. Set the temperature to 110 °C.
  3. Allow the bearing to reach temperature before proceeding to installation.

WARNING

Preheat only the 6202 ZZ bearing — the one installed onto the shaft after the rotor is already in the housing. Do not preheat the 6201 ZZ bearing that is pressed directly onto the rotor shaft; that bearing is installed cold.

CAUTION

Use thermal gloves when handling the heated bearing.

Link to original

DT-ASM-011 ASSEMBLY STEP 11 - Place bearing on shaft

Tools:

  • No tools required.

Installing parts:

Procedure:

  1. Slide the bearing onto the shaft.
Link to original

DT-ASM-012 ASSEMBLY STEP 12 - Press bearing onto shaft

Tools:

Installing parts:

Procedure:

  1. Position the bearing on the shaft.
  2. Slide the pressing sleeve over the shaft.
  3. Press the bearing down by threading the nut onto the shaft.
Link to original

DT-ASM-013 ASSEMBLY STEP 13 - Measure bearing depth

Tools:

Procedure:

  1. Measure the bearing depth using a digital caliper.
  2. Bearing depth must be L = 68,2 mm.
Link to original

DT-ASM-014 ASSEMBLY STEP 14 - Apply grease on bearing

Tools:

  • No tools required.

Consumables:

Procedure:

  1. Apply a moderate layer of grease on top of the bearing.
Link to original

DT-ASM-015 ASSEMBLY STEP 15 - Install wave spring washer

Tools:

  • No tools required.

Installing parts:

Procedure:

  1. Place the wave spring washer on the greased bearing.
Link to original

DT-ASM-016 ASSEMBLY STEP 16 - Install O-rings into housing lid

Tools:

Installing parts:

Procedure:

  1. Install O-ring 70x4 (017010001) and O-ring 78x1 (017010004) into the two grooves on the outer surface of the housing lid.
  2. Install O-ring 35x2 NBR70 (017010006) into the bearing seat groove on the inner surface of the housing lid.
  3. Use a pick for easier installation if needed.

CAUTION

Do not cut, twist or overstretch the O-rings during installation. Make sure each O-ring is fully seated in its groove before proceeding.

Link to original

DT-ASM-017 ASSEMBLY STEP 17 - Apply grease to O-ring and bearing contact surface

Tools:

  • No tools required.

Consumables:

Procedure:

  1. Apply a layer of grease on the bottom side of the O-ring.
  2. Apply a layer of grease on the bearing contact surface.
Link to original

DT-ASM-018 ASSEMBLY STEP 18 - Install housing lid

Tools:

Installing parts:

Procedure:

  1. Align the housing lid with the motor housing and shaft.
  2. Use the bolting tool to align the motor lid with the threads on the housing.
  3. To achieve alignment, rotate the tool anticlockwise.
  4. Tighten until there is no gap between the lid and motor housing.

CAUTION

Make sure the lid is correctly aligned before tightening to avoid damaging the threads.

Link to original

DT-ASM-028 ASSEMBLY STEP 28 - Check wave spring washer compression

Tools:

Procedure:

  1. Before installing the radial shaft seals, measure the shaft protrusion height above the housing lid recess with a digital caliper.
  2. Verify the reading confirms the wave spring washer is correctly compressed.

TODO

Define the target protrusion height and tolerance (the reference photo shows an example reading of 13.96 mm — confirm whether that is the actual spec or just an example measurement).

NOTE

This step is placed here (between “Install housing lid” and “Prepare radial shaft seals”) out of true numeric sequence — it will get its correct step number during the planned final renumbering pass.

Link to original

DT-ASM-019 ASSEMBLY STEP 19 - Prepare radial shaft seals

Tools:

  • No tools required.

Installing parts:

Consumables:

Procedure:

  1. Apply O-ring grease to the grooved side of the radial shaft seals.
  2. Set the radial shaft seals in the upright position.
Link to original

DT-ASM-020 ASSEMBLY STEP 20 - Check radial shaft seal orientation

Tools:

  • No tools required.

Procedure:

  1. Make sure that the shaft seal groove is facing upwards.

CAUTION

Incorrect shaft seal orientation can cause leakage.

Link to original

DT-ASM-021 ASSEMBLY STEP 21 - Press radial shaft seals into housing lid

Tools:

Consumables:

Installing parts:

Procedure:

  1. Spray a small amount of silicone on the sleeve and on the outer sealing edge of the radial shaft seals.
  2. Slide the radial shaft seals onto the sleeve.
  3. Use the radial shaft seal press to push them until they are level with the housing lid.

CAUTION

Press the radial shaft seals evenly to avoid deformation.

Link to original

DT-ASM-022 ASSEMBLY STEP 22 - Inspect radial shaft seals

Tools:

  • No tools required.

Procedure:

  1. Visually inspect that the radial shaft seals are fully seated.
  2. Visually inspect that the radial shaft seals are installed in the correct orientation.
Link to original

DT-ASM-023 ASSEMBLY STEP 23 - Install seal cover

Tools:

Consumables:

Installing parts:

Procedure:

  1. Place the seal cover in the recess of the housing lid.
  2. Apply one drop of Permabond A130 to the threads of each of the three screws.
  3. Tighten the three screws.

Torque specification:

  • Screws: 1,3 Nm
Link to original

DT-ASM-024 ASSEMBLY STEP 24 - Install housing anode

Tools:

Installing parts:

Procedure:

  1. Align the housing lid and anode holes.
  2. Tighten the three screws.

Torque specification:

  • Screws: 1,3 Nm
Link to original

DT-ASM-025 ASSEMBLY STEP 25 - Install washer and shear pin

Tools:

  • No tools required.

Installing parts:

Procedure:

  1. Slide the washer onto the shaft with the sharp edge of the washer facing down.
  2. Slide the shear pin through the hole in the shaft.
Link to original

DT-ASM-026 ASSEMBLY STEP 26 - Install propeller and washer

Tools:

  • No tools required.

Installing parts:

Procedure:

  1. Align the recess in the propeller with the shear pin.
  2. Slide the propeller onto the shaft.
  3. Slide the washer onto the shaft with the sharp edge of the washer facing down.

CAUTION

Make sure the propeller is correctly seated on the shear pin before continuing.

Link to original

DT-ASM-027 ASSEMBLY STEP 27 - Install safety nut and anode

Tools:

Installing parts:

Procedure:

  1. Install the safety nut until it bottoms out.
  2. Install the anode until it bottoms out.
Link to original

Color key

Blue = Disassembly · Red = Check · Green = Reassembly

Graph View

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