Remigo

Check and replace motor power cable

INFORMATION HUB

This short procedure reuses existing service step pages. Edit the referenced step pages to update this procedure everywhere.

WARNING

Read Safety instructions before starting.

  • Remove the kill switch before starting any service procedure to prevent accidental motor start.
  • Disconnect the battery before starting any work on the interface or cables.
  • Wear nitrile gloves when handling silicone/adhesive and when handling the interface during and after degreasing.
  • Do not cut deeper than 2-3 mm when cutting silicone around the interface. Use only plastic tools on the sealing surface.
  • Cables can be sheared during heat sink access if not tucked completely inside the housing bore.

Required tools

Required parts and consumables

Disassembly

IB-DIS-001 DISASSEMBLY STEP 1 - Cut silicone around interface

Tools:

Removing parts:

  • No parts removed in this step.

Procedure:

  1. Place the transom bracket and outboard on a stable holder.
  2. Cut under the interface to a depth of 2-3 mm around the interface edge.

CAUTION

Do not cut deeper than required. Cutting too deep can damage the interface, cables or sealing surface.

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IB-DIS-002 DISASSEMBLY STEP 2 - Remove charging connector

Tools:

Removing parts:

  • No parts removed in this step.

Procedure:

  1. Unscrew the two screws on the charging connector cap.
  2. Pull the charging connector cap out of the housing.
  3. The connector has a locking tab — use the tool to unlock the connector.
  4. Remove the charging connector.
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IB-DIS-003 DISASSEMBLY STEP 3 - Screw in interface removal tool

Tools:

Removing parts:

  • No parts removed in this step.

Procedure:

  1. Screw the interface removal tool (900040006) into the mounting holes next to the charging connector socket.
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IB-DIS-004 DISASSEMBLY STEP 4 - Loosen interface

Tools:

Removing parts:

  • No parts removed in this step.

Procedure:

  1. Set the heat gun to 350°C and heat around the interface joint to soften the silicone.
  2. Move the interface removal tool left, right, up and down until the interface breaks free from the silicone.

CAUTION

Use only a plastic tool on the sealing surface. Metal tools can scratch the housing and cause leakage after assembly.

NOTE

The interface is not reusable once removed and must be replaced — see IB-DIS-005 DISASSEMBLY STEP 5 - Lift interface.

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IB-DIS-005 DISASSEMBLY STEP 5 - Lift interface

Tools:

  • No tools required.

Removing parts:

Procedure:

  1. When the silicone is loosened, lift the interface by hand.
  2. Lift only far enough to access the connectors.

CAUTION

Do not pull the interface away from the housing before all connectors are disconnected.

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IB-DIS-006 DISASSEMBLY STEP 6 - Disconnect interface connectors

Tools:

  • No tools required.

Removing parts:

  • No parts removed in this step.

Procedure:

  1. Carefully disconnect the connectors shown in the picture.
  2. Some connectors have a small locking tab — release it before pulling the connector apart.
  3. Support the connector bodies during removal. Do not pull on the wires.
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IB-DIS-008 DISASSEMBLY STEP 8 - Disconnect motor cable from battery

Tools:

Removing parts:

  • No parts removed in this step.

Procedure:

  1. Use needle-nose pliers to disconnect the motor cable from the battery connector.
  2. Pull on the connector body only.
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Check

IB-CHK-001 CHECK STEP 1 - Inspect removed interface and connectors

Tools:

  • No tools required.

Procedure:

  1. Inspect the motor housing sealing surface for residual silicone, cuts, scratches or other damage. Re-clean if needed before reassembly.
  2. Inspect the interface connectors and signal/charge cables for corrosion, damage or bent pins.
  3. Inspect the Bungie cord used to secure the interface during silicone curing (see IB-ASM-009 ASSEMBLY STEP 9 - Attach first bungee cord point) and its mounting points for wear, cracking or damage.

CAUTION

🗑 Do not reuse the removed Interface assembly GO (120020002) / Interface assembly DE2 (120020003) (select the correct variant for the unit). Cutting the silicone seal during removal compromises its watertight seal — always install a new interface assembly.

TODO

Add a dedicated photo showing the sealing surface and connectors being inspected, separate from the disassembly/reassembly action photos.
Define acceptance criteria for cable/connector wear (e.g. corrosion limits, pin damage tolerance, minimum bungee cord condition).

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IB-DIS-012 DISASSEMBLY STEP 12 - Inspect power cables

Tools:

  • No tools required.

Removing parts:

  • No parts removed in this step.

Procedure:

  1. Inspect the power cables for cuts, damaged insulation, loose terminals or other damage.
  2. If the cables are not damaged, leave them installed.
  3. If the cables are damaged, continue with the cable duct removal step.

NOTE

The cables do not need to be removed if they are not damaged.

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If the power cable is not damaged, no further disassembly is required — continue to Reassembly.

If the power cable is damaged, continue disassembly. The cable is routed through the battery compartment and the drivetrain — both must be opened to access and replace it (bearing removal is not required):

IB-DIS-009 DISASSEMBLY STEP 9 - Remove battery fixing screws

Tools:

Removing parts:

Procedure:

  1. Unscrew the four M4x25 screws.
  2. Remove two screws from each side of the battery.

CAUTION

Work with the housing in a horizontal position. A dropped screw can fall into the battery or motor cavity and cause a short circuit.

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IB-DIS-010 DISASSEMBLY STEP 10 - Remove battery fixing plates

Tools:

Removing parts:

Procedure:

  1. Remove the battery fixing plate with needle-nose pliers.
  2. Repeat on the opposite side of the battery.
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IB-DIS-011 DISASSEMBLY STEP 11 - Remove battery pack

Tools:

Removing parts:

Procedure:

  1. Pull one end of the threaded rod with needle-nose pliers.
  2. Slide the battery pack out of the housing.

CAUTION

Keep the battery straight during removal to avoid damaging the cables or housing channels.

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IB-DIS-013 DISASSEMBLY STEP 13 - Remove plastic cable duct and cables

Tools:

Removing parts:

Procedure:

  1. Pull the plastic cable duct out of the housing channel.
  2. Remove the cables from the channel.
  3. If the cables cannot be removed, disconnect them from the motor controller first as described in RemigoOne Go&DE2 Drivetrain Service Manual.
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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.
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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.
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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.

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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.

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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.
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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.
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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.

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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.

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Reassembly

IB-ASM-001 ASSEMBLY STEP 1 - Route motor cables

Tools:

  • No tools required.

Installing parts:

Procedure:

  1. Position the signal cable deepest in the channel.
  2. Place the power cables on top of the signal cable.
  3. Make sure the power cables run in a straight line.

CAUTION

Incorrect cable routing can make battery installation difficult and can damage the cables.

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IB-ASM-002 ASSEMBLY STEP 2 - Install plastic cable duct

Tools:

Installing parts:

Procedure:

  1. Insert the plastic cable duct into the two aluminium channels.
  2. Use needle-nose pliers for easier insertion if required.
  3. Make sure the plastic cable duct is fully inserted as shown.
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IB-ASM-003 ASSEMBLY STEP 3 - Insert battery pack

Tools:

Installing parts:

Procedure:

  1. Insert the battery pack into the housing using needle-nose pliers.
  2. Orient the battery terminal on the opposite side from the motor cables.

CAUTION

Do not pinch or scrape the cables while inserting the battery. Make sure all cables are fully guided into their dedicated cable holders before sliding the battery in.
Check that the battery is correctly aligned with the housing channels. If it does not slide in easily, stop and re-check alignment rather than forcing it.

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IB-ASM-004 ASSEMBLY STEP 4 - Install cable protection plastic

Tools:

  • No tools required.

Installing parts:

  • Cable protection plastic

Procedure:

  1. Slide the cable protection plastic over the installed plastic cable duct.
  2. Make sure it covers the cable duct in the battery insertion area.
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IB-ASM-005 ASSEMBLY STEP 5 - Install battery fixing plates

Tools:

Installing parts:

Procedure:

  1. Insert the battery fixing plate into the housing channels.
  2. Make sure the fixing plate is correctly seated.
  3. Repeat on the opposite side of the battery.
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IB-ASM-006 ASSEMBLY STEP 6 - Tighten battery fixing screws

Tools:

Consumables:

Installing parts:

Procedure:

  1. Install the four M4x25 screws into the housing channels.
  2. Tighten the screws until the fixing plates compress the battery pack.

CAUTION

Stop tightening when the fixing plates visibly compress the battery pack. Do not overtighten.
Work with the housing in a horizontal position. A dropped screw can fall into the battery or motor cavity and cause a short circuit.
If a screw does not grip because the housing thread is damaged, secure it with Permabond A126 (010010004) instead of continuing to force it.

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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.

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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.
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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.

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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.

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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
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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
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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.
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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.

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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.
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IB-ASM-007 ASSEMBLY STEP 7 - Connect motor cable to battery

Tools:

Installing parts:

  • No parts installed in this step.

Procedure:

  1. Use needle-nose pliers to connect the motor cable to the battery connector.
  2. Tuck the power cables into the housing as shown.
  3. Make sure the cables are not under tension.
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IB-ASM-008 ASSEMBLY STEP 8 - Connect interface cables

Tools:

Consumables:

Installing parts:

Procedure:

  1. Plug in the signal cable connectors. The connectors are keyed and cannot be mismatched.
  2. Plug in the charge connector.
  3. Ensure all connector lock tabs are fully engaged.
  4. Apply a small amount of silicone to the back of the signal connectors.

CAUTION

Do not apply silicone to connector contact surfaces.

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IB-ASM-009 ASSEMBLY STEP 9 - Attach first bungee cord point

Tools:

Installing parts:

  • No parts installed in this step.

Procedure:

  1. Attach one side of the bungee cord to the tiller bolts.
  2. Keep the bungee cord ready for holding the interface after silicone application.
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IB-ASM-010 ASSEMBLY STEP 10 - Clean sealing surfaces

Tools:

  • No tools required.

Consumables:

Procedure:

  1. Clean the sealing surface of the interface with isopropanol.
  2. Clean the sealing surface of the motor housing with isopropanol.
  3. Make sure both surfaces are dry before applying silicone.

CAUTION

Silicone must be applied only to clean and dry sealing surfaces.

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IB-ASM-011 ASSEMBLY STEP 11 - Apply silicone to interface

Tools:

Consumables:

Procedure:

  1. Apply a continuous bead of silicone to the interface sealing surface.
  2. Make sure the silicone is applied around the full sealing perimeter.
  3. Avoid gaps in the silicone bead.

CAUTION

Missing silicone on the sealing perimeter can cause leakage.

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IB-ASM-012 ASSEMBLY STEP 12 - Spread silicone on sealing surface

Tools:

  • No tools required.

Consumables:

  • Rubber gloves

Procedure:

  1. Put on rubber gloves.
  2. Spread the applied silicone evenly around the mating surface with a gloved finger.
  3. Keep the silicone layer continuous around the full perimeter.
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IB-ASM-013 ASSEMBLY STEP 13 - Install interface

Tools:

  • No tools required.

Installing parts:

Procedure:

  1. Position the interface on the motor housing.
  2. Press the interface down firmly.
  3. Hold the interface in position until it is secured with the bungee cords.
  4. Check that a small amount of silicone squeezes out around the edge.

CAUTION

If no silicone squeezes out, remove the interface, clean the sealing surfaces and repeat the sealing procedure from assembly step 10.

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IB-ASM-014 ASSEMBLY STEP 14 - Remove excess silicone

Tools:

Procedure:

  1. Scrape away excess silicone with the silicone squeegee.
  2. Do not disturb the interface position while removing excess silicone.
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IB-ASM-015 ASSEMBLY STEP 15 - Secure interface with bungee cords

Tools:

Procedure:

  1. Attach the bungee cords over the interface.
  2. Apply as much tension as possible without shifting the interface.
  3. Route the first bungee cord between the charging socket and screw.
  4. Route the second bungee cord over the kill switch surface.

CAUTION

Make sure the bungee cords hold the interface evenly against the housing during curing.

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IB-ASM-016 ASSEMBLY STEP 16 - Check bungee cord position

Tools:

  • No tools required.

Procedure:

  1. Check that the first bungee cord is routed between the charging socket and screw.
  2. Check that the second bungee cord is routed over the kill switch surface.
  3. Verify that the interface is still fully seated.
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IB-ASM-017 ASSEMBLY STEP 17 - Final silicone cleanup and curing

Tools:

Consumables:

  • Paper towel
  • Mild window cleaner

Procedure:

  1. Wipe away any remaining silicone from the outboard.
  2. Take extra care in the areas directly below the bungee cords.
  3. Leave the assembly to cure for at least 48 h at room temperature.
  4. After curing, scrape away any remaining silicone.
  5. Clean the interface with a cloth and mild window cleaner for the final finish.

CAUTION

Do not remove the bungee cords or move the interface before the silicone has cured.

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Color key

Blue = Disassembly · Red = Check · Green = Reassembly

Graph View

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