Headlights dont flip up or down

Bill UK · 08-04-2011, 08:27 PM

The springs you’re referring to are carbon brush springs, they push the brushes onto the motor commutator.

Method of re-assembly:

1. Remove the red adjusting knob (gently prise off with a screwdriver) this will release the motor from the black metal cover; you will notice some resistance due to the strong armature magnet. Be careful not to lose the two copper washers at the top of the motor spindle.

2. With a small screwdriver compress the spring into the carbon brush holder so none of the spring is protruding, (use the slot at the top of the holder for better access) hold the spring in position and insert the carbon brush. This is the difficult bit, once the brush is inserted it will try and pop out, you can either ask someone to help or try and hold it in position using the brush copper wire pressed firmly around the corner of the plastic brush holder. (see pic)

3. Carefully insert the motor rotor, you will need to rotate it to engage the worm gear at the end ,(this is when the brushes are likely to pop out) the brushes need to make contact with the commutator as in pic.

4. Release the copper wire around the corner of the plastic brush holder. (if you used this method) and replace the black metal cover with the two copper washers on top of the motor spindle. You will notice the strong pull of the armature magnet against the metal cover.

5. Screw down the cover and push the red adjusting knob back on.

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08-04-2011, 08:27 PM	#5
Bill UK AEM EMS Join Date: Jul 2006 Location: UK Posts: 891	The springs you’re referring to are carbon brush springs, they push the brushes onto the motor commutator. Method of re-assembly: 1. Remove the red adjusting knob (gently prise off with a screwdriver) this will release the motor from the black metal cover; you will notice some resistance due to the strong armature magnet. Be careful not to lose the two copper washers at the top of the motor spindle. 2. With a small screwdriver compress the spring into the carbon brush holder so none of the spring is protruding, (use the slot at the top of the holder for better access) hold the spring in position and insert the carbon brush. This is the difficult bit, once the brush is inserted it will try and pop out, you can either ask someone to help or try and hold it in position using the brush copper wire pressed firmly around the corner of the plastic brush holder. (see pic) 3. Carefully insert the motor rotor, you will need to rotate it to engage the worm gear at the end ,(this is when the brushes are likely to pop out) the brushes need to make contact with the commutator as in pic. 4. Release the copper wire around the corner of the plastic brush holder. (if you used this method) and replace the black metal cover with the two copper washers on top of the motor spindle. You will notice the strong pull of the armature magnet against the metal cover. 5. Screw down the cover and push the red adjusting knob back on.