Stanley CO25 Service Manual page 21

1. Unscrew and remove the valve cap from the top of the valve
handle assembly.
2. Lift out the valve spool.
3. Unscrew and remove the plug from the bottom of the
valve handle assembly. Carefully remove the spring and
poppet (blade brake) from the spool bore if they do not
come out with the plug.
THRUST COLLAR REMOVAL
1. Loosen the setscrew securing the thrust collar to the mo-
tor shaft, using a hex wrench.
2. Remove the key and thrust collar from the motor shaft.
OIL TUBE REMOVAL
The valve handle assembly must be removed from the mo-
tor housing to access the oil tubes.
1. Remove four hex-socket capscrews securing the valve
handle assembly to the motor housing. Carefully separate the
two assemblies by pulling straight apart. The oil tubes may
be damaged if you twist or pull at an angle.
2. Carefully remove the two oil tubes from the motor hous-
ing. Make sure you do not damage the sealing surfaces on
the tubes or motor housing.
MOTOR REMOVAL
Remove the wheel, thrust collar, valve handle, and oil
tubes.
IMPORTANT
Do not remove the bearing housing from the motor
housing unless the oil tubes are removed.
1. Remove two fl at-head machine screws securing the
bearing housing to the motor housing.
2. Remove the motor from the motor housing.
MOTOR DISASSEMBLY
Remove the motor from the motor housing.
1. Remove the tubular handlebar from the cutoff saw by
loosening and removing the hex-socket capscrews from the
top and bottom of the handlebar next to the wheel guard.
SERVICE
2. Slide the handle horizontally off the end of the motor as-
sembly.
3. Remove the handlebar retainers from the ends of the
handle.
4. Remove eight capscrews securing the gear housing to
the bearing housing.
3. Carefully separate the gear and bearing housings using
a fl at-blade screwdriver in the groove in the split between
the housings to pry the parts apart.
Pry only in the groove, not on the mating surfaces.
Be sure not to scratch the mating surfaces.
4. Separate the parts in a straight line to prevent damaging
any internal components.
5. Remove the two gears, needle roller, and idler shaft.
6. Remove the large face seal O-ring. Be careful not to
damage the groove or surrounding surface.
7. Remove the motor shaft from the bearing housing:
8. Be careful to protect the surfaces on the bearing housing
from damage while doing the rest of this step.
9. Remove the large retaining ring securing the bearing (on
the wheel guard side of the motor housing).
10. Tap lightly on the small end of the motor shaft (gear
side) with a soft-faced hammer to remove the shaft and
bearing from the bearing housing. Be careful not to strike
the shaft from an angle or otherwise bend it.
Do not remove the bearing from the motor shaft un-
less it must be replaced. It may be damaged during
removal.
11. To remove a damaged bearing from the motor shaft,
support the bearing's outer race with an appropriate tube or
pipe.
Press the threaded end of the motor shaft out of the bear-
ing. Be careful not to bend the shaft.
Discard the bearing.
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IMPORTANT
IMPORTANT