Cybex 425T Treadmill Service Manual
Service
Page 4-17
5. Remove the brush access covers.
A. Using a flat head screwdriver pry off both brush access covers on the drive motor.
6. Remove the brushes.
A. Using the needle nose pliers pry the brush wire connector off of the terminal in the drive
motor.
B. Using your fingers press in the spring clip until the locking tab disengages and the
spring can be removed from the brush holder.
C. Repeat steps 6A and 6B for other brush.
7. Examine the brush and commutator.
A. Inspect the commutator by looking through the top brush holder into the motor. Slowly spin
the motor by turning the flywheel. Look for noticeable damage and for signs of wear such
as arcing, pitting, burning, or uneven wear. Commutator bars that are ‘dirty penny’ brownish
copper are in great condition. Also, some commutator bars may be pitted or blackened
on one edge. Too many of these indicate a worn commutator, and the motor should be
replaced. The commutator may be cleaned with narrow commutator stone if carbon build-
up is present. Brush dust can be loosened from the motor surfaces where the brush is
placed by lightly filing the surfaces. Dirt and brush dust should be vacuumed out of the
motor.
B. Inspect the brushes for signs of excessive wear or cracks. The motor brushes must be
replaced if one or both is worn to .375” (9.5 mm) or less in length, is broken or chipped,
has a broken spring, or binds in the motor. See Figure 13.
8. Replace the brushes.
A. Slide the new brush into the motor brush holder. If the new brush does not slide in and
out easily, the edges or corners of the brush can be lightly filed down. If cleaning the
motor, (see step 7A), and filing the brush doesn’t allow the brush to slide easily in the
brush holder, the motor should be replaced.
NOTE: The motor may make a clicking noise as new brushes wear in. If you reinstall the
original brushes it is good to install them facing their original position. Reversing the
orientation of the brush can cause a clicking noise during operation until the brushes
wear in.
B. Insert a new spring assembly (B) into the brush housing until the locking tab engages.
C. Using the needle nose pliers slide the brush wire connector onto the drive motor
terminal.
D. Install a new brush access cover by pressing until the end tabs click into place.
E. Repeat steps 8A to 8D for the other brush.
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