Motorola Bpr40 Magone 6816986h01 B Manual

Repair Procedures and Techniques — General 2-3
4.0Repair Procedures and Techniques — General
Any rework or repair on Environmentally Preferred Products must be done using the appropriate 
lead-free solder wire and lead-free solder paste as stated in the following table:
Parts Replacement and Substitution
When damaged parts are replaced, identical parts should be used. If the identical replacement part 
is not locally available, check the parts list for the proper Motorola part number and order the part...

2-4 Repair Procedures and Techniques — General
Flexible Circuits
The flexible circuits are made from a different material than the rigid boards, and require different 
soldering techniques. Excessive prolonged heat on a flexible circuit can damage the material. 
Therefore, avoid excessive heat and excessive bending. 
For parts replacement, use the ST-1087 Temperature-Controlled Solder Station with a 600-700 
degree F tip, and use small diameter solder such as ST-633. The smaller size solder will melt...

Disassembling and Reassembling the Radio — General 2-5
5.0 Disassembling and Reassembling the Radio — General
For disassembly or reassembly of the radio, it is important to pay particular attention to all the snaps 
and tabs, and how parts align with each other.
The following tools are required for disassembling the radio:
•Phillips screwdriver
•Flat head screwdriver
•Chassis Opener
•Crab Eye Nut Opener
•Tw e ez e r s
If a unit requires more complete testing or service than is customarily performed at...

2-6Radio Disassembly — Detailed
6.0 Radio Disassembly — Detailed
6.1 Front Cover from Chassis Disassembly
1. Turn off the radio.
2. Unlatch the battery latch at the bottom of the radio (see “Figure 2-1”). Remove the battery by 
gently lifting the hilt of the battery, nearest to the battery latch, 
away from the housing.
3. Slide the battery downwards to remove the battery.
4. Remove the antenna by unscrewing it (see “Figure 2-2”).
5. Pull the On/Off Volume and Channel knobs out of their shafts using the...

Radio Disassembly — Detailed2-7
6. Insert the Chassis Opener at the bottom of the radio, between the chassis and housing (see 
“Figure 2-2”). Lift the chassis gently. Be careful not to damage the housing or the O-ring 
underneath.
7. Lift rear chassis away from the front cover. Be careful not to damage the speaker wire under-
neath.
8. Slide the rear chassis downwards, and away from the front cover.
9. Remove the speaker connector, which connects between the PC Board and the internal 
speaker on front...

2-8Radio Disassembly — Detailed
12.Slide the battery latch shaft out from the latch. 
13. Unscrew the speaker bracket from the housing (see “Figure 2-6”).
14. Remove the speaker from on top of the speaker felt.
15.Remove the speaker felt from the grille area.
Figure 2-5 
NOTEProceed to perform steps 13, 14, and 15 only if there is a need to replace the speaker, 
speaker bracket or speaker felt.
Figure 2-6  

Radio Reassembly — Detailed2-9
6.2 PC Board Disassembly
1. Remove the audio jack seal.
2. Remove the 10 screws which hold the PC board to the diecast.
3. Next, remove the 2 nuts on the On/Off Volume and Channel knobs shafts with the Crab Eye 
Nut Opener.
4. The PC board can now be removed from the rear diecast.
5. The completely disassembly PC board is shown in “Figure 2-7”.
7.0 Radio Reassembly — Detailed
7.1 PC Board Reassembly
1. Place the PC board on the rear diecast.
2. Tighten the screws and the...

2-10Radio Reassembly — Detailed
7.2 Chassis and Front Cover Reassembly 
1. Place the speaker felt onto the grille area (see “Figure 2-8”) . 
2.Place the speaker on top of the felt.
3. Stick the speaker poron pad onto the back of speaker magnet.
4. Place the speaker bracket and screw the bracket to the housing.
5.Slot the battery latch shaft into the latch (see “Figure 2-9”).
6. Place the latch onto the housing, with the shaft protruding on the right side of the latch (see 
“Figure 2-10”). 
NOTEProceed to...

Radio Reassembly — Detailed2-11
7. With the battery latch placed on the housing, push the shaft in the housing slot to the left (see 
“Figure 2-11”). 
8. Place the small latch pad onto the right slot space (see “Figure 2-11”).
Figure 2-10 
Figure 2-11  

2-12Radio Reassembly — Detailed
9.Connect the internal speaker connector to the PC board (“see “Figure 2-12”).
10. Place the diecast into the front housing (see “Figure 2-13”).
11. Snap the front housing cover firmly into place on the rear diecast .
12. Attach the battery.
13. Attach the On/Off Volume Knob, Channel Knob and Antenna.
Figure 2-12 
Figure 2-13 
Speaker 
Connector