84
MOTOR CONTROLLER -
REMOVAL & INSTALLATION
1.
Remove the seat and the left- and right-side shrouds
).
2.
Remove the battery (
3.
Drain the coolant (
).
4.
Remove the subframe (
) and the rear
shock absorber (
).
5.
Remove the timing cover (
) and the screw,
and detach the ground wire. (
Fig. 7
)
6.
Disconnect the orange HV connector from the DC
Charge Port (
). Also disconnect the LV
connector on the motor controller cover by pulling the
yellow tab away from the plug.
7.
Cut the zip-ties and free the vent hose and wiring
harness from the controller cover. Note how the hose
and harness are routed.
8.
Pull the red U-shaped lock out from the LV receptacle
by pressing down on both ends of the ‘U’ with equal
pressure. Loosen the 11 cover screws a little at a time in
a criss-cross pattern, and remove them. Remove the
cover. Separate the receptacle housing from the cover,
and set the cover aside. (
Fig. 8
)
9.
Remove the nuts; cut the zip ties; disconnect the
motor wires from the controller terminals (
A
). Note
what color ring terminal is mated to what post. Also
disconnect the temp sensor (
B
) and position sensor
(
C
). Feed all wires through the wire passage in the
RBH including the ground strap from the timing cover
side. (
Fig. 9
)
10.
From the back of the RBH, loosen the 6 motor
controller mounting bolts a little at a time in a criss-
cross pattern, and then remove them. (
Fig. 10
)
11.
Separate the controller from the RBH using one
hand to guide the loose wiring through the wire
passage. Be prepared for some coolant to spill out.
12.
Thoroughly clean the mating surfaces of the
coolant passage and wire passage. Caution: Be careful
not to scratch the mating surfaces – a coolant leak
could result. Follow up by cleaning the wires and
mating surface with isopropyl alcohol and allowing it
to dry.
CHAPTER 6
