Club Car Carryall 1, Maintenance And Service Manual Supplement, Page: 131 / 176

MOTOR (MODEL 5BC59JBS6390) Motor Installation
2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 16a-13
16A
4. Install motor on transaxle.
4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE.
NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle.
When the motor is pushed onto the input shaft, the motor adapter ring (1) will not bottom out
against the transaxle housing
(Figure 16a-9, Page 16a-8) . There will be approximately 1/16 inch
(1.6 mm) gap between the motor adapter ring and transaxle housing as shown (Figure 16a-16,
Page 16a-13) .
4.2. Loosely install four motor bolts and washers that secure the motor to the transaxle. Do not tighten.
4.3. Begin finger-tightening the bolts in the sequence indicated
(Figure 16a-18, Page 16a-14) . Con-
tinue tightening by hand until the motor is seated in the transaxle housing. See following CAU-
TION and NOTE.
CAUT ION
• Make sure the motor is properly seated in the transaxle housing.
NOTE: Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper
tightness may result in motor noise during operation.
4.4. Tighten the right bolt (1) to 65 in-lb (7.3 N·m).
4.5. Tighten the left bolt (2) to 65 in-lb (7.3 N·m).
4.6. Tighten the center bolt (3) to 65 in-lb (7.3 N·m)
(Figure 16a-18, Page 16a-14) .
4.7. Tighten the bolt (24) inserted through the tab to 155 in-lb (17.5 N·m) (Figure 16a-17, Page 16a-14) .
4.8. Install the motor wires, making sure they are connected to the correct motor terminals and that the
terminal orientation is correct. See Wiring Diagrams, Section 11, Page 11-2. Tighten the terminal
retaining nuts to 65 in-lb (7.3 N·m).
4.9. Secure the white, orange, green, and blue wires with a wire tie so that none of the motor wires will
scrub the motor or transaxle when the vehicle is in operation.
4.10. Connect the three-pin speed sensor wire to the vehicle wire harness.
5. If using a chain hoist, lower the vehicle and guide the leaf springs into the shackles. If using a floor jack,
raise the transaxle until the leaf springs can be guided into the shackles.
Figure 16a-15 Clean Chamfer and Input Shaft End Figure 16a-16 Gap at Motor and Transaxle
SHAFT END
CHAMFER
1/16 INCH (1.6 MM)