Club Car Carryall 1, Maintenance And Service Manual Supplement, Page: 143 / 176

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection
2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 16b-9
16B
3. Inspect the brush springs (14) (Figure 16b-15, Page 16b-11) . Replace springs that are discolored from
heat (light gold or blue tinted).
4. Test the brush springs for proper tension.
4.1. Place a C-shaped steel plate on a scale.
4.2. Place the end of the C-shaped plate so that it is between the spring and the brush as shown
(Figure 16b-13, Page 16b-10) .
4.3. Gently pull the scale to obtain the spring tension reading. See following CAUTION.
CAUT ION
• When checking brush spring tension, do not over-extend the spring. Using excessive force
will damage the spring.
4.4. Replace springs which require a force of less than 35 oz. (990 grams) (Figure 16b-13,
Page 16b-10) . See following NOTE.
NOTE: When installing new brushes, remove and replace brushes one at a time. This method ensures the
terminals and brushes will be properly positioned in the rigging. Refer to Motor Assembly for brush
installation.
See Motor Assembly on page 16b-12.
When replacing brushes, replace all four brushes. Never replace only two.
Install the brushes in the same rigging 180° apart from each other.
Brush Inspection
1. Remove the motor from the vehicle. See Motor Removal, Section 16b, Page 16b-3.
2. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on
page 16b-5.
3. Inspect the brushes (13) for damage or excessive wear (Figure 16b-15, Page 16b-11) . Replace
brushes if required. See preceding NOTE.
4. Use dial calipers or a micrometer to measure the brush length. The minimum-allowable brush length is
0.62 inches (16 mm). Replace the set of brushes as required. See preceding NOTE.