Club Car Carryall 500, Maintenance And Service Manual

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16
Motor Installation
MOTOR (MODEL DA5-4006): ELECTRIC
VEHICLES
1
2
1/2
mm
inch
1
2
1 1/2
mm
inch
1/8 INCH
(3.1 MM)
3/8 INCH (9.5 MM)
Figure 16-17 Grease on Putty Knife Figure 16-18 Application of grease to Input Shaft Grooves
2.6. Check the chamfer (1) and end (2) of the input shaft to ensure these areas are completely clean of grease
as shown (Figure 16-19, Page 16-15) .
3. Install motor on transaxle.
3.1. 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 housing will not bottom out against the transaxle
housing. There will be approximately 1/16 inch (1.6 mm) gap between the motor adapter ring and transaxle
housing as shown
(Figure 16-20, Page 16-15) .
3.2. Loosely install the four bolts that secure the motor to the transaxle. Do not tighten.
3.3. Begin finger-tightening the bolts (1 and 2) in the sequence indicated (Figure 16-21, Page 16-16) . Continue
tightening by hand until the motor is seated in the transaxle housing. See following CAUTION and NOTE.
CAUTION
• 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.
3.4. Tighten the right bolt (1) to 65 in·lb (7.3 N·m) (Figure 16-21, Page 16-16) .
3.5. Tighten the left bolt (2) to 65 in·lb (7.3 N·m) (Figure 16-21, Page 16-16) .
3.6. Tighten the center bolt (3) to 65 in·lb (7.3 N·m).
3.7. Tighten the bolt (4) inserted through the tab to 155 in·lb (17.5 N·m).
3.8. Install the motor wires, making sure they are connected to the correct motor terminals and that the terminal
orientation is correct. See Wiring Diagrams on page 12-4. Tighten the terminal retaining nuts to 65 in·lb
(7.3 N·m). Use a wrench on the bottom nuts to keep the terminals from moving.
3.9. 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.
3.10. Connect the three-pin speed sensor plug to the vehicle wire harness.
Page 16-14 2017 Carryall 500 and 700 Maintenance and Service Manual