Club Car IQ PLUS 2008, Maintenance And Service Manual Supplement

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MOTOR (MODEL DA5-4006) Motor Installation
Page 16-14 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement
16
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 16-20, Page 16-15) .
Continue 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.
3.4. Tighten the right bolt (1) to 65 in-lb (7.3 N·m) (Figure 16-20, Page 16-15) .
3.5. Tighten the left bolt (2) to 65 in-lb (7.3 N·m) (Figure 16-20, Page 16-15) .
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, Section 11, Page 11-2. 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.
4. 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.
5. Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install
locknuts. Tighten the bolts to 23 ft-lb (31 N·m). See Section 9 – Rear Suspension in the appropriate
maintenance and service manual .
6. Install the shock absorbers. Tighten nut until rubber bushing expands to the diameter of the cup washer.
7. If removed, install wheels and finger tighten the lug nuts.
8. Lift vehicle and remove jack stands. Lower vehicle to the floor and tighten lug nuts, using a crisscross pat-
tern, to 55 ft-lb (74.6 N·m).
Figure 16-18 Clean Chamfer and Input Shaft End Figure 16-19 Gap at Motor and Transaxle
SHAFT END
CHAMFER
1/16 INCH (1.6 MM)