Motor Installation - Club Car 2009-20011 Electric Precedent Maintenance And Service Manual

20

Motor Installation

MOTOR INSTALLATION
See General Warnings on page 1-1.
1. Clean the transaxle input shaft.
1.1. Spray the input shaft thoroughly with CRC
1.2. Wipe input shaft with a clean cloth.
1.3. Inspect the grooves of the input shaft and remove any remaining debris.
1.4. Repeat steps 1.1 through 1.3 until input shaft is clean.
2. Lubricate the transaxle input shaft.
2.1. Squeeze approximately 1/2 inch (1.3 cm) of moly-teflon lubricant (P/N 102243403) from tube onto a putty
knife as shown (Figure 20-20, Page 20-14).
2.2. Rotate wheels to rotate input shaft.
2.3. Apply motor coupling grease evenly to the rotating input shaft starting at approximately 1/8 inch (3.1
mm) from the end of the shaft and working back toward the transaxle (away from the end of the shaft)
(Figure 20-21, Page 20-14).
2.4. The grease should be evenly distributed in the grooves to a width of approximately 3/8 inch (9.5 mm).
2.5. Use a flat screwdriver to clean the grease out of one of the grooves and allow air to escape when the
motor is pushed onto the input shaft.
741
Figure 20-20 Grease on Putty Knife
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 20-22, Page 20-15).
3. Install the molded bumper.
3.1. With the flat side toward the bottom of the coupling, install the molded bumper (30) into the motor coupling
(Figure 20-15, Page 20-11). See following NOTE.
NOTE: The motor coupling and the new molded bumper must be free of grease and debris.
3.2. Ensure that the installed bumper is seated at the bottom of the coupling.
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.
Page 20-14 2009-2011 Electric Precedent Maintenance and Service Manual
® Brakleen™ or equivalent brake cleaner degreaser.
mm
inch
742
Figure 20-21 Application of grease to Input Shaft Grooves
MOTOR (MODEL EJ4-4001 AND EJ8-4001A)
mm
inch
3/8 INCH (9.5 MM)
1/8 INCH
(3.1 MM)