Motor Assembly - Club Car DS Villager 4 Maintenance And Service Manual Supplement

16A
MOTOR (MODEL 5BC59JBS6390)

MOTOR ASSEMBLY

See General Warning, Section 10, Page 10-1.
1. If the bearing has been removed, replace the bearing. See Bearing Installation on page 16a-7.
2. Install the brushes. 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 16a-10.
When replacing brushes, replace all four brushes. Never replace only two.
Install the brushes in the same rigging 180° apart from each other.
2.1. With brush rigging facing down and held slightly above stator shell, insert the two terminal posts
through insulators in stator shell wall at the A1 and A2 positions. Insert brush holder screws through
the holes in the brush rigging and into the threaded holes in the mounting bracket (Figure 16a-11,
Page 16a-11). Tighten the screws to 20 in-lb (2.3 N·m).
2.2. One at a time, push brush spring extensions back from brushes and slide the brushes back until
they are completely retracted into their mounting slots. Then position the brush springs against the
sides of the brushes so that spring pressure will hold them in the retracted position (Figure 16a-5,
Page 16a-4).
PRESS
RAM
BEARING PULLER
(CCI P/N 1012811)
Figure 16a-10 Bearing Removal
Page 16a-10 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
WEDGE ATTACHMENT TOOL
(CCI P/N 1012812)
Reconditioning the Motor