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

16A
MOTOR (MODEL 5BC59JBS6390)

MOTOR INSTALLATION

See General Warning, Section 10, Page 10-1.
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 (CC P/N 102243403) from tube
onto a putty knife as shown (Figure 16a-13, Page 16a-12).
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 16a-14, Page 16a-12).
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.
Figure 16a-13 Grease on Putty Knife
2.6. Check the chamfer and end of the input shaft to ensure these areas are completely clean of grease
as shown (Figure 16a-15, Page 16a-13).
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 16a-9, Page 16a-8). 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.
Page 16a-12 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
®
Brakleen™ or equivalent brake cleaner degreaser.
mm
inch
mm
GREASE
inch
3/8 INCH (9.5 MM)
Figure 16a-14 Application of grease to Input
Shaft Grooves
Motor Installation
1/8 INCH
(3.1 MM)