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

MOTOR (MODELS EJ4-4001 AND EJ8-4001A)

MOTOR DISASSEMBLY

1. Before beginning disassembly, place match marks on the motor end cap and motor frame.
2. Remove speed sensor and magnet.
2.1. Remove the two screws (25) that secure the speed sensor (10) to the end cap (11) (Figure 16b-15,
Page 16b-11).
2.2. Remove the screw securing the magnet to the armature shaft (Figure 16b-4, Page 16b-4).
2.3. Inspect the speed sensor magnet. See Speed Sensor Magnet Inspection on page 16b-10.
3. Loosen, but do not remove, the two screws securing the end cap to the motor frame (Figure 16b-5,
Page 16b-4).
Figure 16b-6 End Cap Disengagement
4. Orient the motor so that the splined end of the armature is facing down.
5. Inspect the area where the end cap mates with the motor frame. If the end cap appears to be loose where
it connects to the motor frame, proceed to step 6; otherwise, disengage the end cap from the motor frame
using the following procedure:
5.1. With the end cap bolts loose (about 1/4 inch between the end cap and the head of the bolt), place
a socket on the head of the bolt. See following CAUTION.
CAUT ION
• Ensure that there is sufficient thread engagement of the end cap bolts before proceeding.
Performing the procedure without having adequate thread engagement could damage the
motor frame, end cap, or end cap bolts.
5.2. Gently tap each bolt, alternating between blows, until the end cap and motor frame become disen-
gaged (Figure 16b-6, Page 16b-5).
6. Remove the two end cap bolts.
7. Remove the end cap and armature from the motor frame (Figure 16b-7, Page 16b-5).
8. Inspect the brush springs for proper tension. See Motor Brush, Spring, and Terminal Insulator
Inspection on page 16b-8.
9. Remove the armature from the end cap bearing. See following CAUTION and NOTE.
2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
Figure 16b-7 End Cap Removal
16B
Motor
Page 16b-5