Motor Installation - Club Car Turf 252 2007 Maintenance And Service Manual

MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES

MOTOR INSTALLATION

See General Warning 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 (CCI P/N 102243403) from tube onto a
putty knife as shown (Figure 27-16, Page 27-13).
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 27-17, Page 27-13).
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 27-16 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 27-18, Page 27-14).
3. Install motor on transaxle.
3.1. 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.
When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle
housing. There will be approximately 1/16 inch (1.6 mm) gap between the motor adapter ring and transaxle
housing as shown (Figure 27-19, Page 27-14).
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 27-20, Page 27-15). Continue
tightening by hand until the motor is seated in the transaxle housing. See following CAUTION and NOTE.
2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual
® Brakleen™ or equivalent brake cleaner degreaser.
mm
inch
Figure 27-17 Application of grease to Input Shaft Grooves
Motor Installation
mm
inch
3/8 INCH (9.5 MM)
27
1/8 INCH
(3.1 MM)
Page 27-13