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Sierra AX3 2024 Service Manual

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  • Page 2 SAFETY DETAILS Please obey (Danger, Warning, Caution, and Notice) wording in this manual, as well as obey all instructions, safety precautions, and safety decals on the vehicle. Replace missing or damaged safety decals immediately to prevent possible property damage or personal injury, or death. Understand and follow all laws and regulations for operating the vehicle in your area.
  • Page 3 If any of the operation or safety decals on the vehicle become damaged, have been removed or cannot be easily read, they should be replaced immediately to avoid possible property damage, personal injury, or death. Contact your distributor/dealer. DANGER • A DANGER indicates an immediate hazard that will result in severe personal injury or death. WARNING • A WARNING indicates an immediate hazard that could result in severe personal injury or death. CAUTION • A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury. CAUTION • A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage. HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty, you must present the vehicle or defective component with evidence of proof of purchase date and number of amp hours (if applicable) to an authorized Sierra LSV dealer. For warranty-related communication, contact your sales. CONTACT INFORMATION Website: www.sierralsv.com Email: infor@sierralsv.com Phone: 1-877-877-5993 Address: 317 Industrial Blvd Thomasville, GA 31792...
  • Page 4 PRACTICE SAFETY ATTENTION SAFETY FIRST ROLLOVER WARNING Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe tailored for improved off-road performance, offering personal injury. nd clearance compared to its class counterparts. Your safety and satisfaction are of the utmost importance to us. That is why before operating the vehicle, we urge you to review the information in this manual. Understand and become familiar with the DANGER, WARNING, and CAUTION on and avoid abrupt maneuvers, such as sharp statements and procedures it contains, along with the safety decals that are affected to your vehicle. n level terrain, as they may result in loss of control, Take time to understand the language of safety. It is a language that can save your life.

  • Page 5: Table Of Contents

    VEHICLE PREP ....................2 Battery On/Off Chock Wheels ....................2 Lifting Front Body ....................3 Lifting Rear Body ....................3 Dash Removal ....................4 Torque Tightening Guide ....................5 MOTOR Electric Motor Replacement (All models) ....................6-7 Encoder Replacement ....................8-9 Encoder Replacement (AX4 only) ..................10-11 Run/Tow Switch (All models) ..................12-13 BRAKES E-Brake Replacement (All models)

  • Page 6: Vehicle Prep

    VEHICLE PREP SEQUENCE Battery On/Off Models: All Models Estimated Completion Time: 1 minute 1) Turn the Key swtitch to OFF, or press the START/STOP button to turn off the vehicle. 2) Turn off the lithium battery by pushing the power button located between the battery terminals on the passenger side. (No LED light will show when off ) Chock Wheels TOOLS NEEDED 2 Wheel Chocks Models: AX1, AX2, AX3, AX4 Torque Wrench Estimated Completion Time: 1 minute 1) Make sure your vehicle is on a flat terrain and the brake engaged. 2) If you’re lifting the rear you will want to chock the front wheels. If you’re lifting the front you will want to chock the rear wheels. (This ensures a secure and stable environment and prevents the vehicle from rolling away.)

  • Page 7: Lifting Front Body

    VEHICLE PREP SEQUENCE Lifting Front Body TOOLS NEEDED Floor Jack Models: All Models Jack Stands Estimated Completion Time: 1 minute 1) Position the Floor Jack under the metal frame and lift. 2) Slide Jack floor stands under the metal frame. Lifting Rear Body TOOLS NEEDED Floor Jack Models: All Models Jack Stands Estimated Completion Time: 1 minute 1) Position the Floor Jack under the metal frame and lift. 2) Place Jack Stands at the rear under the metal frame and axle.

  • Page 8: Dash Removal

    VEHICLE PREP SEQUENCE Dash Removal TOOLS NEEDED Models: All Models Phillips Screwdriver Panel Removal Tool Estimated Completion Time: 5 Minutes INSTRUCTIONS 1) Remove the wireless phone charger pad and using the phillips head screwdriver remove the screw under the pad. 2) Using the panel removal tool carefully find the 6 tabs holding the cup holder panel and push them back with the tool to remove the cup holder panel.

  • Page 9: Torque Tightening Guide

    VEHICLE PREP SEQUENCE Torque Tightening Guide Models: All Models Maximum Tightening Torque (Nm) Ft lbs. Size Property Class (mm) Grade 8.8 Grade 9.8 Grade 10.9 Grade 12.9 10.0 11.7 5.17 5.76 7.38 8.63 11.8 13.3 17.0 19.9 8.71 9.82 12.5 14.7 28.8 32.3...

  • Page 10: Motor

    SIERRA LSV SERVICE MANUAL MOTOR Electric Motor Replacement TOOLS NEEDED 11mm Socket Models: All Models 13mm Socket Strap/Belt Estimated Completion Time: 45 minutes Part# WHI-005 INSTRUCTIONS NOTE: AX4 motors can be accessed under the rear seat bottom cushion, AX1, AX2, and AX3 carts must be accessed from under the cart. 1) Prep the vehicle for service (See pages 2-3). 2) Remove 3 M8 nuts holding motor cables on the motor studs with a 13mm socket. Note orientation of cables before removing. 3) Remove the 3 M6 bolts facing passenger side tire using a 11mm socket.
  • Page 11 SIERRA LSV SERVICE MANUAL MOTOR 4) Remove the M8 bolt facing driver side with a 13mm socket. 5) With the help of an assistant slide the motor free from the input shaft for the differential and lower to the ground to remove. NOTE: Loop a strap or belt around the motor for easier lifting. CAUTION: The motor is quite heavy use caution when removing it. 6) Reverse these steps to install the replacement motor. Refer to Torque tightening guide on page 5 for securing any hardware.

  • Page 12: Encoder Replacement

    SIERRA LSV SERVICE MANUAL MOTOR Encoder Replacement TOOLS NEEDED 5mm Allen Key Models: AX1, AX2, AX3 Estimated Completion Time: 30 minutes Part# X1-074 INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove the allen screw on the top of the motor using the 5mm allen key. 3) Unplug the 4 pin connector from the wiring harness.
  • Page 13 SIERRA LSV SERVICE MANUAL MOTOR 4) Pull the encoder out of the electric motor. 5) Reverse these steps to install the replacement encoder. Refer to Torque tightening guide on page 5 for securing any hardware.
  • Page 14 SIERRA LSV SERVICE MANUAL MOTOR Encoder Replacement TOOLS NEEDED 5mm Allen Key Models: AX4 Only Estimated Completion Time: 15 minutes Part# X1-074 INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) The encoder can be accessed under the rear seat bottom cushion. 3) Remove the allen screw attaching the encoder to the motor. 4) Unplug the 4 pin connector from the wiring harness.
  • Page 15 SIERRA LSV SERVICE MANUAL MOTOR 5) Pull the encoder out of the motor. 6) Reverse these steps to install the replacement encoder.

  • Page 16: Run/Tow Switch (All Models)

    SIERRA LSV SERVICE MANUAL MOTOR Run/Tow Switch Replacement TOOLS NEEDED #3 Phillips Models: All Models Estimated Completion Time: 15 minutes Part# WX1-048 INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove controller cover using #3 phillips to remove the 4 screws. 3) Unplug the connectors for the switch.
  • Page 17 SIERRA LSV SERVICE MANUAL MOTOR 4) Unscrew the threaded trim ring for the switch and remove it. 5) Reverse these steps to install new Run/Tow switch.

  • Page 18: Brakes

    SIERRA LSV SERVICE MANUAL BRAKES E-Brake Replacement TOOLS NEEDED 19mm Socket Models: All Models 4mm Allen Key (2” T-handle) Estimated Completion Time: 15 minutes Part# WX1-011 INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove the driver side rear tire using 19mm socket. 3) Remove the 3 screws attaching the brake to the motor using the 4mm allen key.
  • Page 19 SIERRA LSV SERVICE MANUAL BRAKES 4) Unplug the brake wire connector. 5) Slide the brake off of the motor shaft. 6) Reverse these steps to install the replacement brake. Refer to Torque tightening guide on page 5 for securing any hardware. (Torque wheel to 65ft lbs)

  • Page 20: Brake Disc/Rotor Replacement (All Models)

    SIERRA LSV SERVICE MANUAL BRAKES Brake Disc/Rotor Replacement TOOLS NEEDED Small Flathead Screwdriver Models: All Models 15mm Socket 19mm Socket Estimated Completion Time: 45 minutes Front 30mm Socket 15 minutes Rear Part# X1-001(Front), X1-002 (Rear) INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove the tire/wheel using the 19mm socket. 3) For front only, remove the 2 bolts holding the caliper on using the 15mm socket and move the caliper to the side to allow removal of the disc/rotor.
  • Page 21 SIERRA LSV SERVICE MANUAL BRAKES 4) For front only, remove the nut in the center of the disc/rotor using the 30mm socket for the front wheel. Use the small flat head screwdriver to release the tab on the nut. Remove the disc/rotor. 5) For rear only, remove the caliper mounting bolt using the 15mm socket. The rotor will now slide off the lug studs. 6) Reverse these steps to install brake disc/rotor. Refer To Torque Tightening Guide for securing Caliper Hardware (Page 9).

  • Page 22: Brake Pad Replacement (All Models)

    SIERRA LSV SERVICE MANUAL BRAKES Brake Pad Replacement TOOLS NEEDED Models: All Models 15mm Socket 19mm Socket Estimated Completion Time: 15 minutes per wheel Small C-Clamp (or channel lock pliers) INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove the Tire/wheel using a 19mm socket. 3) Remove the 2 bolts attaching the caliper using the 15mm socket.
  • Page 23 SIERRA LSV SERVICE MANUAL BRAKES 4) Remove the old pads. 5) Using a C clamp or channel lock pliers force the brake piston back into the caliper. 6) Install the new pads and reattach the calipers. 7) Pump the brake pedal until you get a hard pedal. 8) Lower the cart and test drive in a safe area with room for a rolling stop in case of brake failure.

  • Page 24: Brake Caliper Replacement (All Models)

    SIERRA LSV SERVICE MANUAL BRAKES Brake Caliper Replacement TOOLS NEEDED 15mm Socket Models: All Models 19mm Socket 14mm Open end Wrench Estimated Completion Time: 45 minutes per wheel Part# X1-003(Driver), X1-004 (Pass) INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove the wheel and tire using the 19mm socket. 3) Remove the brake line using the 14mm wrench. NOTE: Use a drip pan to catch any fluid that may leak out. DO NOT lose Crush washers. Cover line with a bag and tie up high if going to be off for an extended period of time.
  • Page 25 SIERRA LSV SERVICE MANUAL BRAKES 4) Remove the caliper by removing the 2 bolts attaching it using the 15mm socket. Retain the bolts for reinstallation. 5) Attach the replacement caliper using the 15mm socket and retained bolts. Refer To Torque Tightening Guide for securing Caliper Hardware (Page 5). 6) Follow brake bleeding instructions (NEXT PAGE) to bleed the air from the brake line(s).

  • Page 26: Brake Bleeding Instructions (All Models)

    SIERRA LSV SERVICE MANUAL BRAKES Brake Bleeding TOOLS NEEDED 10mm Wrench Models: All Models Vacuum Brake Bleeding Tool DOT3 Brake Fluid Estimated Completion Time: 1 Hour INSTRUCTIONS 1) When bleeding the brakes jack up the end of the cart you are bleeding and chock the other 2 wheels. This way gravity is working with you and not against you. 2) Keep a close eye on the brake fluid reservoir to make sure it does not run out of fluid during the bleeding process. If it does you have to start the process over again.
  • Page 27 SIERRA LSV SERVICE MANUAL BRAKES 3) Attach the vacuum brake bleeding tool to the bleeding nipple on each of the calipers. The open the bleeding nipple using the 10mm wrench. 4) Use the vacuum bleeding tool until air bubbles are no longer visible in the hose. 5) Tighten the bleeding nipple and remove the vacuum bleeding tool. 6) Repeat this process for the other 3 brake calipers. NOTE: After bleeding the brakes the brake pedal should stop before hitting the floor as the brakes are applied. Always use a safe area to test the brakes with plenty of room for a rolling stop in case the brakes fail to work properly.

  • Page 28: Master Cylinder Removal

    SIERRA LSV SERVICE MANUAL BRAKES Master Cylinder Removal TOOLS NEEDED #3 Phillips Screwdriver Models: AX1, AX2, AX3 10mm Wrench 14mm Wrench Estimated Completion Time: 1 Hour 13mm Deep Socket Drip Pan Part# X1-006 INSTRUCTIONS 1) Remove the Floor Mat and Prep the vehicle for service (See pages 2-3). 2) Using the 10mm wrench remove the metal brake lines from the master cylinder. CAUTION! Brake fluid will now be released from the master cylinder and is very corrosive. 3) Using the 14mm wrench loosen the lock nut for the brake linkage and thread the linkage off of the master cylinder.
  • Page 29 SIERRA LSV SERVICE MANUAL BRAKES 4) Using a #3 phillips screwdriver remove the 2 hose clamps and the 2 hoses. 5) Using the 13mm socket remove the mounting bolts for the master cylinder. 6) Reverse these steps to install the replacement master cylinder. Refer To Torque Tightening Guide for securing all Hardware (Page 5). 7) Follow brake bleeding instructions after brake master cylinder replacement (PREVIOUS PAGE).

  • Page 30: Brake Master Replacement (Ax4 Only)

    SIERRA LSV SERVICE MANUAL BRAKES Brake Master Replacement TOOLS NEEDED #3 Phillips Screwdriver Models: AX4 #2 Stubby Phillips Screwdriver 10mm Wrench 14mm Wrench Estimated Completion Time: 90 Minutes 8mm Socket 10mm Socket Part# X1-006 13mm Deep Socket INSTRUCTIONS 1) Remove both kick panels using the #3 screwdriver and 10mm socket. 2) Remove the #2 screws with spacers from the inside of the front body above and to the rear of the front tires.
  • Page 31 SIERRA LSV SERVICE MANUAL BRAKES 3) Remove the #3 phillips under the plastic cover. 4) Remove the six 8mm screws under the dash. 5) Pull the floormat back to expose the cover over the master cylinder in the floor just to the rear of the cart from the brake pedal. Take out the six #3 screws attaching the cover and remove it.
  • Page 32 SIERRA LSV SERVICE MANUAL BRAKES 6) Use the 10mm wrench to remove the metal brake lines. CAUTION! Brake fluid will now be released from the master cylinder and is very corrosive. 7) Using the 14mm wrench loosen the lock nut for the brake linkage and thread the linkage off of the master cylinder. 8) Remove the 2 hose clamps using the #2 phillips screwdriver and remove the hoses. 9) Using the 13mm socket remove the mounting bolts for the master cylinder. 10) Reverse these steps to reinstall the replacement master cylinder. Refer to Torque tightening guide on page 5 for securing any hardware. 11) Follow brake bleeding instructions after brake master cylinder replacement (Page 22).

  • Page 33: Electrical

    SIERRA LSV SERVICE MANUAL ELECTRICAL DNR Switch Replacement TOOLS NEEDED Phillips Screwdriver Models: All Models Panel Removal Tool Estimated Completion Time: 30 minutes Part# WX1-066 INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Refer to Dash removal section (Page 4) 3) Take a picture of the wiring or write down the wire colors and position on the switch before removing the eight wires. All wires are tagged to match pin position as shown...
  • Page 34 SIERRA LSV SERVICE MANUAL ELECTRICAL 5) Squeeze the retaining tabs on the switch and push it out of the dash. 6) Reverse these steps to install the switch.

  • Page 35: Lithium Battery Replacement (All Models)

    SIERRA LSV SERVICE MANUAL ELECTRICAL Lithium Battery Replacement TOOLS NEEDED 13mm Socket Models: All Models Estimated Completion Time: 45 Minutes INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove the terminal covers and unplug the two connectors from the battery. Pay close attention to the orientation of the positive and negative cables. Remove one side at a time and secure the first cable before moving to the next, reattach the terminal cover before moving to the next terminal. 3) Remove the 4 mounting bolts using the 13mm socket.
  • Page 36 SIERRA LSV SERVICE MANUAL ELECTRICAL 4) Using 2 people carefully lift the lithium battery from the cart. 5) Reverse these steps to install a replacement battery pack. Refer to Torque tightening guide on page 5 for securing any hardware. CAUTION: Ensure Battery is off before installation.

  • Page 37: Charger Replacement (All Models)

    SIERRA LSV SERVICE MANUAL ELECTRICAL Charger Replacement TOOLS NEEDED #2 Phillips Models: All Models 8mm Socket 10mm Socket Estimated Completion Time: 30 Minutes INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Unplug the charger connectors. NOTE: On the AX4 you will need to disconnect the two main, If charger is still connected to battery remove the two main leads and camera interface wire. 3) Using the phillips screwdriver and 8mm socket remove the receptacle cover. Remove the four- #2 phillips screws from the receptacle and remove receptacle from cart.
  • Page 38 SIERRA LSV SERVICE MANUAL ELECTRICAL 4) Remove the two bolts with 10mm nuts attaching the charger to the mounting plate using a 10mm socket and wrench. Shown on AX4 5) ) Remove the four- #2 phillips screws with 10mm nuts attaching charger to mounting plate. Shown on AX2 6) Reverse these steps to install replacement charger. Refer to Torque tightening guide on page 5 for securing any hardware. NOTE: A small arc will occur when replugging in converter.

  • Page 39: Controller Replacement (All Models)

    SIERRA LSV SERVICE MANUAL ELECTRICAL Controller Replacement TOOLS NEEDED #3 Phillips Screwdriver Models: All Models 13mm Socket Estimated Completion Time: 30 Minutes Part# H1-006 INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove the four screws attaching the controller cover using the #3 phillips.
  • Page 40 SIERRA LSV SERVICE MANUAL ELECTRICAL 3) Move the cover to the side and remove the cables from the controller using a 13mm socket. *Unplug the wiring harness connector from the controller. Note the position of the cables on the motor so that they can be reinstalled correctly. NOTE: Retain or replace fuse 4) Remove the four screws attaching the controller to the cart using the #3 phillips. 5) Reverse these steps to install replacement controller.

  • Page 41: Key Switch Replacement

    SIERRA LSV SERVICE MANUAL ELECTRICAL Key Switch Replacement TOOLS NEEDED #2 Phillips Models: AX2, AX3, AX4 Panel Removal Tool Channel Locks Estimated Completion Time: 30 Minutes Part# H1-006 INSTRUCTIONS 1) Refer to Dash removal section (Page 4) 2) Turn off lithium pack. 3) Unplug the 2 pin connector from the key switch and remove the threaded bezel of the switch. 4) Push the switch back through the hole in the dash to remove it. 5) Reverse these steps to install new key switch. NOTE: Keys are unique to each switch.

  • Page 42: Start Stop Button Replacement (Ax1 Only)

    SIERRA LSV SERVICE MANUAL ELECTRICAL Push Start/Stop Button Replacement TOOLS NEEDED Models: AX1 Phillips Screwdriver Panel Removal Tool Estimated Completion Time: 30 Minutes Part# WG1-005A INSTRUCTIONS 1) Refer to Dash removal section (Page 4) 2) Turn off lithium pack (Page 2). 3) Unplug the connector for the switch. 4) Carefully bend the tabs on the back of the switch to release it. 5) Pull the switch out of the dash. 6) Reverse these steps to install new start/stop switch. NOTE: Key Fobs do NOT need to be reprogrammed if only replacing the Start/Stop Button.

  • Page 43: Bluetooth Start/Stop Receiver (Ax1 Only)

    SIERRA LSV SERVICE MANUAL ELECTRICAL Bluetooth Start/Stop Receiver TOOLS NEEDED Models: AX1 #2 Phillips Panel Removal Tool Estimated Completion Time: 30 Minutes Part# WG1-005B INSTRUCTIONS 1) Refer to Dash removal section (Page 4) 2) Turn off the lithium battery pack. 3) Unplug the connector from the bluetooth receiver. 6) Remove receiver from dash area by using a #2 Phillips head screwdriver if necessary. 7) Reverse these steps to install a new receiver. NOTE: Key Fobs will need to be reprogrammed. Remove tape covering pin and using a small paper clip hold until fob is recognized.

  • Page 44: Display Screen Replacement (All Models)

    SIERRA LSV SERVICE MANUAL ELECTRICAL Display Screen Replacement TOOLS NEEDED #2 Phillips Screwdriver Models: All Models Panel Removal Tool Estimated Completion Time: 45 Minutes Part# WG1-007 INSTRUCTIONS 1) Refer to Dash removal section (Page 4). 2) Turn off lithium battery pack (Page 2). 3) Remove the four #2 phillips screws attaching the display screen to the bezel. AM/FM Controller Speaker Info Camera USB Port Diagnostics Power 4) Carefully push the screen out of the bezel. Speaker 4) Reverse these steps to install replacement display screen.

  • Page 45: Voltage Converter Replacement (All Models)

    SIERRA LSV SERVICE MANUAL ELECTRICAL Voltage Converter Replacement TOOLS NEEDED Models: AX1, AX2, AX3 #2 Phillips Screwdriver 8mm Socket Estimated Completion Time: 15 Minutes 10mm Socket Part# WG1-004 INSTRUCTIONS 1) Turn off the battery (Page 2). 2) Remove the 4 screws attaching the charger to the bracket using the #2 phillips and 10mm socket 3) Disconnect the converter plug. NOTE: A small arc will occur when replugging in converter...
  • Page 46 SIERRA LSV SERVICE MANUAL ELECTRICAL Voltage Converter Replacement TOOLS NEEDED #2 Phillips Screwdriver Models: AX4 8mm Socket 10mm Socket Estimated Completion Time: 15 Minutes Part# WG1-004 INSTRUCTIONS 1) Turn off the battery (Page 2). 2) Remove the 4 screws attaching the charger to the bracket using the #2 phillips and 10mm socket 3) Disconnect the converter plug. NOTE: A small arc will occur when replugging in converter.

  • Page 47: Suspension

    SIERRA LSV SERVICE MANUAL SUSPENSION Front Shock Replacement TOOLS NEEDED 5/8” Socket Models: All Models 5/8” Wrench 5/8” Ratchet Estimated Completion Time: 15 Minutes per Shock INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove the nuts at the top and bottom mounts of the shock using the 5/8” socket and wrench. 3) Pay close attention to the order of the shock, spacer and other hardware so you can reinstall it the same way.
  • Page 48 SIERRA LSV SERVICE MANUAL SUSPENSION 4) Remove shock(s) and retain all hardware. 5) Reinstall the shock, spacers, and hardware in the correct order at the top and bottom of the shock. Refer To Torque Tightening Guide for securing all Hardware (Page 5).

  • Page 49: Rear Shock Replacement (All Models)

    SIERRA LSV SERVICE MANUAL SUSPENSION Rear Shock Replacement TOOLS NEEDED 17mm Socket Models: All Models Wrench Estimated Completion Time: 20 Minutes per Shock Part# X1-032 (AX1), X1-033 (AX2/AX3/AX4) INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Jack up rear wheels and support cart on jack stands. 3) Remove nuts from shock mounting bolts using the 17mm socket and wrench and remove mounting bolts and shocks and retain all hardware.
  • Page 50 SIERRA LSV SERVICE MANUAL SUSPENSION 4) AX4 upper shock mount bolts can be accessed under the rear seat cushion, all other models must be accessed from under the cart. Note: Pay attention to the order of the hardware so you can reinstall it the same way. 6) Reinstall the replacement shocks using retained hardware. Refer To Torque Tightening Guide for securing all hardware (Page 5).

  • Page 51: Rear Spring/Bushing Replacement (All Models)

    SIERRA LSV SERVICE MANUAL SUSPENSION Rear Spring/Bushing Replacement TOOLS NEEDED 13mm Socket Models: All Models 15mm Socket 17mm Socket Estimated Completion Time: 60 Minutes per Spring Part# X1-012 (AX2/AX4), X1-013 (AX1/AX3) INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Use a second floor jack to support the rear differential so it does not drop when the spring is detached.
  • Page 52 SIERRA LSV SERVICE MANUAL SUSPENSION 3) Using a 13mm and 15mm socket remove the bolts from the front and rear eyes of the spring, retain all hardware. NOTE: Only remove one side at a time. 4) If replacing bushings use the jack supporting the differential to lower it to gain access to the bushings to replace them. NOTE: Be careful not to over tighten the hardware for the bushings, just tighten it until the connection has no slop.
  • Page 53 SIERRA LSV SERVICE MANUAL SUSPENSION 5) If replacing the spring use the 17mm socket to remove the nuts from the u bolts. IMPORTANT Do not remove the u bolts from both Driver and Passenger Side Springs at the same time this could cause the axle to rotate and damage the motor or wiring. 6) Remove spring and replace by reversing the above steps. Refer to Torque tightening guide on page 5 for securing any hardware.

  • Page 54: Front Suspension Alignment (All Models)

    SIERRA LSV SERVICE MANUAL SUSPENSION Front Suspension Alignment TOOLS NEEDED 13mm Wrench Framing Square Models: All Models 16mm Wrench Tape Measure 18mm Wrench Estimated Completion Time: 45 minutes 24mm Wrench INSTRUCTIONS CAMBER 1) To check camber on a flat level surface place one leg of the square on the floor and use the other leg to see if the front tires are 90 degrees. If the tire is not 90 degrees, jack up the front wheels and support with jack stands, use a 24mm wrench to loosen the outer nut on the heim joint on the end of the lower a arm. 2) Using the inner and outer nuts on the threaded portion of the heim joint, adjust the heim joint in or out to make the tire 90 degrees. 3) Tighten both nuts to secure the heim joint. 4) Lower the cart to the ground, drive vehicle around, and recheck camber using framing square.
  • Page 55 SIERRA LSV SERVICE MANUAL SUSPENSION TOW ALIGNMENT 5) For tow adjustment measure between the inner sidewalls of the front tires at the front of the tire and again at the back. 6) Some tires have a mold line in the center this can also be used for this measurement.
  • Page 56 SIERRA LSV SERVICE MANUAL SUSPENSION 7) Proper toe setting is 1/8” to 1/4” toed in. Meaning the measurement between the sidewalls of the tires is shorter measured at the front of the tires than at the back of tires. 8) If the toe adjustment is not set properly loosen the lock nuts for the tie rod ends using a 13mm wrench. 9) Using the 13mm wrench on the hex portion of the steering arm connecting the steering rack to the tie rod end, rotate the steering shaft to thread the tie rod in or out to change the adjustment.
  • Page 57 SIERRA LSV SERVICE MANUAL SUSPENSION 10) Adjust both tie rods the same amount so that the steering wheel does not get off center. 11) Once the correct alignment is achieved retighten the tie rod end lock nuts. 12) Drive vehicle around then recheck alignment.

  • Page 58: Lower A Arm Heim Joint Replacement (All Models)

    SIERRA LSV SERVICE MANUAL SUSPENSION Lower A-Arm Heim Joint Replacement TOOLS NEEDED 18mm Socket Models: All Models 19mm Socket 24mm Socket Estimated Completion Time: 15 minutes Part# X1-044 INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Remove front tire using 19mm socket. 3) Remove cotter pin from castle nut and use 18mm socket to remove castle nut, retain all hardware.
  • Page 59 SIERRA LSV SERVICE MANUAL SUSPENSION 4) Remove heim joint using 24 mm socket. 5) Reverse these steps to install new heim joint and reassemble front suspension. 6) Follow front suspension alignment instructions. NOTE: If Heim joint is stuck in spindle arm, lightly tap spindle arm with mallet to free it.

  • Page 60: Upper Tie Rod End Replacement (All Models)

    SIERRA LSV SERVICE MANUAL SUSPENSION Upper Tie Rod End Replacement TOOLS NEEDED 18mm Socket Models: All Models 19mm Socket 16mm Wrench Estimated Completion Time: 30 Minutes Part# X1-043 INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Use the 19mm socket to remove the front tire. 3) Mark the position of the tie rod end using a tape or marker on the threaded steering shaft so the alignment process will be easier after reinstallation.
  • Page 61 SIERRA LSV SERVICE MANUAL SUSPENSION 4) Remove the cotter pin and use the 18mm socket to remove the castle nut. 5) Press or tap the tie rod end out of the steering arm of the spindle. 6) Be careful not to damage the threads of the tie rod end.
  • Page 62 SIERRA LSV SERVICE MANUAL SUSPENSION 7) Use the 16mm wrench to loosen the lock nut for the tie rod end, then thread the tie rod end off of the steering shaft. 8) Reverse these steps to install a replacement tie rod end. Refer to Torque tightening guide on page 5 for securing any hardware. 9) Follow front suspension alignment instructions.

  • Page 63: Steering Rack Replacement (All Models)

    SIERRA LSV SERVICE MANUAL SUSPENSION Steering Rack Replacement TOOLS NEEDED 10mm Socket Models: All Models 13mm Socket 18mm Socket Estimated Completion Time: 45 Minutes 19mm Socket 16mm Wrench Part# X1-045 INSTRUCTIONS 1) Prep the vehicle for service (See pages 2-3). 2) Use the 19mm socket and remove the front tires. 3) Remove the cotter pins from Driver and Passenger’s side Tie ends and retain.
  • Page 64 SIERRA LSV SERVICE MANUAL SUSPENSION 4) Use the 18mm socket to remove the castle nuts for both tie rod ends. 5) Press or tap the tie rod ends out of the steering arms for the spindles. NOTE: Be careful not to damage the threads on the tie rod ends. 6) Using the 13mm socket loosen the clamp connection from the steering column shaft to the steering rack.
  • Page 65 SIERRA LSV SERVICE MANUAL SUSPENSION 7) Using the 16mm wrench loosen the lock nuts for the tie rod ends. 9) Mark the location of the tie rod ends on the threaded shaft to help make the alignment easier.
  • Page 66 SIERRA LSV SERVICE MANUAL SUSPENSION 10) Using the 10mm socket remove the 4 bolts attaching the steering rack to the golf cart. 11) Slide the steering rack off of the steering column shaft. 12) Reverse these steps to reinstall a replacement steering rack. Refer to Torque tightening guide on page 5 for securing any hardware. 13) Follow front suspension alignment instructions.

  • Page 67: Body & Accessories

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Front Bumper Replacement TOOLS NEEDED 10mm Socket/Wrench Models: All Models Stubby #2 Phillips Screwdriver Estimated Completion Time: 15 Minutes Part# Y1-001 INSTRUCTIONS 1) Using the 10mm socket and phillips screwdriver remove the four bolts attaching the bumper to the cart. 2) Remove bumper. 3) Reverse these steps to install a replacement bumper. Refer to Torque tightening guide on page 5 for securing any hardware.

  • Page 68: Rear Bumper Replacement (All Models)

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Rear Bumper Replacement TOOLS NEEDED 8mm Socket/Wrench Models: AX2, AX3, AX4 Estimated Completion Time: 15 Minutes Part# Y1-024 INSTRUCTIONS 1) Remove the Two- 8mm nuts attaching the bumper to the cart. 2) Remove bumper. 3) Reverse these steps to install a replacement bumper.

  • Page 69: Headlight Replacement (All Models)

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Headlight Replacement TOOLS NEEDED T25 Torx Models: All Models Estimated Completion Time: 15 Minutes Part# WY1-010A (Driver), WY1-010B (Pass) INSTRUCTIONS 1) Unplug the 4 pin wiring connector from the headlight. 2) Remove the four- T25 Torx screws. 3) Remove the headlight by pushing it forward out of the body. 4) Reverse these steps to reinstall the headlight, do not use a power tool to install the Torx screws as that may damage the threads in the plastic housing of the light. Refer to Torque tightening guide on page 5 for securing any hardware.

  • Page 70: Tail Light Replacement (Ax1)

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Tail Light Replacement TOOLS NEEDED Models: AX1 #2 Phillips Screwdriver 8mm Socket Estimated Completion Time: 30 Minutes Part# WY1-010C (Driver), WY1-010D (Pass) INSTRUCTIONS 1) Make sure that the key switch is off. 2) Using the phillips head screwdriver and the 8mm socket, remove the inner fender liner.
  • Page 71 SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES 3) Unplug the wiring harness connector from the tail light. 4) Using the #2 phillips screwdriver, remove the 4 screws attaching the light and push it out of the rear body. 5) Reverse these steps to install the tail light, do not use a power tool to reinstall the #2 phillips screws as that may damage the threads in the plastic housing of the light. Refer to Torque tightening guide on page 5 for securing any hardware.

  • Page 72: Tail Light Replacement (Ax2/Ax3)

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Tail Light Replacement TOOLS NEEDED #2 Phillips Screwdriver Models: AX2, AX3 Panel Removal Tool Estimated Completion Time: 15 Minutes Part# WY1-011C (Driver), WY1-011D (Pass) INSTRUCTIONS 1) Make sure that the key switch is off. 2) Using the panel removal tool remove the christmas tree rivet attaching the rear fender liner to the bumper. Gently pull back to expose the Connector and Tail Light. 3) Disconnect the harness connector from the tail light.
  • Page 73 SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES 4) Using the #2 phillips screwdriver remove the 4 screws attaching the tail light to the body. 5) Carefully push the tail light out of the body. 6) Reverse these steps to install the tail light, do not use a power tool to install the #2 phillips screws as that may damage the threads in the plastic housing of the light.

  • Page 74: Tail Light Replacement (Ax4)

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Tail Light Replacement TOOLS NEEDED #2 Phillips Screwdriver Models: AX4 Estimated Completion Time: 15 Minutes Part# WY1-011C (Driver), WY1-011D (Pass) INSTRUCTIONS 1) Make sure that the key switch is off. 2) Lift the rear seat bottom. 3) Unplug the wiring harness connector from the tail light.
  • Page 75 SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES 4) Using the #2 phillips screwdriver remove the 4 screws holding the tail light to the body. 5) Carefully push the tail light out of the body. 6) Reverse these steps to install the tail light, do not use a power tool to reinstall the #2 phillips screws as that may damage the threads in the plastic housing of the light.

  • Page 76: Turn Signal Replacement (All Models)

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Turn Signal Assy. Replacement TOOLS NEEDED #2 Phillips Screwdriver Models: All Models Panel Removal Tool Estimated Completion Time: 45 Minutes Part# WY1-010G INSTRUCTIONS 1) Remove the wireless phone charger pad and using the phillips head screwdriver remove the screw under the pad. 2) Using the panel removal tool carefully find the 6 tabs holding the cup holder panel and push them back with the tool to remove the cup holder panel.
  • Page 77 SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES 3) Remove the steering column cover and the cover for the turn signal stalk. 4) Using the #2 phillips screwdriver remove the 4 screws for the clamps holding the turn signal assembly to the steering column. 5) Follow the wiring down the steering column to the connector plugged into the harness and unplug connector. NOTE: Ensure harness does not get pinched when reattaching the turn signal assembly. 6) Reverse these steps to install a replacement turn signal switch.

  • Page 78: Top Replacement (All Models)

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Top Replacement TOOLS NEEDED 13mm Socket Models: All Models Panel Removal Tool Estimated Completion Time: 45 Minutes Part# J1-003, J1-004 (AX3) INSTRUCTIONS 1) Using the panel removal tool or screwdriver to remove the 8 plugs from the top of the front and rear struts. 2) Using the 13mm socket remove the 8 locknuts from the top bolts in the front and rear struts.
  • Page 79 SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES 3) Remove top from cart and remove the 8 bolts from the top. 4) Install the 8 bolts in the new top using the openings cut into the top track. 5) Align the bolts with the holes in the struts by sliding them in the tracks in the aluminum extrusions.
  • Page 80 SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES 6) The top spacing is measured from the rear of the horizontal top portion of the front strut to where the aluminum side track meets the plastic corner. For AX1 and AX2 carts use 12 1/4” for AX4 carts use 10 3/4”. 7) When the top is in the correct position install the eight lock nuts using the 13mm socket and reinstall the eight plugs. Refer to Torque tightening guide on page 5 for securing any hardware.

  • Page 81: Windshield Replacement (All Models)

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Windshield Replacement TOOLS NEEDED 10mm Socket/Wrench Models: All Models Estimated Completion Time: 30 Minutes Part# J1-005 INSTRUCTIONS 1) Using a10mm socket and wrench remove the two bolts at the base of the windshield then remove the cross bar at the base of the windshield. Note: The orientation of the holes in the mounting brackets at the end of the cross bar, they should be on the top side of the bar when reinstalling. 2) With the windshield folded down carefully remove the plastic clips by pushing them forward so they unclip from the front strut. 3) Reverse these steps to install the replacement windshield and cross bar. Refer to Torque tightening guide on page 5 for securing any hardware.

  • Page 82: Speaker Replacement (All Models)

    SIERRA LSV SERVICE MANUAL BODY & ACCESSORIES Speaker Replacement TOOLS NEEDED #2 Phillips Screwdriver Models: All Models Estimated Completion Time: 15 Minutes Part# WG1-008 INSTRUCTIONS 1) Using a #2 phillips screwdriver remove the four- #2 phillips screws attaching the speaker. 2) Pull the speaker into the dash compartment and disconnect the 2 connectors. 3) Reverse these steps to install the replacement speaker.

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