Motor Removal - Club Car Gasoline Service Manual

MOTOR REMOVAL

WARNING
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL ELECTRICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL
WARNINGS STATED IN THIS MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY PRIOR TO SERVICING.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON-
NECTIONS.
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT THE BATTERIES AS
SHOWN IN FIGURES 22-5 AND 22-6, PAGE 22-5.
• ON POWERDRIVE SYSTEM 48 VEHICLES, DISCHARGE THE CONTROLLER AS INSTRUCTED
IN THE WARNING ON PAGE 24-1
1. Disconnect the battery cables negative cable first (Figure 22-5 or 22-6, Page 22-5).
2. Using two wrenches to prevent the stud from turning, disconnect the motor wires. Label them so they
will be reconnected properly.
NOTE
• TAG THE MOTOR WIRES FOR IDENTIFICATION BEFORE DISCONNECTING THEM.
3. Slightly loosen all the lug nuts on both rear wheels.
4. Place a floor jack under the transaxle and raise the rear of the vehicle (Figure 24-2), then place jack-
stands under the frame cross-member between the spring mount and the side stringer, just forward of
each rear wheel. Then lower the vehicle to let the jackstands support the vehicle (Figure 24-3). See
WARNING below.
WARNING
• LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES AND
CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE
(CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454 KG.) MINIMUM LIFTING
CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS
USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE.
5. Remove both rear wheels.
6. Remove the nut, cup washer, and bushing from the bottom side of the shock absorber. Compress the
shock absorber (pushing upwards) to move it out of the way.
7. Remove the nuts and bolts mounting the rear leaf springs to the shackles (Figure 24-4, Page 24-4).
24
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Page 24-3