1992 EZGO RXV ELECTRIC SERVICE & REPAIR MANUAL 611103 – PDF DOWNLOAD

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1992 EZGO RXV ELECTRIC SERVICE & REPAIR MANUAL 611103 – PDF DOWNLOAD

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1992 EZGO RXV ELECTRIC SERVICE & REPAIR MANUAL 611103 – PDF DOWNLOAD

Language : English
Pages :192
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

1992 EZGO RXV ELECTRIC SERVICE & REPAIR MANUAL 611103 – PDF DOWNLOAD

E-Z-GO Division of TEXTRON, Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice 0
E-Z-GO Division of TEXTRON, Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual 0
GENERAL INFORMATION 0
SERVICE AND REPAIR MANUAL 0
ELECTRIC POWERED 0
GOLF CARS & PERSONAL VEHICLES 0
RXV FLEET GOLF CAR 0
RXV FREEDOM GOLF CAR 0
RXV SHUTTLE 2+2 0
STARTING MODEL YEAR 2008 0
BATTERY PROLONGED STORAGE 0
P-LIGHTNING AND GROUND-29junepdf 0
1 Grounding Requirements 0
2 Ground Systems 0
3 Lightning Protection Requirements 0
4 Equipment Fault and Personal Safety System 0
5 Ground Network Requirements 0
6 External Grounding Requirements 0
7 Materials 0
8 Earth Electrode System 0
9 Lightning Protection System 0
10 Equipment Fault and Personal Safety System 0
D-TOC AND WHEELS 14DEC07pdf 0
WHEEL AND TIRE SERVICE 0
Tire condition should be inspected per the Periodic Service Schedule Inflation pressures should be checked when the tires are c 0
Use caution when inflating tires Due to the low volume of these small tires, over inflation can occur in a matter of seconds O 0
Tire Repair 0
The vehicle is fitted with low pressure tubeless tires mounted on one piece rims 0
Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel 0
If the tire is flat, remove the wheel and inflate the tire to the maximum recommended pressure for the tire Immerse the tire in water to locate the leak and mark with chalk Insert tire plug in accordance with manufacturer’s specifications 0
Wheel Installation 0
It is important to follow the ‘cross sequence’ pattern when installing lug nuts This will assure even seating of the wheel against the hub 0
With the valve stem to the outside, mount the wheel onto the hub Install lug nuts (1) finger tight; make sure that the tapered 0
Fig 1 Tire Mounting & Cross Sequence for Tightening 0
J-TOC AND BRAKES-17dec07pdf 0
Fig 1 Brake Pedal 0
GENERAL 0
For information on the Motor Brake see the Motor section of this manual, Section G 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
The recommended method for removing christmas tree rivets is to slide a notched pry bar under the head of the rivet and press downward on the bar to pull the rivet from the hole 0
Fig 2 Christmas Tree Rivet Removal 0
The brake pedal assembly is a modular unit that contains the brake pedal, a rotary position sensor and a brake switch The only 0
Brake Pedal Assembly 0
To access the pedal assembly, remove the upper rocker panels, the lower rocker panels and the floormat (refer to page C2 for removal of rocker panels and floormat) 0
1 Remove four christmas tree rivets (20) securing pedal cover (21) to floorboard 0
2 Remove pedal cover (21) 0
Fig 3 Pedal Cover 0
3 Mark the position of the retaining nut (12) on the threaded portion of the pedal return spring rod 0
4 Loosen the retaining nut (12) to release the spring tension 0
5 Disconnect the brake pedal return spring (2) by removing the E-ring (3) and the clevis pin (1) 0
Fig 4 Brake Pedal Return Spring 0
6 Remove four socket head hex screws (6) securing the brake pedal assembly to the floorboard (Ref Fig 5) 0
7 Disconnect the wires from the rotary position sensor (8) and the brake enable switch (9) 0
8 Remove the two Torx screws (6) from the rotary position sensor (7) and remove sensor 0
9 Remove the two Torx screws (11) from the throttle enable switch (10) and remove the switch 0
10 Align the slot in the rotary position sensor (8) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (9) Use Loctite® 242, according to product instructions, with the two Torx screws (8) 0
Fig 5 Brake Pedal 0
11 Position the brake switch (10) oriented as shown, secure in place with two Torx screws (11) Use Loctite 242, according to product instructions, with the two Torx screws (11) 0
12 Reconnect electrical harness to rotary position sensor (8) and to the brake switch (10) 0
13 Place pedal assembly (5) in position on the floorboard and secure with four socket head hex screws (6) 0
14 Install the clevis pin (1) through the brake pedal return spring arm (2) and secure with the E-clip (3) 0
15 Tighten the return spring retaining nut (12) to the position marked 0
16 Install the pedal cover (21), using new christmas tree rivets (20), replace the floormat and rocker panels‘ 0
‘ 0
K-Electrical Wiring-11march08pdf 0
Fig 1 Main Electrical Harness 0
MAIN WIRING HARNESS 0
Replacing the Main Wiring Harness 0
1 Disconnect the main wiring harness from the battery pack using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run’ position, turn the key switch to reverse, 0
3 Locate the tab under the cowl that extends from the instrument panel through a slot in the cowl, squeeze the legs of the tab 0
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 2 Instrument Panel & Trim 0
6 Remove the wiring harness from the front splash shield retaining clips 0
7 If vehicle is equipped with brake lights, disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder 0
8 Remove the Diagnostic Plug from the bottom of the cup holder 0
9 Disconnect the plug to the throttle enable switch 0
10 Disconnect the plug from the rotary position sensor 0
11 Disconnect the plug from the brake enable switch 0
12 Disconnect the wires from the rotary position sensor 0
13 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
14 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
15 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
16 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
17 Remove two Torx head screws securing the controller splash shield to the rear body and the christmas tree rivet securing it to the controller heat sink, raise splash shield and move it out of the way 0
18 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
19 Unplug the large 23 pin connector (3) from the controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
20 Disconnect the plug for the resistor as well as the plug to the sensor on top of the resistor 0
Fig 3 Controller 0
21 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through 0
Fig 4 Run / Tow Switch 0
22 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
Fig 5 Reverse Warning Indicator 0
23 Remove hex nuts (16) and disconnect the red wire to the positive battery, BL+, terminal (20) and the yellow wire (17) to the 0
Fig 6 Solenoid Removal 0
24 Remove two hex head bolts (22) securing the solenoid (18) to the controller heat sink 0
25 Unplug the connectors from the motor brake (23), the motor temperature sensor (24) and the motor sensor (25) 0
Fig 7 Motor Connections 0
26 Remove main wiring harness from the vehicle 0
27 Install new main wiring harness making sure that it follows the proper path 0
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1, 2 & 3) 0
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels 0
Fig 8 Harness Routing & Pedal Connections 0
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4) 0
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6) 0
e) Connect the wires to the brake pedal rotary position sensor (8) and the brake enable switch connector (9) 0
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10) 0
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel 0
h) Feed the connectors for the key switch, the optional fuel gauge/state of charge meter and the diagnostic plug through the ope 0
Fig 9 Cup Holder 0
i) Route the wires (14) for the key switch and the optional fuel gauge/state of charge meter through the guide (15) on the front 0
l 0
Fig 10 Front Splash Shield 0
j) Connect the wire harness to the key switch 0
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side 0
l) Plug the connector (20) for the charger receptacle into the connector on the main wiring harness 0
Fig 11 Charger Receptacle 0
m) Install the Red wire (23) to the B+ terminal of the controller (Do not over tighten the terminal screw (24)) 0
n) Install the solenoid (25) on the controller heat sink using two hex head bolts (26) Make sure that the black wires from the solenoid to the wire harness are located at the top of the solenoid 0
o) Connect the Red wire (23) from the controller B+ to the bottom terminal of the solenoid (25), using a slim wrench to keep the 0
0
Fig 12 Controller Connections 0
p) Plug the 23 pin connector (3) from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
0
Fig 13 23 Pin Connector 0
q) Plug the connectors for the motor brake (31), the motor temperature sensor (32) and the motor sensor (33) into the connectors on the motor and motor brake 0
0
Fig 14 Motor Connections 0
18 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10) 0
19 Press the fuse holder (12) into the hole on the controller splash shield 0
Fig 15 Reverse Warning Indicator & Fuse 0
20 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notc 0
Fig 16 Run / Tow Switch 0
21 Replace the controller splash shield and secure it to the body with two Torx head screws 0
22 Connect the negative battery wires using an insulated wrench 0
23 Connect the positive battery wires using an insulated wrench 0
24 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL COMPONENTS 0
Run / Tow Switch (Ref Fig 17 on page K-6) 0
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench 0
2 Remove two Torx head screws and the christmas tree rivet securing the controller splash shield to the rear body, raise splash shield and turn over to expose the switch and wires 0
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts 0
4 Cut the wires from the existing run/tow switch close to the switch 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness 0
6 Remove the upper nut and seal (7) from the new switch (8) 0
7 Install the switch (8) with the notch towards the RUN direction 0
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table 0
Fig 17 Run / Tow Switch 0
9 Install the splash shield using the two Torx screws to secure the shield to the body and a new christmas tree rivet 0
Reverse Warning Indicator (Ref Fig 18 on page K-7) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove two Torx head screws securing the controller splash shield to the rear body, then remove the christmas tree rivet secu 0
3 Remove the two torx head screws (5) securing the reverse warning indicator (4) to the splash shield 0
4 Cut the wires close to the reverse warning indicator (4) 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (4) to the wire harness 0
6 Secure the new reverse warning indicator (4) to the splash shield with the torx head screws (5) 0
7 Reinstall the splash shield 0
Fig 18 Reverse Warning Indicator 0
Fig 19 Main Wiring Harness 0
Fig 20 Accessory Wiring Harness 0
Fig 21 Accessory Wiring Harness and Accessories 0
ACCESSORY WIRING HARNESS 0
Replacing the Accessory Wiring Harness 0
1 Using an insulated wrench disconnect the accessory harness from the battery pack 0
2 Unplug the red and purple wires from the brake light relay to the main harness 0
3 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn, fuel gage (state of charge meter) and brake lights 0
4 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder 0
5 Remove the three fuse holders from the controller splash shield 0
6 Disconnect the tail light wiring connectors 0
7 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
8 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
9 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
10 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
11 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
12 Remove the accessory wiring harness from the vehicle 0
13 Install new accessory wiring harness making sure that it follows the proper path 0
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that 0
b) Route the wires for the headlight switch and the fuel gauge/state of charge meter through the opening in the instrument panel and connect them to the headlight switch and fuel gauge 0
c) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle 0
d) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn 0
e) Connect the horn button connector to the accessory harness under the cup holder 0
f) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmastree rivet (2) 0
0
Fig 22 Brake Light Relay 0
g) Connect the red and purple wires from the accessory harness to the matching wires from the main wire harness 0
h) Route the rest of the harness down through the cup holder and in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor 0
i) Route the wires and connector for the driver side brake light between the rear body and the battery pack and around the drive 0
j) Route the fuses and the passenger side brake light wires between the rear body and the battery pack 0
k) Snap the fuse holders into the holes on the controller splash shield 0
l) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light 0
13 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL ACCESSORIES 0
Head Light Replacement 0
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward 0
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward 0
3 Disconnect the accessory harness connector (5) from the headlight (3) and turn signal (4) 0
0
Fig 23 Headlight Assembly 0
4 To install the headlight assembly, connect the accessory harness connection (6) to the turn signal (4) and the accessory harness connection (5) to the headlight bulb (3) 0
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position 0
Head Light Bulb Replacement 0
1 Turn the headlight bulb (3) clockwise and pull to remove 0
2 Disconnect the accessory harness from the light bulb 0
3 Connect the accessory harness to the light bulb 0
4 Align the bulb with the opening in the back of the headlight assembly 0
5 Turn the bulb (3) counter clockwise until it stops 0
Turn signal Bulb Replacement 0
1 Grip the turn signal bulb housing (7) and turn to align with slot then pull backward to remove housing from headlight assembly 0
Fig 24 Turn Signal Bulb Replacement 0
2 Remove bulb from housing and replace with a new one 0
3 Align housing with slot and insert turn signal housing (7) into headlight assembly, turn to lock in place 0
Head Light Switch Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel 0
Fig 25 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the head light switch (13) 0
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11) 0
Fig 26 Head Light Switch 0
4 Insert the new head light switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the accessory harness (12) to the headlight switch (13) 0
6 Push the instrument panel trim into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Turn Signal Switch Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the connector from the turn signal switch harness to the main electrical harness 0
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder 0
4 Remove the plastic cover from the steering column 0
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw 0
6 Remove the turn signal switch assembly including the clamp 0
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column 0
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape 0
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column 0
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove 0
11 Route the wire harness under the floor mat to the cupholder 0
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet 0
13 Plug the turn signal wire harness connector into the accessory wire harness 0
Turn signal Flasher Unit Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the flasher unit from the turn signal wire harness 0
3 Install the new flasher unit in the wire harness receptacle 0
4 Replace the top part of the cup holder (ref Section B) 0
Tail Light Assembly Replacement 0
1 Remove the four Torx head screws (15) that secure the tail light assembly (16) to the rear body 0
2 Pull the tail light (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17) 0
Fig 27 Tail Light Assembly 0
3 Plug the new tail light assembly (15) into the accessory wire harness connector (16) and push the tail light assembly (16) into the opening 0
4 Install the four Torx head screws (15) 0
Tail Light Lens Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Install the new lens and secure in place with the two phillips head screws 0
Tail Light Bulb Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Remove the light bulb 0
3 Install the new light bulb 0
4 Install the lens and secure in place with the two phillips head screws 0
Horn Button Replacement 0
1 Remove the horn button cover using a flat blade to work the cover off of the switch 0
2 Pull the upper corner of the floormat down to expose the switch retaining nut 0
3 Remove the nut that secures the horn button 0
4 Remove the horn button switch from the floor1board 0
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch 0
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder 0
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame 0
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness 0
9 Replace the floormat and install the horn button cover 0
Horn Replacement 0
1 Disconnect the accessory wire harness from the horn 0
2 Remove the hex head bolt that secures the horn to the mounting bracket 0
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt 0
4 Connect the accessory wire harness to the horn 0
State of Charge / Fuel Gauge Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel 0
Fig 28 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20) 0
3 Depress the tabs on the fuel gage/state of charge meter (20) and push the unit out of the trim panel (11) 0
Fig 29 Fuel Gage/State of Charge Meter 0
4 Insert the new fuel gage/state of charge meter (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the accessory harness (21) to the fuel gage/ state of charge meter (20) 0
6 Push the instrument panel trim (11) into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Q-Specification-19march08pdf 0
RXV ELECTRIC – FLEET VEHICLE SPECIFICATIONS 0
RXV ELECTRIC – FREEDOM VEHICLE SPECIFICATIONS 0
RXV ELECTRIC – SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS 0
Fig 1 Fleet & Freedom Vehicle Dimensions 0
Fig 2 Shuttle 2 + 2 Vehicle Dimensions 0
Fig 3 Vehicle Incline Specifications and Turning Diameter 0
Fig 4 Powerwise QE 48V Charger 0
Front Cover Warningpdf 0
SAFETY 0
L-REAR SUSPENSION-25july08pdf 0
Fig 1 Rear Suspension 0
GENERAL 0
In the following text, there are references to removing/installing hardware (nuts, bolts, screws, washers, etc) Hardware that 0
SHOCK ABSORBER (Ref Fig 2) 0
1 Remove the two Torx head screws that secure the rear access panel 0
2 Remove the rear access panel 0
3 Raise the rear of the vehicle in accordance with the instructions provided in Section B of this manual and support the rear of the vehicles on the outer ends of the rear bumper 0
4 Remove the hex head bolt (5) and washer (4) from the lower end of the shock absorber 0
5 Remove the hex head bolt (1) and washer (2) from the upper end of the shock absorber 0
Fig 2 Shock Absorber 0
6 Install the hex head bolt (1) and washer (2) for the upper shock mount, make sure that the shock (3) is oriented as shown 0
7 Install the hex head bolt (5) and washer (4) through the lower end of the shock (3) into the mounting bracket on the axle 0
REAR LEAF SPRING (Ref Fig 3) 0
If both leaf springs are to be replaced and the rear axle is not being removed, it is important to remove and replace one leaf spring at a time It is recommended that leaf springs be replaced in pairs 0
Removal 0
1 Raise the rear of the vehicle in accordance with the instructions provided in Section B of this manual 0
2 Place a floor jack under the center section of the rear axle and raise the jack just enough to place a second set of jack stands under the axle tubes 0
3 Remove the two hex nuts (3) from the U-bolt (1) on the axle allowing the leaf spring plate (2) to slide off of the U-bolt 0
4 Remove the hex head bolts (15) and nuts (11) from the shackle plates (12) at the rear of the frame Remove the flanged urethane bushings (13) and spacers (14) as well 0
5 Remove the hex head bolt (7) and nut (4) from the forward leaf spring mounting bracket The leaf spring (16) can now be removed from the vehicle 0
6 Remove the flanged urethane bushings (6) and the spacer (5) from the leaf spring 0
Installation 0
7 Apply a commercially available anti-seize compound to the large flanged urethane bushings (6) 0
8 Install the large flanged urethane bushings (6) and spacer (5) in the end of the leaf spring (16) and place the leaf spring in the forward mounting bracket 0
9 Install the hex head bolt (7) and nut (4) to secure the forward end of the leaf spring in the bracket 0
10 Apply a commercially available anti-seize compound to the flanged urethane bushings (13) 0
11 Install one set of the smaller flanged urethane bushings (13) and spacer (14) in the rear frame mounting holes 0
12 Position the shackle plates (12) over the bushings and install the hex head bolt (15) and nut (11) 0
13 Install the remaining pair of flanged urethane bushings (13) and spacer (14) in the leaf spring (16) Position the leaf spring between the shackle plates (12) and install the hex head bolt (15) and nut (11) 0
14 Align the pin on the leaf spring (16) with the hole in the axle bracket and install the leaf spring plate (2) on to the U-bolt (1) Secure plate in place with two hex nuts (3) and tighten both nuts equally to the specified torque 0
15 Torque all hardware as specified making sure that the leaf spring pin remains aligned with the holes in the axle mounting bracket and the leaf spring mounting plate 0
Fig 3 Rear Leaf Spring 0
O-Diagnostics and Troubleshooting-19aug08pdf 0
HOW TO USE THE HAND HELD DIAGNOSTIC UNIT 0
Fig 1 Hand Held Diagnostic Unit 0
MENUS 0
DIAGNOSTICS REPORT (real time read only) 0
1 BATTERY VOLTAGE: displayed as ’VOLTAGE’, the next line displays ’HIGH’, the actual voltage or ’LOW’ in tenths of a volt 0
0
2 CALCULATED BATTERY CURRENT: displayed as ’CURRENT’, the next line displays calculated current as ’LOW’, the actual number in DC Amps or as ’HIGH’ 0
3 STATE OF CHARGE: displayed as ’SOC’, the next line displays the state of charge for the battery pack as ’NORMAL’ or ’LOW BATT’ 0
4 THROTTLE SENSOR VOLTAGE: displayed as ’THROTVOLT’, the next line displays the sensor voltage as ’LOW’, ’NORMAL’ or ’HIGH’ 0
5 THROTTLE SWITCH POSITION: displayed as ’THROTTLESW’, the next line displays the switch voltage as ’NORMAL’ or ’HIGH’ 0
0
6 BRAKE SENSOR VOLTAGE: displayed as ’BRAKEVOLT’, the next line displays the sensor voltage as ’LOW’, ’NORMAL’ or ’HIGH’ 0
7 BRAKE SWITCH POSITION: displayed as ’BRAKE SW’ the next line displays the switch voltage as ’NORMAL’ or ’HIGH’ 0
0
8 MOTOR COMMAND SPEED: displayed as ’CMDSPEED’, the next line displays the speed in RPMs (revolutions per minute) that is being requested of the motor by the pedal position 0
9 MOTOR ACTUAL SPEED: displayed as ’ACTSPEED’, the next line displays the actual motor speed in RPMs 0
0
10 MOTOR CURRENT: displayed as ’AC CURRENT’, the next line displays the AC current in Amps 0
11 MOTOR TEMPERATURE: displayed as ’MOTORTEMP’, the next line displays the internal motor temperature in C 0
12 FORWARD SWITCH: displayed as ’FWD SWITCH’, the next line displays the switch position as ’ON’ or ’OFF’ 0
13 REVERSE SWITCH: displayed as ’REV SWITCH’, the next line displays the direction selection as ’ON’ or ’OFF’ 0
14 RUN TOW SWITCH POSITION: displayed as ’RUN TOW SW’, the next line displays the position of the run/tow switch as ’RUN’ or ’TOW’ 0
0
15 REVERSE WARNING BUZZER: displayed as ’BUZZER’, the next line displays the buzzer state as ’ON’ or ’OFF’ 0
16 SOLENOID: displayed as ’SOLENOID’, the next line displays the solenoid state as ’ON’ or ’OFF 0
’ 0
17 ELECTRIC BRAKE CURRENT: displayed as ’EBRAKECURR’, the next line displays the brake current as a three place decimal in Amps; the brake current displayed below is 3 milliAmps 0
BATTERY AND WARRANTY (read only) 0
0
1 STATE OF BATTERY CHARGE: displayed as ’SOCBATT’, the next line displays the battery pack state of charge; the battery pack state of charge shown below is 85% 0
2 TOTAL AMP-HOURS: displayed as ’TOTAL AH’, this is the total Amp-Hours used for the life of the car 0
3 TOTAL MINUTES: displayed as ’TOTAL’, this is the total running time of the vehicle, the next line displays the hours 0
0
4 TOTAL ROUNDS: displayed as ’EST TOTAL RNDS’, the next line displays the number of rounds as calculated based on 42 minutes running time per round played 0
5 CHARGE CONSUMED: displayed as ’CHARGE’, the next line displays the total charge consumed in kw-hrs 0
0
0
ERROR MESSAGES 0
0
WARNING MESSAGES 0
SETTING TOP SPEED AND PERFORMANCE PROFILES (read and write) 0
COURSE ENERGY CONSUMPTION (read only) 0
DIGITAL VOLT OHM METER 0
Fig 2 DVOM 0
TROUBLESHOOTING 0
ACCESSORY WIRING HARNESS 0
POWER SUPPLY 0
Check For Loose or Bare Wires 0
If any DVOM readings indicate a faulty wire, it is recommended that the condition of the terminals and wire junction be examined 0
Check Battery Condition 0
B-SAFETY-15sep08pdf 0
NOTES, CAUTIONS AND WARNINGS 0
A NOTE indicates a condition that should be observed 0
IMPORTANT SAFETY WARNING 0
MODIFICATIONS TO VEHICLE 0
GENERAL MAINTENANCE 0
BEFORE SERVICING THE VEHICLE 0
Additional Warnings 0
Fig 1 Attach Accessory Wires to Battery Pack 0
Fig 2 Batteries, Charger Receptacle & Controller 0
BATTERY REMOVAL & INSTALLATION 0
The following text, there are references to removing/installing bolts, etc Additional hardware (nuts, washers, etc) that is re 0
1 Turn vehicle key to the off position and remove the key 0
2 Using an insulated wrench, disconnect the main negative (-) battery cable, BL- 0
3 Using an insulated wrench, disconnect the main positive (+) battery cable, BL+ 0
4 Using an insulated wrench, disconnect and remove all other wires connected to the batteries 0
5 Remove the two pan head Torx screws, (one on each side) from the battery strap 0
6 Remove the battery hold down and the battery strap by loosening all three hex nuts until they are at the end of the J-bolt an 0
7 Remove the batteries using commercially available battery carrier straps (2 per battery) and a portable lifting device Remov 0
Fig 3 Battery Removal 0
8 Check the area surrounding the battery tray for corrosion If any corrosion is found, it should be immediately removed with a 0
9 Replace the batteries, starting with the battery located at the back of the battery tray (4), making sure that it is positioned as shown 0
0
Fig 4 Battery Placement & Orientation 0
10 With the J-bolts in the battery hold down and held in place by the hex nuts on the end of the threaded portion; carefully po 0
11 Install the two pan head Torx screws through the ends of the battery strap into the holes on the vehicle frame and tighten them to 80 – 97 in lbs (9 – 11 Nm) torque 0
12 Inspect all wires and terminals and clean any corrosion from the battery terminals or wire terminals with a solution of baking soda and water, use a wire brush to completely remove corrosion if required 0
13 Carefully replace the wires on the battery terminals as shown Make sure to reconnect the main negative (-) battery cable, BL-, from the controller last 0
Fig 5 Battery Hold Down 0
Fig 6 Battery Connections 0
14 Tighten all battery terminal hardware to 95 – 105 in lbs (11 – 12 Nm) torque 0
15 Protect the battery terminals and battery cable ends with a commercially available protective coating 0
LIFTING THE VEHICLE 0
Fig 7 Lifting Points 0
A3-GENERAL INFO-15sep08pdf 0
SERIAL NUMBER LOCATION 0
Fig 1 Serial Number Location on Steering Column 0
Fig 2 Serial Number on Front Frame 0
Fig 3 Serial Number on Rear Frame 0
0
Fig 4 Initial Service Chart 0
Towing 0
If a vehicle is towed in excess of 15 mph the motor brake will engage and slow the vehicle down 0
Servicing The Vehicle 0
Routine Maintenance 0
Rear Axle 0
Tires 0
Vehicle Cleaning And Care 0
Sun Top And Windshield 0
Hauling 0
T 0
HARDWARE 0
CAPACITIES AND REPLACEMENT PARTS 0
Fig 5 Capacities 0
Fig 6 Replacement Part 0
Fig 7 Torque Specifications and Bolt Grades 0
PERIODIC SERVICE SCHEDULE 0
3 – CHECK C&A – CHECK & ADJUST CL – CLEAN R – REPLACE 0
Fig 8 Periodic Service Schedule 0
C-BODY-15sep08pdf 0
Fig 1 Body 0
GENERAL 0
Vehicle accessories, such as the sun top and windshield, need to be removed before removing many body components 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
Fig 2 Christmas Tree Rivet Removal 0
BODY COMPONENT REPLACEMENT 0
Front Bumper and Cowl Support (Ref Fig 3) 0
1 Remove two phillips head screws (15) securing the cowl support (14) to the bumper 0
2 Remove two hex nuts (11) securing the top of the bumper to the front strut mounting bolts 0
3 Pull top of bumper (12) forward and off of the bolts then lift upward to clear the frame channel between the front struts and pull the lower edge of the bumper down and away from the vehicle 0
4 Remove the washers (13) 0
Fig 3 Front Bumper and Cowl Support 0
Rocker Panels (Ref Fig 4) 0
1 Remove the lower rocker panel (1) by removing three torx screws (3) 0
2 Remove the upper rocker panel (2) by removing the two remaining torx screw (3) 0
Fig 4 Rocker Panel Removal 0
Floor Mat (Ref Fig 5) (Ref Fig 6) 0
1 Remove six christmas tree rivets (5) securing the floor mat to the floorboard (4) (Ref Fig 5) 0
2 Pull edge of floor mat from under edge of instrument panel and lift over accelerator and brake pedals 0
I 0
Fig 5 Floor Mat Fastener Removal 0
Fig 6 Floor Mat 0
Cowl and Instrument Panel (Ref Fig 7) (Ref Fig 8) 0
1 Remove four torx screws (11) securing the trim panel (12) to the instrument panel (13) and cowl (14) 0
2 Locate the tab in the fender well area, under the cowl The tab extends from the instrument panel through a slot in the cowl, 0
3 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
4 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 7 Cowl and Instrument Panel Trim 0
5 Remove three self threading nuts (20) securing the cup holder assembly (15) to the instrument panel Remove the cup holder an 0
Fig 8 Instrument Panel and Cup Holder 0
6 Remove four torx screws (16) and flat washers (17) securing the instrument panel along its lower edge and the two torx screws (18) located near the top of the instrument panel; one on each side The instrument panel can now be removed 0
Front Splash Guard (Ref Fig 9) 0
1 Remove two christmas tree rivets (22) securing front splash guard (21) to vehicle(Ref Fig 2) 0
Fig 9 Front Splash Guard 0
Fig 10 Golf Car Rear Body, Sweater Basket, Rear Bumper & Fender Liner 0
Sweater Basket (Ref Fig 10) 0
1 Remove four torx screws (28) and flanged nuts (29) on the top edge of the sweater basket assembly (27) 0
2 Remove two torx screws (30) securing the back of the sweater basket to the seat back supports 0
3 Slide the sweater basket assembly (27) off the seat back supports 0
Seat Back Assembly 0
1 Remove four torx screws (26) that secure the seat back assembly (25) to the support struts 0
Fender Liner (Ref Fig 2) (Ref Fig 10) 0
1 Remove four christmas tree rivets (42) that secure the liner (41) to the frame of the vehicle Two christmas tree rivets are located on the lower front edge of the fender liner, the two remaining are located along the inside surface above the wheel 0
Rear Body (Ref Fig 10) 0
1 Raise and remove the seat bottom assembly from the vehicle Remove four torx screws (26) securing the seat back (25) to the seat back supports 0
2 Using an insulated wrench, disconnect the battery cable at the negative (-), BL-, battery terminal 0
3 Remove the two Torx head screws that secure the controller splash shield to the body on the passenger side of the vehicle 0
4 Remove the two strut covers (36) by sliding the covers up and off of the struts 0
5 Disconnect the wires from the charging receptacle to the battery and unplug the wire to the main wiring harness If vehicle is equipped with an on board battery charger skip this step 0
6 Remove two torx screws (33) securing each hinge plate (32) along the front edge of the rear body then remove both hinge plates 0
7 Remove two inner torx screws (34) from the back edge of seat opening in the rear body 0
8 Remove four torx screws (31) from the lower edge of the rear body, two on the driver side and two on the passenger side 0
9 Remove two torx screws (35) from the bagwell floor 0
10 Lift the rear body, pivot the seat opening upward and towards the back of the vehicle to clear the seat back supports 0
Rear Bumper (Ref Fig 10) 0
1 Remove two torx head screws (item 35) from the bag well floor If the rear body has been removed from the vehicle go to step 2 0
2 Remove four hex head bolts (37) securing the bumper to the vehicle frame 0
3 Pull the rear bumper backwards off the frame; lifting the rear edge of the body may make removal easier 0
Fig 11 2 + 2 Rear Facing Seat & Foot Rest 0
2 + 2 Rear Facing Seat & Foot Rest 0
1 Remove four hex head bolts (10) that secure the seat bottom to the hip restraints 0
2 Lift the seat bottom (11) up and remove it from the vehicle 0
Fig 12 Rear Facing Seat Bottom 0
3 Loosen the torx head bolts (23) and nuts (22) (Ref Fig 15) that secure the seat back mounting brackets and hip restraint to the seat back support (14) 0
4 Slide the seat back assembly (15) with the brackets attached towards the back of the vehicle and remove it from the vehicle 0
5 To separate the seat back assembly (15) from the mounting brackets (16) remove the four torx head screws (17), two from each bracket 0
Fig 13 Rear Facing Seat Back 0
6 Remove the hex head bolt (20) and nut (21) from the lower leg of the driver side hip restraint 0
Fig 14 Rear Facing Seat Hip Restraint 0
7 Remove the hex nuts (22) from the torx head bolts (23) that secure the driver side hip restraint to the seat back support 0
8 Hold or support the hip restraint before removing the torx head bolts (23), once these bolts are removed the hip restraint is free from the vehicle 0
Fig 15 Upper Hip Restraint Bolts 0
9 Repeat steps 6 – 8 for the removal of the passenger side hip restraint 0
10 Remove four torx head bolts (25) that secure the front seat back to the seat back support bracket 0
Fig 16 Front Seat Back 0
11 Remove two torx head bolts (28) from the bagwell floor 0
Fig 17 Rear Facing Seat Foot Rest 0
12 Loosen four hex head bolts (30) Support the rear foot rest (29) before removing the two bolts closest to the rear of the ve 0
Fig 18 Foot Rest Removal 0
13 Remove four hex head bolts (31) and nuts (32) that secure the seat back support (33) to the frame, slide the seat back support up until it clears the rear body 0
Fig 19 Seat Back Support 0
Floorboard 0
1 Remove the two Torx screws (44) securing the front seat support frame (45) to the floorboard (48) 0
2 Remove two Torx socket head cap screws (46) and washers (47) that secure the floorboard (48) to the vehicle frame 0
Fig 20 Front Seat Support and Floorboard 0
BODY CARE MAINTENANCE 0
Cleaning 0
1 Wet the body with a low pressure hose to rinse off any loose dust and dirt 0
2 Wash the vehicle with a solution of mild soap and water using a soft cotton cloth Do not use abrasive cleaners or solvents 0
3 Apply clear coat safe automotive car wax to revive lost luster as needed Test the wax on an inconspicuous area before applying to the entire vehicle Buff the wax by hand Do not use a power buffer to remove wax from the body panels 0
PAINTING 0
Light Scratches 0
1 Clean the area to be repaired with clean, clear water 0
2 Using 1200 grit sandpaper, water sand the entire area of the scratch in a circular motion, spraying with water as needed, until the original scratch is no longer visible 0
3 Wipe the area dry and visually inspect to be sure that the original scratch has completely disappeared 0
4 Using 1500 grit sandpaper, wet sand the area until all of the marks left by the 1200 grit sandpaper are gone, pay close attention to the edges of the sanded area 0
5 Using the buffer with the 3-M 39001 compound on the foam pad, turn the buffer on at slow speed Use a cris- crossed pattern t 0
6 Using the buffer with the 3-M 39003 or 3-M 05995 Polishing glaze (depending upon the color of the vehicle body) on the foam p 0
7 Wipe with a clean, soft cloth to remove any compound from the surrounding area Any dirt on the cloth may mar the surface 0
Minor Scratches 0
1 Thoroughly clean the surface to be repaired with alcohol and dry 0
2 Touch up damaged area with sequential coats (two coats minimum recommended, allowing 30 – 45 minutes between coats, increasin 0
3 Use 1200 grit “wet” sand paper to blend touch up area level with the rest of the part being repaired Use a polishing compound to renew gloss and to further blend and transition newly painted surface 0
4 Clean with alcohol and dry 0
5 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 0
6 Wax or polish with Carnauba base product, available at any automotive parts distributor 0
Larger Scratches 0
1 Thoroughly clean the surface to be repaired with alcohol and dry 0
2 Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type touch- up paint 0
3 Apply spray touch up paint in light, even, overlapping strokes Multiple coats may be applied to provide adequate coverage and finish Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best color match 0
4 After painting, allow to dry overnight Smooth the mask lines using 1200 grit “wet” sand paper to blend touch up area level w 0
5 Clean with alcohol and dry 0
6 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 0
7 Wax or polish with Carnauba base product, available at any automotive parts distributor 0
Complete Panel Repair 0
Most paint manufacturers can perform a computer paint match to assure accurate color matching 0
E-ELEC SPEED CONTROLLER-15sep08pdf 0
Fig 1 Electronic Speed Control 0
GENERAL 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
The recommended method for removing christmas tree rivets is to slide a notched pry bar under the head of the rivet and press downward on the bar to pull the rivet from the hole 0
Fig 2 Christmas Tree Rivet Removal 0
The Electronic Speed Control System consists of two separate units, the accelerator pedal assembly and the controller 0
Fig 3 Pedal Cover 0
Accelerator Pedal Assembly 0
The accelerator pedal assembly is a modular unit, the only serviceable items contained in the assembly are the pedal pad, the rotary position sensor and the throttle enable switch The complete pedal assembly may be replaced as a unit 0
To access the pedal assembly, remove the upper rocker panels, the lower rocker panels and the floormat (refer to page C2 for removal of rocker panels and floormat) 0
1 Remove four christmas tree rivets securing pedal cover to floorboard 0
2 Remove pedal cover 0
3 Remove three torx screws (2) securing accelerator pedal assembly (1) to the floorboard (Ref Fig 4) 0
4 Disconnect the wires from the rotary position sensor (5) and the throttle enable switch (12) 0
5 Remove the two Torx screws (4) from the rotary position sensor (5) and remove sensor 0
6 Remove the two Torx screws (8) from the throttle enable switch (7) and remove the switch 0
Installation 0
7 Align the slot in the rotary position sensor (5) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (4) Use Loctite® 242; according to product instructions; on the two Torx screws 0
8 Position the throttle enable switch (7) oriented as shown, secure in place with two Torx screws (6) Use Loctite 242; according to product instructions; on the two Torx screws 0
Fig 4 Accelerator Pedal 0
9 Reconnect electrical harness to rotary position sensor (5) and to the throttle enable switch connector (7) 0
10 Place pedal assembly in position on the floorboard and secure with three Torx screws (2) 0
11 Install the pedal cover, using new christmas tree rivets, replace the floormat and rocker panels 0
Solenoid Replacement (Ref Fig 5) 0
The Solenoid is located on the passenger side of the vehicle under the seat and the Controller Splash Shield The Solenoid is hard-wired into the main electrical wiring harness 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove two Torx head screws (4) and the christmas tree rivet (2) securing the controller splash shield to the rear body, raise the splash shield and place it off to one side out of the way 0
3 Disconnect the red wire from the upper terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire to the main wiring harness by removing the upper hex nut (6) 0
4 Disconnect the red wire from the lower terminal on the solenoid to B+ on the controller by removing the lower hex nut (6) 0
5 Remove two hex head bolts (7) securing the solenoid to the controller heat sink 0
6 Cut and strip the insulation from the end of one black wire from the solenoid to the wire harness; using a butt splice connector and heat shrink tubing splice the replacement solenoid wire to the wire harness, repeat for the remaining wire 0
7 Secure the new solenoid to the controller heat sink with the two hex head bolts (7) Orient the solenoid with the wires on top as shown 0
8 Connect the red wire from the controller B+ to the lower terminal of the solenoid and the white wire to the resistor, secure in place using a hex nut (6) 0
9 Connect the red wire from the positive (+), BL+, battery terminal and the yellow wire from the wiring harness to the upper terminal of the solenoid, secure in place with a hex nut (6) 0
10 Reinstall the splash shield 0
Fig 5 Controller 0
Controller (Ref Fig 5) 0
The controller is a solid state unit activated by a solenoid The solenoid is hard wired to the electrical harness and mounted t 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
3 Remove two Torx head screws (4) securing the controller splash shield to the rear body and the christmas tree rivet (2) securing the splash shield to the controller heat sink; position splash shield off to one side to allow access to the controller 0
4 Disconnect the Red positive (+) battery cable from the upper terminal of the solenoid 0
5 Disconnect the Red wire from the controller B+ terminal to the lower terminal of the solenoid 0
6 Remove two hex head bolts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 0
7 Disconnect the 2 pin connector (14) from the wire harness 0
8 Disconnect the 3 pin connector (12) from the resistor control (13) connector 0
9 Disconnect the 23 pin connector (9) from controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
10 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 0
11 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 0
12 Remove the front two hex head bolts (10) securing the controller assembly to the floorboard and loosen the rear hex head bolt (10) Slide the controller towards the front of the car and lift it out 0
13 To install the controller, position it on the floorboard; making sure that all wires are not pinched or under the controller 0
14 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 0
15 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 0
16 Install the solenoid on the controller heat sink using two hex head bolts (7) Make sure that the black wires from the solenoid to the wire harness are located at the top of the solenoid 0
17 Install the Red wire to the B+ terminal of the controller (Do not over tighten the terminal screw (11) 0
18 Plug the 23 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
19 Check all wires to be sure they are connected to the proper terminal 0
20 Position the Splash Shield under the edge of the seat opening, install the christmas tree rivet (2) and the two Torx head screws (4) 0
21 Reconnect wires to the battery pack 0
F-FR SUSP-STEER-15sep08pdf 0
Fig 1 Front Suspension and Steering 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
MAINTENANCE 0
Tire Wear Diagnosis 0
Fig 2 Tire Wear 0
Wheel Alignment (Ref Fig 3) (Ref Fig 4) 0
1 Lift the front of the vehicle and support on jack stands as instructed in the SAFETY section 0
2 Rotate each wheel and scribe a paint line around the circumference of the tire at the center of the tread pattern 0
3 Lower vehicle with the tires in the straight ahead position 0
4 Roll vehicle forward approximately five feet in order to allow the tires to take their normal running position 0
0
Fig 3 Wheel Alignment 0
5 Measure the distance between the paint lines at both the front and rear of the tires The measurement taken at the front of the tires should be 0″ – 1/8″ (0 – 3 mm) less than the rear measurement 0
6 To adjust the wheel alignment, loosen the tie rod jam nut (1) and turn the tie rods and equal number of turns until the correct alignment is achieved Failure to turn both tie rods the same number of turns will result in poor turning radius 0
7 Tighten the tie rod jam nuts (1) and torque as specified 0
Fig 4 Tie Rod Jam Nut 0
Hub Assembly (Ref Fig 5) 0
1 Remove the dust cap (1) by tapping around the cap flange using a flat blade screwdriver and a ball peen hammer 0
2 Remove the lock nut (2) Note: it is recommended that locking nuts be replaced after a maximum of 5 removals 0
3 Remove hub (3) by sliding it off of the spindle 0
4 Clean spindle (4) thoroughly with solvent and inspect spindle threads; if threads are damaged replace the spindle 0
Spindle Assembly (Ref Fig 5) 0
1 Remove the hub assembly as described in the previous section 0
2 Loosen the nut securing the tie rod end to the spindle arm until it is flush with the end of the tie rod end 0
3 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the hammer to release the tie rod end from the spindle arm 0
4 Remove the nut and the tie rod end from the spindle arm 0
5 Remove hex nut (9) and hex head bolt (8), remove the spindle assembly (4 & 5) 0
Struts (Ref Fig 5) 0
1 Loosen the nut securing the tie rod end to the spindle arm until it is flush with the end of the tie rod end 0
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the hammer to release the tie rod end from the spindle arm 0
3 Remove the nut and the tie rod end from the spindle arm 0
4 Remove hex nut (9) and hex head bolt (8); the spindle and hub assemblies (1 – 7) can then be removed as a single unit 0
5 Remove the hex head bolt (11) securing lower end of strut to A-arm (13) 0
6 Remove the hex nut (20) and the hex head bolt (19) securing the top of the strut to the frame 0
Fig 5 Hub, Spindle, Strut and A-Arm Assemblies 0
A-Arm Assembly (Ref Fig 5) 0
1 Remove the hex head bolt (11) securing the a-arm (13) to the strut 0
2 Remove bushings (14 & 16) from a-arm, being careful to retain sleeve (15) 0
3 Inspect the sleeve (15) for wear or pitting; replace if sleeve (15) shows signs of wear or pitting 0
4 Remove two hex head bolts (17 & 18) securing the a- arm to the frame brackets 0
Clipboard and Steering Wheel (Ref Fig 6) (Ref Fig 7) (Ref Fig 8) 0
To maintain correct orientation when replacing steering wheel, first turn wheels straight ahead 0
1 Pull straight up on the lower edge of the clipboard to release the two retaining tabs 0
2 Using thumb for leverage as shown, reach from underneath the steering wheel with fingertips to first pull down, and then push up to release the two top clipboard retaining tabs 0
0
Fig 6 Clipboard Removal 0
3 Loosen the steering wheel retaining nut two or three turns Do not remove nut at this time 0
4 Apply upward pressure to the steering wheel by placing a plastic faced hammer against the steering wheel retaining nut Strik 0
Fig 7 Loosen Steering Wheel 0
5 When steering wheel is loosened, remove steering wheel retaining nut (1) and steering wheel (3) 0
Installation 0
6 Coat steering shaft splines lightly with a commercially available anti-seize compound 0
7 Make sure that wheels are positioned straight ahead 0
8 Align the steering wheel (3) on the steering shaft and push into place 0
Fig 8 Steering Wheel 0
9 Install steering wheel retaining nut (2) 0
10 Inspect the four retaining tabs on the clipboard (1) for white stress lines If stress lines are present, replace clipboard with a new one 0
11 Carefully press the top two tabs into the matching slots in the steering wheel, then press the bottom two tabs into the matching slots in the steering wheel 0
Steering Column Assembly & Yoke (Ref Fig 9) (Ref Fig 10) (Ref Fig 11) 0
1 Disconnect wiring for turn signals if vehicle is so equipped, as described in the Electrical Wiring section of this manual 0
2 Remove the lower cross bolt (8) from the yoke 0
Fig 9 Lower Cross Bolt 0
3 Remove four torx head screws (9) securing steering column assembly to vehicle frame 0
Fig 10 Steering Column Assembly Screws 0
4 Loosen the upper cross bolt (10) on the yoke and slide the yoke upward on the intermediate shaft to disengage from the steering box pinion 0
5 Turn the steering column assembly CCW about 10 to disengage the locking tabs and lift steering column with intermediate shaft and yoke out of vehicle, making note of the location of the notch in the steering column mounting bracket (up or down) 0
6 To separate the yoke from the intermediate shaft remove the upper cross bolt (10) and nut (11) then pull the yoke off of the intermediate shaft splines 0
Fig 11 Upper Cross Bolt 0
7 Apply a commercially available anti seize compound to the splines of the intermediate shaft and install the yoke onto the shaft Do not tighten the upper cross bolt and nut 0
8 To install the steering column assembly align the locking tabs on the mounting bracket with the slots in the frame and turn t 0
9 Install the four Torx screws (9) finger tight and then tighten to the proper toque 0
10 Apply a commercially available anti-seize compound to the splines of the steering box pinion before installing the yoke Do not install the lower cross bolt (8) at this time 0
11 To align the steering wheel with the front wheels use the following procedure: 0
a) Install the front wheels if they have been removed 0
b) Remove the jack stands and lower the vehicle to the ground 0
c) Push vehicle backward about 5 feet and then forward about 5 feet 0
d) If the steering wheel is not oriented properly remove the yoke from the steering box pinion and turn the steering wheel to the correct orientation 0
e) Install the yoke on the spline of the steering box pinion 0
6 Install the lower cross bolt (13) through the un- threaded portion of the yoke, making sure that the lock washer (14) is in place, into the threaded side 0
7 Tighten the upper cross bolt (10) and nut (11), making sure that the lock washer (12) is in place, then tighten the lower cross bolt (13) to the proper torque 0
Rod End / Ball Joint 0
1 Loosen the nut securing the tie rod end to the spindle arm 0
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the ball peen hammer to release tie rod from spindle arm 0
3 Remove the nut and remove the tie rod end from the spindle arm 0
4 Measure the length of the threaded part of the rod end to the jam nut or count the number of turns that it takes to remove the rod end 0
5 Install the new rod end the same number of turns that were counted when removing the old rod end or to the same measured length of the threaded part of the rod end to the jam nut 0
6 Install the rod end into the spindle 0
7 Tighten the jam nut against the rod end 0
8 Replace the other rod end if necessary 0
9 Check the wheel alignment and correct if necessary The procedure for alignment is detailed at the beginning of this section 0
Steering Box (Ref Fig 12) 0
1 Loosen the nut securing the tie rod end to the spindle arm 0
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the ball peen hammer to release tie rod from spindle arm 0
3 Remove the nut and remove the tie rod end from the spindle arm 0
4 Repeat steps 3 through 5 for the remaining tie rod end 0
5 Remove the lower cross bolt securing the yoke to the steering box pinion 0
6 Loosen the upper cross bolt securing the yoke to the intermediate shaft 0
7 Remove the yoke from the steering box pinion by sliding it up the intermediate shaft 0
8 Remove three torx head screws (15) securing the steering box (16) to the vehicle frame 0
9 Remove steering box from the driver’s side of the vehicle 0
Fig 12 Steering Box 0
G-MOTOR-15sep08pdf 0
Fig 1 Motor 0
GENERAL 0
Motor 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 With an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Remove two Torx head screws securing the controller splash shield to body on the passenger side of the seat opening 0
7 Disconnect motor wires from controller terminals, U, V and W, refer to the Speed Control section of this manual for torque complete information on these connections 0
8 Disconnect the main harness connector (31) to the motor brake 0
9 Disconnect main harness connector (32) to the motor temperature sensor and the main harness connector (33) to the motor sensor 0
0
Fig 2 Motor Connections 0
10 Pull the motor wires out through the bagwell 0
11 Remove the six hex head bolts (2) and split lock washers (3) securing the motor (1) to the axle and carefully slide the moto 0
Fig 3 Motor 0
12 Before installing the motor on the axle apply lubricant (80% molybdenum disulfide paste) to the input shaft spline The approved lubricants are: Dow Corning 77, Molykote (r) M-77 paste or Tribology TAS 100 EP 0
13 Carefully align the motor spline with the input shaft, orient the motor with the wires near the top and install the six hex 0
Fig 4 Motor Bolt Tightening Sequence 0
14 Connect the wires from the main harness to the motor brake, the motor sensor and the motor temperature sensor 0
15 Connect the wires from the motor to the controller; the green wire to terminal U, the yellow wire to terminal V and the blue 0
Fig 5 Motor to Controller Connections 0
16 Connect the negative (-) battery cable, BL-, to the battery pack 0
Motor Brake 0
REMOVAL 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 Using an insulated wrench, disconnect the negative (- ) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Disconnect wire harness from motor brake 0
7 Remove three hex head bolts (32) from the motor brake assembly (31) 0
Fig 6 Motor Brake 0
8 Removing the hex head bolt (33) will allow the handle (34) and the return spring (35) to be removed 0
INSTALLATION 0
1 Position the brake with the connector at the top as shown above and install the three hex head bolts (32) loosely 0
2 Connect the wire harness to the motor brake and move the Run/Tow switch to the ’TOW’ position This will provide power to the brake to align the disc material 0
3 Tighten the three hex head bolts evenly to the specified torque 0
4 Move the Run/Tow switch to the ’RUN’ position 0
I-BATTERY CHARGER-15sep08pdf 0
CHARGER DESCRIPTION 0
PORTABLE CHARGER INSTALLATION 0
Fig 1 Charger Installation 0
Looping the DC cord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished with charging The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away 0
UNDERSTANDING THE CHARGER 0
LED DISPLAY INFORMATION 0
LED Operation Codes: 0
LED Fault Code: 0
MAINTENANCE INSTRUCTIONS 0
1 For flooded lead-acid batteries, regularly check the water levels of each battery cell after charging and add distilled water 0
2 Make sure the charger connections to the battery terminals are tight and clean Check for any deformations or cracks in the p 0
3 Keep the cooling fins free of dirt and debris, do not expose the charger to oil, dirt, mud or to direct heavy water spray when cleaning equipment 0
4 Inspect the plug of the battery charger and the vehicle receptacle housing for dirt or debris Clean the DC connector monthly or more often if needed 0
M-REAR AXLE-15sep08pdf 0
Fig 1 Rear Axle 0
REAR AXLE MAINTENANCE 0
Checking the Torque to Rotate 0
1 Remove the driver side rear wheel as noted in section D of this manual 0
2 Remove the cotter pin from the castle nut 0
3 With the socket and torque wrench apply pressure in a clockwise motion If the axle hub moves at 60 ft lbs or less replace t 0
Replacing the Lubricant 0
1 Remove bolts securing the oil pan 0
2 Using the rigid gasket scraper and the hammer separate the oil pan from the axle 0
3 Remove all traces of the old gasket material from the both surfaces and from the bolt holes 0
4 Clean oil pan after emptying the old oil 0
5 Apply Permatex RTV or equivalent to the gasket flange on the oil pan according to product instructions 0
6 Install the oil pan, tightening the bolts finger tight and then tighten to the proper torque value in a cross bolt pattern 0
7 Remove the driver side rear wheel as shown in the Tire and Wheel section of this manual 0
8 Remove the driver side rear hub as shown in the rear hub in the next section 0
9 Remove the driver side axle shaft as shown in the next section 0
10 Thread flexible tubing into the axle tube, past the seal and into the gear area 0
11 Connect the flexible tubing to the fluid pump 0
12 Fill with 25 oz of Mobile 424 lubricant slowly 0
13 Install the axle as shown in the next section 0
14 Install the rear hub as shown in the next section 0
15 Install the rear wheel as shown in the Tire and Wheel section of this manual 0
REAR AXLE DISASSEMBLY 0
0
It is recommended that whenever a bearing seal or ’O’ ring is removed, it be replaced with a new one regardless of the mileage Always wipe the seals and ’O’ rings with a light oil before installing 0
Rear Hub 0
1 Remove cotter pin (1) 0
2 Remove castle nut (2) and flat washer(3) 0
3 Remove hub (4) from axle splines (5) 0
Fig 2 Hub 0
4 Coat the splines of the axle shaft (5) with a Dow-Corning Moly Coat TM77 anti-seize compound 0
5 Install hub (4) onto the axle shaft splines (5) 0
6 Install the flat washer (3) and the castle nut (2) onto the axle 0
7 Tighten castle nut (2) to specified torque If cotter pin (1) can not pass through the hole in the axle shaft continue to tig 0
Axle Shaft, Bearing and Seal Removal and Disassembly 0
1 Remove the outer snap ring from the axle tube 0
Fig 3 Outer Snap Ring 0
2 Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube 0
Fig 4 Remove Axle Shaft 0
3 Remove the bearing by supporting the inner race of the bearing on an arbor press bed and applying pressure to the threaded end of the axle shaft 0
Fig 5 Press Bearing from Shaft 0
4 Remove the inner snap ring 0
5 Remove the oil seal using a seal puller 0
Fig 6 Oil Seal Removal 0
6 Install the new oil seal using the seal installer (E-Z-GO P/N 18739-G1) to drive the seal into its correct position 0
Fig 7 Seal Installation 0
7 Install the inner snap ring 0
8 Carefully insert the axle shaft and bearing through the oil seal Rotate the shaft until the spline engages with the differential side gears 0
9 Install the outer snap ring 0
N-WEATHER PROTECTION-15sep08pdf 0
Fig 1 Top and Windshield 0
TOP AND WINDSHIELD 0
Trailering 0
WINDSHIELD 0
1 Remove two torx head screws (1) from the lower portion of the windshield 0
2 Release the rubber latches (2) and fold the top portion of the windshield down 0
3 Carefully pull the outer edge of the windshield sash (3) forward and slide the flat screw driver into the opening Pull towards the front of the vehicle separating the sash from the front strut Repeat for the other side 0
4 To reinstall the windshield, hang the windshield on the front strut using the rubber latches (2) on the top portion of the windshield 0
5 Align the holes in the lower section with the holes in the front strut Alignment guides (long thin screw driver or bolts) may be helpful in keeping the holes aligned as the windshield is carefully pushed onto the front strut 0
6 Install two torx head screws (1) carefully, do not over tighten 0
Fig 2 Windshield 0
GOLF CAR TOP 0
Removal 0
1 Remove six flanged hex nuts (1) and the hex bolts (2) securing the top to the struts 0
2 Lift the top off of the struts and set it aside 0
3 Remove the access cover (5) by sliding a flat screwdriver under the edge of it and prying it away from the instrument panel, repeat for the other side 0
4 Remove the two hex head bolts (6) from each side that secure the front strut to the vehicle, lift the strut up until it clears the instrument panel and cowl 0
5 Remove the rubber grommets (7) from the front strut holes if they did not come off with the struts 0
6 Remove four flanged hex nuts (3) from inside the sweater basket then remove the four hex head bolts (4) that slide through the rear top strut, lift the strut up to clear the sweater basket Repeat for the other side 0
Installation 0
1 Place the rubber grommets (7) into the holes in the front cowl making sure that they are oriented properly for each side The grommet should follow the contour of the body 0
2 Position the front strut with the bend angled to the rear of the vehicle, slide the strut through the grommets and into posit 0
3 Position the rear struts so that they are bent to the outside of the vehicle and the top legs point to the front of the vehic 0
4 Place the top onto the struts and install six hex head bolts (2) down through the top and struts, place the nuts (1) on finger tight 0
5 Make sure that the grommets (7) on the front strut are in place 0
6 Tighten all fasteners to the proper torque 0
7 Replace the access covers (5) in the instrument panel 0
Fig 3 Golf Car Top 0
2 + 2 TOP 0
Removal 0
1 Remove four hex nuts (10) and the hex bolts (8) securing the rear of the top (3) to the struts (5 & 6) 0
2 Remove two hex nuts (10) and hex bolts (13) with spacers (12) securing the top (3) at the front to the strut (4) 0
Fig 4 2 + 2 Top 0
3 Lift the top (3) off of the struts and set it aside 0
4 Remove the access cover (1) by sliding a flat screwdriver under the edge of it and prying it away from the instrument panel, repeat for the other side 0
5 Remove the two hex head bolts (11) from each side that secure the front strut to the vehicle, lift the strut (4) up until it clears the instrument panel and cowl 0
6 Remove the rubber grommets (14 & 15) from the front strut holes if they did not come off with the struts 0
7 Remove two hex bolts (9) from one rear strut (5 or 6) then, repeat for the other side 0
Installation 0
1 Place the rubber grommets (14 & 15) into the holes in the front cowl making sure that they are oriented properly for each side The grommet should follow the contour of the body 0
2 Position the front strut (4) with the bend angled to the rear of the vehicle, slide the strut through the grommets and into p 0
3 Position the rear struts (5 & 6) so that they are bent to the outside of the vehicle and the top legs point to the rear of th 0
4 Place the top onto the struts and install two hex head bolts (13) and spacers (12) at the front through the struts, place the nuts (10) only finger tight 0
5 Install four hex head bolts (8) and hex nuts (10) through the rear struts (5 & 6) only finger tight 0
6 Make sure that the grommets (14 & 15) on the front strut (4) are in place 0
7 Tighten all fasteners to the proper torque 0
8 Replace the access covers (1) in the instrument panel 0
H-BATTERIES AND CHARGING-15sep08pdf 0
Fig 1 Batteries and Charging Receptacle 0
SAFETY 0
Always observe the following warnings when working on or near batteries: 0
BATTERY 0
BATTERY MAINTENANCE 0
At Each Charging Cycle 0
Monthly 0
Electrolyte Level and Water 0
Fig 2 Correct Electrolyte Level 0
Fig 3 Water Purity Table 0
Fig 4 Automatic Watering Gun 0
The watering device should only be used if the electrolyte level is less than 1/2” (13 mm) above top of plates 0
Cleaning Batteries 0
Fig 5 Preparing Acid Neutralizing Solution 0
BATTERY REMOVAL & INSTALLATION 0
The following text, there are references to removing/installing bolts, etc Additional hardware (nuts, washers, etc) that is re 0
1 Turn vehicle key to the off position and remove the key 0
2 Using an insulated wrench, disconnect the main negative (-), BL-, battery cable 0
3 Using an insulated wrench, disconnect the main positive (+), BL+, battery cable 0
4 Using an insulated wrench, disconnect and remove all other wires connected to the batteries 0
5 Remove the two pan head Torx screws (one each side) securing the battery strap 0
6 Remove the battery hold down by loosening all three hex nuts until they are at the end of the J-bolt and unhooking the J-bolt 0
7 Remove the batteries using commercially available battery carrier straps (2 per battery) Remove the three front batteries (1 0
Fig 6 Battery Removal 0
8 Check the area surrounding the battery tray for corrosion If any corrosion is found, it should be immediately removed with a 0
9 Replace the batteries, starting with the battery located at the back of the battery tray (4), making sure that it is positioned as shown 0
Fig 7 Battery Placement & Orientation 0
10 With the J-bolts in the battery hold down and held in place by the hex nuts on the end of the threaded portion; carefully po 0
11 Install the two pan head Torx screws through the ends of the battery strap into the holes on the vehicle frame and tighten them to 80 – 97 in lbs (9 – 11 Nm) torque 0
Fig 8 Battery Components 0
12 Inspect all wires and terminals and clean any corrosion from the battery terminals or wire terminals with a solution of baking soda and water, use a wire brush to completely remove corrosion if required 0
13 Carefully replace the wires on the battery terminals as shown Make sure to reconnect the main negative (-) battery cable, BL-, from the controller last 0
14 Tighten all battery terminal hardware to 90 – 105 in lbs (10 – 12 Nm) torque 0
15 Protect the battery terminals and battery cable terminals wit a commercially available protective coating 0
0
Fig 9 Battery Connections 0
PROLONGED STORAGE 0
Fig 10 Freezing Point of Electrolyte 0
BATTERY CHARGING 0
In some portable chargers, there will be a rattle present in the body of the charger DC plug This rattle is caused by an intern 0
TROUBLESHOOTING 0
Hydrometer 0
Fig 11 Hydrometer 0
Do not perform a hydrometer test on a battery that has just been watered The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte 0
Using A Hydrometer 0
16 Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and no 0
17 Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without contacting the top or bottom of the cylinder 0
18 Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float 0
19 Add or subtract four points (004) to the reading for every 10° F (6° C) the electrolyte temperature is above or below 80° F 0
20 Test each cell and note the readings (corrected to 80° F or 27° C) A variation of fifty points between any two cell readings (example 1250 – 1200) indicates a problem with the low reading cell(s) 0
Fig 12 Hydrometer Temperature Correction 0
RMTOC-16sep08pdf 0
TITLE SECTION 0
a2–Safety_Info-16sep08pdf 0
GENERAL 0
GENERAL OPERATION 0
MAINTENANCE 0
VENTILATION 0
RMTOC-28OCT08pdf 0
TITLE SECTION 0
F-FR SUSP-STEER-29oct08pdf 0
Fig 1 Front Suspension and Steering 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
MAINTENANCE 0
Tire Wear Diagnosis 0
Fig 2 Tire Wear 0
Wheel Alignment (Ref Fig 3) (Ref Fig 4) 0
1 Lift the front of the vehicle and support on jack stands as instructed in the SAFETY section 0
2 Rotate each wheel and scribe a paint line around the circumference of the tire at the center of the tread pattern 0
3 Lower vehicle with the tires in the straight ahead position 0
4 Roll vehicle forward approximately five feet in order to allow the tires to take their normal running position 0
0
Fig 3 Wheel Alignment 0
5 Measure the distance between the paint lines at both the front and rear of the tires The measurement taken at the front of the tires should be 0″ – 1/8″ (0 – 3 mm) less than the rear measurement 0
6 To adjust the wheel alignment, loosen the tie rod jam nut (1) and turn the tie rods and equal number of turns until the correct alignment is achieved Failure to turn both tie rods the same number of turns will result in poor turning radius 0
7 Tighten the tie rod jam nuts (1) and torque as specified 0
Fig 4 Tie Rod Jam Nut 0
Hub Assembly (Ref Fig 5) 0
1 Remove the dust cap (1) by tapping around the cap flange using a flat blade screwdriver and a ball peen hammer 0
2 Remove the lock nut (2) Note: it is recommended that locking nuts be replaced after a maximum of 5 removals 0
3 Remove hub (3) by sliding it off of the spindle 0
4 Clean spindle (4) thoroughly with solvent and inspect spindle threads; if threads are damaged replace the spindle 0
Spindle Assembly (Ref Fig 5) 0
1 Remove the hub assembly as described in the previous section 0
2 Loosen the nut securing the tie rod end to the spindle arm until it is flush with the end of the tie rod end 0
3 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the hammer to release the tie rod end from the spindle arm 0
4 Remove the nut and the tie rod end from the spindle arm 0
5 Remove hex nut (9) and hex head bolt (8), remove the spindle assembly (4 & 5) 0
Struts (Ref Fig 5) 0
1 Loosen the nut securing the tie rod end to the spindle arm until it is flush with the end of the tie rod end 0
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the hammer to release the tie rod end from the spindle arm 0
3 Remove the nut and the tie rod end from the spindle arm 0
4 Remove hex nut (9) and hex head bolt (8); the spindle and hub assemblies (1 – 7) can then be removed as a single unit 0
5 Remove the hex head bolt (11) securing lower end of strut to A-arm (13) 0
6 Remove the hex nut (20) and the hex head bolt (19) securing the top of the strut to the frame 0
Fig 5 Hub, Spindle, Strut and A-Arm Assemblies 0
A-Arm Assembly (Ref Fig 5) 0
1 Remove the hex head bolt (11) securing the a-arm (13) to the strut 0
2 Remove bushings (14 & 16) from a-arm, being careful to retain sleeve (15) 0
3 Inspect the sleeve (15) for wear or pitting; replace if sleeve (15) shows signs of wear or pitting 0
4 Remove two hex head bolts (17 & 18) securing the a- arm to the frame brackets 0
Clipboard and Steering Wheel (Ref Fig 6) (Ref Fig 7) (Ref Fig 8) 0
To maintain correct orientation when replacing steering wheel, first turn wheels straight ahead 0
1 Pull straight up on the lower edge of the clipboard to release the two retaining tabs 0
2 Using thumb for leverage as shown, reach from underneath the steering wheel with fingertips to first pull down, and then push up to release the two top clipboard retaining tabs 0
0
Fig 6 Clipboard Removal 0
3 Loosen the steering wheel retaining nut two or three turns Do not remove nut at this time 0
4 Apply upward pressure to the steering wheel by placing a plastic faced hammer against the steering wheel retaining nut Strik 0
Fig 7 Loosen Steering Wheel 0
5 When steering wheel is loosened, remove steering wheel retaining nut (1) and steering wheel (3) 0
Installation 0
6 Coat steering shaft splines lightly with a commercially available anti-seize compound 0
7 Make sure that wheels are positioned straight ahead 0
8 Align the steering wheel (3) on the steering shaft and push into place 0
Fig 8 Steering Wheel 0
9 Install steering wheel retaining nut (2) 0
10 Inspect the four retaining tabs on the clipboard (1) for white stress lines If stress lines are present, replace clipboard with a new one 0
11 Carefully press the top two tabs into the matching slots in the steering wheel, then press the bottom two tabs into the matching slots in the steering wheel 0
Steering Column Assembly & Yoke (Ref Fig 9) (Ref Fig 10) (Ref Fig 11) 0
1 Disconnect wiring for turn signals if vehicle is so equipped, as described in the Electrical Wiring section of this manual 0
2 Remove the lower cross bolt (8) from the yoke 0
Fig 9 Lower Cross Bolt 0
3 Remove four torx head screws (9) securing steering column assembly to vehicle frame 0
Fig 10 Steering Column Assembly Screws 0
4 Loosen the upper cross bolt (10) on the yoke and slide the yoke upward on the intermediate shaft to disengage from the steering box pinion 0
5 Turn the steering column assembly CCW about 10 to disengage the locking tabs and lift steering column with intermediate shaft and yoke out of vehicle, making note of the location of the notch in the steering column mounting bracket (up or down) 0
6 To separate the yoke from the intermediate shaft remove the upper cross bolt (10) and nut (11) then pull the yoke off of the intermediate shaft splines 0
Fig 11 Upper Cross Bolt 0
7 Apply a commercially available anti seize compound to the splines of the intermediate shaft and install the yoke onto the shaft Do not tighten the upper cross bolt and nut 0
8 To install the steering column assembly align the locking tabs on the mounting bracket with the slots in the frame and turn t 0
9 Install the four Torx screws (9) finger tight and then tighten to the proper toque 0
10 Apply a commercially available anti-seize compound to the splines of the steering box pinion before installing the yoke Do not install the lower cross bolt (8) at this time 0
11 To align the steering wheel with the front wheels use the following procedure: 0
a) Install the front wheels if they have been removed 0
b) Remove the jack stands and lower the vehicle to the ground 0
c) Push vehicle backward about 5 feet and then forward about 5 feet 0
d) If the steering wheel is not oriented properly remove the yoke from the steering box pinion and turn the steering wheel to the correct orientation 0
e) Install the yoke on the spline of the steering box pinion 0
6 Install the lower cross bolt (13) through the un- threaded portion of the yoke, making sure that the lock washer (14) is in place, into the threaded side 0
7 Tighten the upper cross bolt (10) and nut (11), making sure that the lock washer (12) is in place, then tighten the lower cross bolt (13) to the proper torque 0
Rod End / Ball Joint 0
1 Loosen the nut securing the tie rod end to the spindle arm 0
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the ball peen hammer to release tie rod from spindle arm 0
3 Remove the nut and remove the tie rod end from the spindle arm 0
4 Measure the length of the threaded part of the rod end to the jam nut or count the number of turns that it takes to remove the rod end 0
5 Install the new rod end the same number of turns that were counted when removing the old rod end or to the same measured length of the threaded part of the rod end to the jam nut 0
6 Install the rod end into the spindle 0
7 Tighten the jam nut against the rod end 0
8 Replace the other rod end if necessary 0
9 Check the wheel alignment and correct if necessary The procedure for alignment is detailed at the beginning of this section 0
Steering Box (Ref Fig 12) 0
1 Loosen the nut securing the tie rod end to the spindle arm 0
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the ball peen hammer to release tie rod from spindle arm 0
3 Remove the nut and remove the tie rod end from the spindle arm 0
4 Repeat steps 3 through 5 for the remaining tie rod end 0
5 Remove the lower cross bolt securing the yoke to the steering box pinion 0
6 Loosen the upper cross bolt securing the yoke to the intermediate shaft 0
7 Remove the yoke from the steering box pinion by sliding it up the intermediate shaft 0
8 Remove three torx head screws (15) securing the steering box (16) to the vehicle frame 0
9 Remove steering box from the driver’s side of the vehicle 0
Fig 12 Steering Box 0
L-REAR SUSPENSION-29oct08pdf 0
Fig 1 Rear Suspension 0
GENERAL 0
In the following text, there are references to removing/installing hardware (nuts, bolts, screws, washers, etc) Hardware that 0
SHOCK ABSORBER (Ref Fig 2) 0
1 Remove the two Torx head screws that secure the rear access panel 0
2 Remove the rear access panel 0
3 Raise the rear of the vehicle in accordance with the instructions provided in Section B of this manual and support the rear of the vehicles on the outer ends of the rear bumper 0
4 Remove the hex head bolt (5) and washer (4) from the lower end of the shock absorber 0
5 Remove the hex head bolt (1) and washer (2) from the upper end of the shock absorber 0
Fig 2 Shock Absorber 0
6 Install the hex head bolt (1) and washer (2) for the upper shock mount, make sure that the shock (3) is oriented as shown 0
7 Install the hex head bolt (5) and washer (4) through the lower end of the shock (3) into the mounting bracket on the axle 0
REAR LEAF SPRING (Ref Fig 3) 0
If both leaf springs are to be replaced and the rear axle is not being removed, it is important to remove and replace one leaf spring at a time It is recommended that leaf springs be replaced in pairs 0
Removal 0
1 Raise the rear of the vehicle in accordance with the instructions provided in Section B of this manual 0
2 Place a floor jack under the center section of the rear axle and raise the jack just enough to place a second set of jack stands under the axle tubes 0
3 Remove the two hex nuts (3) from the U-bolt (1) on the axle allowing the leaf spring plate (2) to slide off of the U-bolt 0
4 Remove the hex head bolts (15) and nuts (11) from the shackle plates (12) at the rear of the frame Remove the flanged urethane bushings (13) and spacers (14) as well 0
5 Remove the hex head bolt (7) and nut (4) from the forward leaf spring mounting bracket The leaf spring (16) can now be removed from the vehicle 0
6 Remove the flanged urethane bushings (6) and the spacer (5) from the leaf spring 0
Installation 0
7 Apply a commercially available anti-seize compound to the large flanged urethane bushings (6) 0
8 Install the large flanged urethane bushings (6) and spacer (5) in the end of the leaf spring (16) and place the leaf spring in the forward mounting bracket 0
9 Install the hex head bolt (7) and nut (4) to secure the forward end of the leaf spring in the bracket 0
10 Apply a commercially available anti-seize compound to the flanged urethane bushings (13) 0
11 Install one set of the smaller flanged urethane bushings (13) and spacer (14) in the rear frame mounting holes 0
12 Position the shackle plates (12) over the bushings and install the hex head bolt (15) and nut (11) 0
13 Install the remaining pair of flanged urethane bushings (13) and spacer (14) in the leaf spring (16) Position the leaf spring between the shackle plates (12) and install the hex head bolt (15) and nut (11) 0
14 Align the pin on the leaf spring (16) with the hole in the axle bracket and install the leaf spring plate (2) on to the U-bolt (1) Secure plate in place with two hex nuts (3) and tighten both nuts equally to the specified torque 0
15 Torque all hardware as specified making sure that the leaf spring pin remains aligned with the holes in the axle mounting bracket and the leaf spring mounting plate 0
Fig 3 Rear Leaf Spring 0
C-BODY-DEC08pdf 0
Fig 1 Body 0
GENERAL 0
Vehicle accessories, such as the sun top and windshield, need to be removed before removing many body components 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
Fig 2 Christmas Tree Rivet Removal 0
BODY COMPONENT REPLACEMENT 0
Front Bumper and Cowl Support (Ref Fig 3) 0
1 Remove two hex nuts (11) securing the top of the bumper to the front strut mounting bolts 0
2 Pull top of bumper (12) forward and off of the bolts then lift upward to clear the frame channel between the front struts and pull the lower edge of the bumper down and away from the vehicle 0
3 Remove the washers (13) 0
Fig 3 Front Bumper and Cowl Support 0
Rocker Panels (Ref Fig 4) 0
1 Remove the lower rocker panel (1) by removing three torx screws (3) 0
2 Remove the upper rocker panel (2) by removing the two remaining torx screw (3) 0
Fig 4 Rocker Panel Removal 0
Floor Mat (Ref Fig 5) (Ref Fig 6) 0
1 Remove six christmas tree rivets (5) securing the floor mat to the floorboard (4) (Ref Fig 5) 0
2 Pull edge of floor mat from under edge of instrument panel and lift over accelerator and brake pedals 0
I 0
Fig 5 Floor Mat Fastener Removal 0
Fig 6 Floor Mat 0
Cowl and Instrument Panel (Ref Fig 7) (Ref Fig 8) 0
1 Remove four torx screws (11) securing the trim panel (12) to the instrument panel (13) and cowl (14) 0
2 Locate the tab in the fender well area, under the cowl The tab extends from the instrument panel through a slot in the cowl, 0
3 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
4 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 7 Cowl and Instrument Panel Trim 0
5 Remove three self threading nuts (20) securing the cup holder assembly (15) to the instrument panel Remove the cup holder an 0
Fig 8 Instrument Panel and Cup Holder 0
6 Remove four torx screws (16) and flat washers (17) securing the instrument panel along its lower edge and the two torx screws (18) located near the top of the instrument panel; one on each side The instrument panel can now be removed 0
Front Splash Guard (Ref Fig 9) 0
1 Remove two christmas tree rivets (22) securing front splash guard (21) to vehicle(Ref Fig 2) 0
Fig 9 Front Splash Guard 0
Fig 10 Golf Car Rear Body, Sweater Basket, Rear Bumper & Fender Liner 0
Sweater Basket (Ref Fig 10) 0
1 Remove four torx screws (28) and flanged nuts (29) on the top edge of the sweater basket assembly (27) 0
2 Remove two torx screws (30) securing the back of the sweater basket to the seat back supports 0
3 Slide the sweater basket assembly (27) off the seat back supports 0
Seat Back Assembly 0
1 Remove four torx screws (26) that secure the seat back assembly (25) to the support struts 0
Fender Liner (Ref Fig 2) (Ref Fig 10) 0
1 Remove four christmas tree rivets (42) that secure the liner (41) to the frame of the vehicle Two christmas tree rivets are located on the lower front edge of the fender liner, the two remaining are located along the inside surface above the wheel 0
Rear Body (Ref Fig 10) 0
1 Raise and remove the seat bottom assembly from the vehicle Remove four torx screws (26) securing the seat back (25) to the seat back supports 0
2 Using an insulated wrench, disconnect the battery cable at the negative (-), BL-, battery terminal 0
3 Remove the two Torx head screws that secure the controller splash shield to the body on the passenger side of the vehicle 0
4 Remove the two strut covers (36) by sliding the covers up and off of the struts 0
5 Disconnect the wires from the charging receptacle to the battery and unplug the wire to the main wiring harness If vehicle is equipped with an on board battery charger skip this step 0
6 Remove two torx screws (33) securing each hinge plate (32) along the front edge of the rear body then remove both hinge plates 0
7 Remove two inner torx screws (34) from the back edge of seat opening in the rear body 0
8 Remove four torx screws (31) from the lower edge of the rear body, two on the driver side and two on the passenger side 0
9 Remove two torx screws (35) from the bagwell floor 0
10 Lift the rear body, pivot the seat opening upward and towards the back of the vehicle to clear the seat back supports 0
Rear Bumper (Ref Fig 10) 0
1 Remove two torx head screws (item 35) from the bag well floor If the rear body has been removed from the vehicle go to step 2 0
2 Remove four hex head bolts (37) securing the bumper to the vehicle frame 0
3 Pull the rear bumper backwards off the frame; lifting the rear edge of the body may make removal easier 0
Fig 11 2 + 2 Rear Facing Seat & Foot Rest 0
2 + 2 Rear Facing Seat & Foot Rest 0
1 Remove four hex head bolts (10) that secure the seat bottom to the hip restraints 0
2 Lift the seat bottom (11) up and remove it from the vehicle 0
Fig 12 Rear Facing Seat Bottom 0
3 Loosen the torx head bolts (23) and nuts (22) (Ref Fig 15) that secure the seat back mounting brackets and hip restraint to the seat back support (14) 0
4 Slide the seat back assembly (15) with the brackets attached towards the back of the vehicle and remove it from the vehicle 0
5 To separate the seat back assembly (15) from the mounting brackets (17) remove the four torx head screws (16), two from each bracket 0
Fig 13 Rear Facing Seat Back 0
6 Remove the hex head bolt (20) and nut (21) from the lower leg of the driver side hip restraint 0
Fig 14 Rear Facing Seat Hip Restraint 0
7 Remove the hex nuts (22) from the torx head bolts (23) that secure the driver side hip restraint to the seat back support 0
8 Hold or support the hip restraint before removing the torx head bolts (23), once these bolts are removed the hip restraint is free from the vehicle 0
Fig 15 Upper Hip Restraint Bolts 0
9 Repeat steps 6 – 8 for the removal of the passenger side hip restraint 0
10 Remove four torx head bolts (25) that secure the front seat back to the seat back support bracket 0
Fig 16 Front Seat Back 0
11 Remove two torx head bolts (28) from the bagwell floor 0
Fig 17 Rear Facing Seat Foot Rest 0
12 Loosen four hex head bolts (30) Support the rear foot rest (29) before removing the two bolts closest to the rear of the ve 0
Fig 18 Foot Rest Removal 0
13 Remove four hex head bolts (31) and nuts (32) that secure the seat back support (33) to the frame, slide the seat back support up until it clears the rear body 0
Fig 19 Seat Back Support 0
Floorboard 0
1 Remove the two Torx screws (44) securing the front seat support frame (45) to the floorboard (48) 0
2 Remove two Torx socket head cap screws (46) and washers (47) that secure the floorboard (48) to the vehicle frame 0
Fig 20 Front Seat Support and Floorboard 0
BODY CARE MAINTENANCE 0
Cleaning 0
1 Wet the body with a low pressure hose to rinse off any loose dust and dirt 0
2 Wash the vehicle with a solution of mild soap and water using a soft cotton cloth Do not use abrasive cleaners or solvents 0
3 Apply clear coat safe automotive car wax to revive lost luster as needed Test the wax on an inconspicuous area before applying to the entire vehicle Buff the wax by hand Do not use a power buffer to remove wax from the body panels 0
PAINTING 0
Light Scratches 0
1 Clean the area to be repaired with clean, clear water 0
2 Using 1200 grit sandpaper, water sand the entire area of the scratch in a circular motion, spraying with water as needed, until the original scratch is no longer visible 0
3 Wipe the area dry and visually inspect to be sure that the original scratch has completely disappeared 0
4 Using 1500 grit sandpaper, wet sand the area until all of the marks left by the 1200 grit sandpaper are gone, pay close attention to the edges of the sanded area 0
5 Using the buffer with the 3-M 39001 compound on the foam pad, turn the buffer on at slow speed Use a cris- crossed pattern t 0
6 Using the buffer with the 3-M 39003 or 3-M 05995 Polishing glaze (depending upon the color of the vehicle body) on the foam p 0
7 Wipe with a clean, soft cloth to remove any compound from the surrounding area Any dirt on the cloth may mar the surface 0
Minor Scratches 0
1 Thoroughly clean the surface to be repaired with alcohol and dry 0
2 Touch up damaged area with sequential coats (two coats minimum recommended, allowing 30 – 45 minutes between coats, increasin 0
3 Use 1200 grit “wet” sand paper to blend touch up area level with the rest of the part being repaired Use a polishing compound to renew gloss and to further blend and transition newly painted surface 0
4 Clean with alcohol and dry 0
5 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 0
6 Wax or polish with Carnauba base product, available at any automotive parts distributor 0
Larger Scratches 0
1 Thoroughly clean the surface to be repaired with alcohol and dry 0
2 Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type touch- up paint 0
3 Apply spray touch up paint in light, even, overlapping strokes Multiple coats may be applied to provide adequate coverage and finish Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best color match 0
4 After painting, allow to dry overnight Smooth the mask lines using 1200 grit “wet” sand paper to blend touch up area level w 0
5 Clean with alcohol and dry 0
6 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 0
7 Wax or polish with Carnauba base product, available at any automotive parts distributor 0
Complete Panel Repair 0
Most paint manufacturers can perform a computer paint match to assure accurate color matching 0
C-BODY-DEC08pdf 0
Fig 1 Body 0
GENERAL 0
Vehicle accessories, such as the sun top and windshield, need to be removed before removing many body components 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
Fig 2 Christmas Tree Rivet Removal 0
BODY COMPONENT REPLACEMENT 0
Front Bumper and Cowl Support (Ref Fig 3) 0
1 Remove two hex nuts (11) securing the top of the bumper to the front strut mounting bolts 0
2 Pull top of bumper (12) forward and off of the bolts then lift upward to clear the frame channel between the front struts and pull the lower edge of the bumper down and away from the vehicle 0
3 Remove the washers (13) 0
Fig 3 Front Bumper and Cowl Support 0
Rocker Panels (Ref Fig 4) 0
1 Remove the lower rocker panel (1) by removing three torx screws (3) 0
2 Remove the upper rocker panel (2) by removing the two remaining torx screw (3) 0
Fig 4 Rocker Panel Removal 0
Floor Mat (Ref Fig 5) (Ref Fig 6) 0
1 Remove six christmas tree rivets (5) securing the floor mat to the floorboard (4) (Ref Fig 5) 0
2 Pull edge of floor mat from under edge of instrument panel and lift over accelerator and brake pedals 0
I 0
Fig 5 Floor Mat Fastener Removal 0
Fig 6 Floor Mat 0
Cowl and Instrument Panel (Ref Fig 7) (Ref Fig 8) 0
1 Remove four torx screws (11) securing the trim panel (12) to the instrument panel (13) and cowl (14) 0
2 Locate the tab in the fender well area, under the cowl The tab extends from the instrument panel through a slot in the cowl, 0
3 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
4 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 7 Cowl and Instrument Panel Trim 0
5 Remove three self threading nuts (20) securing the cup holder assembly (15) to the instrument panel Remove the cup holder an 0
Fig 8 Instrument Panel and Cup Holder 0
6 Remove four torx screws (16) and flat washers (17) securing the instrument panel along its lower edge and the two torx screws (18) located near the top of the instrument panel; one on each side The instrument panel can now be removed 0
Front Splash Guard (Ref Fig 9) 0
1 Remove two christmas tree rivets (22) securing front splash guard (21) to vehicle(Ref Fig 2) 0
Fig 9 Front Splash Guard 0
Fig 10 Golf Car Rear Body, Sweater Basket, Rear Bumper & Fender Liner 0
Sweater Basket (Ref Fig 10) 0
1 Remove four torx screws (28) and flanged nuts (29) on the top edge of the sweater basket assembly (27) 0
2 Remove two torx screws (30) securing the back of the sweater basket to the seat back supports 0
3 Slide the sweater basket assembly (27) off the seat back supports 0
Seat Back Assembly 0
1 Remove four torx screws (26) that secure the seat back assembly (25) to the support struts 0
Fender Liner (Ref Fig 2) (Ref Fig 10) 0
1 Remove four christmas tree rivets (42) that secure the liner (41) to the frame of the vehicle Two christmas tree rivets are located on the lower front edge of the fender liner, the two remaining are located along the inside surface above the wheel 0
Rear Body (Ref Fig 10) 0
1 Raise and remove the seat bottom assembly from the vehicle Remove four torx screws (26) securing the seat back (25) to the seat back supports 0
2 Using an insulated wrench, disconnect the battery cable at the negative (-), BL-, battery terminal 0
3 Remove the two Torx head screws that secure the controller splash shield to the body on the passenger side of the vehicle 0
4 Remove the two strut covers (36) by sliding the covers up and off of the struts 0
5 Disconnect the wires from the charging receptacle to the battery and unplug the wire to the main wiring harness If vehicle is equipped with an on board battery charger skip this step 0
6 Remove two torx screws (33) securing each hinge plate (32) along the front edge of the rear body then remove both hinge plates 0
7 Remove two inner torx screws (34) from the back edge of seat opening in the rear body 0
8 Remove four torx screws (31) from the lower edge of the rear body, two on the driver side and two on the passenger side 0
9 Remove two torx screws (35) from the bagwell floor 0
10 Lift the rear body, pivot the seat opening upward and towards the back of the vehicle to clear the seat back supports 0
Rear Bumper (Ref Fig 10) 0
1 Remove two torx head screws (item 35) from the bag well floor If the rear body has been removed from the vehicle go to step 2 0
2 Remove four hex head bolts (37) securing the bumper to the vehicle frame 0
3 Pull the rear bumper backwards off the frame; lifting the rear edge of the body may make removal easier 0
Fig 11 2 + 2 Rear Facing Seat & Foot Rest 0
2 + 2 Rear Facing Seat & Foot Rest 0
1 Remove four hex head bolts (10) that secure the seat bottom to the hip restraints 0
2 Lift the seat bottom (11) up and remove it from the vehicle 0
Fig 12 Rear Facing Seat Bottom 0
3 Loosen the torx head bolts (23) and nuts (22) (Ref Fig 15) that secure the seat back mounting brackets and hip restraint to the seat back support (14) 0
4 Slide the seat back assembly (15) with the brackets attached towards the back of the vehicle and remove it from the vehicle 0
5 To separate the seat back assembly (15) from the mounting brackets (17) remove the four torx head screws (16), two from each bracket 0
Fig 13 Rear Facing Seat Back 0
6 Remove the hex head bolt (20) and nut (21) from the lower leg of the driver side hip restraint 0
Fig 14 Rear Facing Seat Hip Restraint 0
7 Remove the hex nuts (22) from the torx head bolts (23) that secure the driver side hip restraint to the seat back support 0
8 Hold or support the hip restraint before removing the torx head bolts (23), once these bolts are removed the hip restraint is free from the vehicle 0
Fig 15 Upper Hip Restraint Bolts 0
9 Repeat steps 6 – 8 for the removal of the passenger side hip restraint 0
10 Remove four torx head bolts (25) that secure the front seat back to the seat back support bracket 0
Fig 16 Front Seat Back 0
11 Remove two torx head bolts (28) from the bagwell floor 0
Fig 17 Rear Facing Seat Foot Rest 0
12 Loosen four hex head bolts (30) Support the rear foot rest (29) before removing the two bolts closest to the rear of the ve 0
Fig 18 Foot Rest Removal 0
13 Remove four hex head bolts (31) and nuts (32) that secure the seat back support (33) to the frame, slide the seat back support up until it clears the rear body 0
Fig 19 Seat Back Support 0
Floorboard 0
1 Remove the two Torx screws (44) securing the front seat support frame (45) to the floorboard (48) 0
2 Remove two Torx socket head cap screws (46) and washers (47) that secure the floorboard (48) to the vehicle frame 0
Fig 20 Front Seat Support and Floorboard 0
BODY CARE MAINTENANCE 0
Cleaning 0
1 Wet the body with a low pressure hose to rinse off any loose dust and dirt 0
2 Wash the vehicle with a solution of mild soap and water using a soft cotton cloth Do not use abrasive cleaners or solvents 0
3 Apply clear coat safe automotive car wax to revive lost luster as needed Test the wax on an inconspicuous area before applying to the entire vehicle Buff the wax by hand Do not use a power buffer to remove wax from the body panels 0
PAINTING 0
Light Scratches 0
1 Clean the area to be repaired with clean, clear water 0
2 Using 1200 grit sandpaper, water sand the entire area of the scratch in a circular motion, spraying with water as needed, until the original scratch is no longer visible 0
3 Wipe the area dry and visually inspect to be sure that the original scratch has completely disappeared 0
4 Using 1500 grit sandpaper, wet sand the area until all of the marks left by the 1200 grit sandpaper are gone, pay close attention to the edges of the sanded area 0
5 Using the buffer with the 3-M 39001 compound on the foam pad, turn the buffer on at slow speed Use a cris- crossed pattern t 0
6 Using the buffer with the 3-M 39003 or 3-M 05995 Polishing glaze (depending upon the color of the vehicle body) on the foam p 0
7 Wipe with a clean, soft cloth to remove any compound from the surrounding area Any dirt on the cloth may mar the surface 0
Minor Scratches 0
1 Thoroughly clean the surface to be repaired with alcohol and dry 0
2 Touch up damaged area with sequential coats (two coats minimum recommended, allowing 30 – 45 minutes between coats, increasin 0
3 Use 1200 grit “wet” sand paper to blend touch up area level with the rest of the part being repaired Use a polishing compound to renew gloss and to further blend and transition newly painted surface 0
4 Clean with alcohol and dry 0
5 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 0
6 Wax or polish with Carnauba base product, available at any automotive parts distributor 0
Larger Scratches 0
1 Thoroughly clean the surface to be repaired with alcohol and dry 0
2 Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type touch- up paint 0
3 Apply spray touch up paint in light, even, overlapping strokes Multiple coats may be applied to provide adequate coverage and finish Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best color match 0
4 After painting, allow to dry overnight Smooth the mask lines using 1200 grit “wet” sand paper to blend touch up area level w 0
5 Clean with alcohol and dry 0
6 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 0
7 Wax or polish with Carnauba base product, available at any automotive parts distributor 0
Complete Panel Repair 0
Most paint manufacturers can perform a computer paint match to assure accurate color matching 0
G-MOTOR-3Dec08pdf 0
Fig 1 Motor 0
GENERAL 0
Motor 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 With an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Remove two Torx head screws securing the controller splash shield to body on the passenger side of the seat opening 0
7 Disconnect motor wires from controller terminals, U, V and W, refer to the Speed Control section of this manual for torque complete information on these connections 0
8 Disconnect the main harness connector (31) to the motor brake 0
9 Disconnect main harness connector (32) to the motor temperature sensor and the main harness connector (33) to the motor sensor 0
0
Fig 2 Motor Connections 0
10 Pull the motor wires out through the bagwell 0
11 Remove the six hex head bolts (2) and split lock washers (3) securing the motor (1) to the axle and carefully slide the moto 0
Fig 3 Motor 0
12 Before installing the motor on the axle apply lubricant (80% molybdenum disulfide paste) to the input shaft spline The approved lubricants are: Dow Corning 77, Molykote (r) M-77 paste or Tribology TAS 100 EP 0
13 Carefully align the motor spline with the input shaft, orient the motor with the wires near the top and install the six hex 0
Fig 4 Motor Bolt Tightening Sequence 0
14 Connect the wires from the main harness to the motor brake, the motor sensor and the motor temperature sensor 0
15 Connect the wires from the motor to the controller; the green wire to terminal U, the yellow wire to terminal V and the blue 0
Fig 5 Motor to Controller Connections 0
16 Connect the negative (-) battery cable, BL-, to the battery pack 0
Motor Brake 0
REMOVAL 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Disconnect wire harness from motor brake 0
7 Remove three hex head bolts (32) from the motor brake assembly (31) 0
Fig 6 Motor Brake 0
8 Removing the hex head bolt (33) will allow the handle (34) and the return spring (35) to be removed 0
INSTALLATION 0
1 Position the brake with the connector at the top as shown above and install the three hex head bolts (32) loosely 0
2 Connect the wire harness to the motor brake and move the Run/Tow switch to the ’TOW’ position This will provide power to the brake to align the disc material 0
3 Tighten the three hex head bolts evenly to the specified torque 0
4 Move the Run/Tow switch to the ’RUN’ position 0
Elec Front Cover Warningpdf 0
NOTICES, CAUTIONS AND WARNINGS 0
A1_Model_Info-Jan09pdf 0
E-Z-GO Division of TEXTRON Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice 0
E-Z-GO Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual 0
GENERAL INFORMATION 0
SERVICE AND REPAIR MANUAL 0
ELECTRIC POWERED 0
GOLF CARS & PERSONAL VEHICLES 0
RXV FLEET GOLF CAR 0
RXV FREEDOM GOLF CAR 0
RXV SHUTTLE 2+2 0
STARTING MID-MODEL YEAR 2009 0
(Manufactured Begining February 23, 2009) 0
BATTERY PROLONGED STORAGE 0
RMTOC-Jan09pdf 0
TITLE SECTION 0
Elec Front Cover Warningpdf 0
NOTICES, CAUTIONS AND WARNINGS 2
A1_Model_Info-Jan09pdf 0
E-Z-GO Division of TEXTRON Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice 0
E-Z-GO Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual 0
GENERAL INFORMATION 0
SERVICE AND REPAIR MANUAL 0
ELECTRIC POWERED 0
GOLF CARS & PERSONAL VEHICLES 0
RXV FLEET GOLF CAR 0
RXV FREEDOM GOLF CAR 0
RXV SHUTTLE 2+2 0
STARTING MID-MODEL YEAR 2009 0
(Manufactured Begining February 23, 2009) 0
BATTERY PROLONGED STORAGE 0
RMTOC-Jan09pdf 0
TITLE SECTION 5
a2–Safety_Info-Jan09pdf 0
GENERAL 7
GENERAL OPERATION 7
MAINTENANCE 8
VENTILATION 9
A3-GENERAL INFO-Jan09pdf 0
SERIAL NUMBER LOCATION 0
Fig 1 Serial Number Location on Steering Column 0
Fig 2 Serial Number on Front Frame 0
Fig 3 Serial Number on Rear Frame 0
0
Fig 4 Initial Service Chart 0
Towing 0
If a vehicle is towed in excess of 15 mph the motor brake will engage and slow the vehicle down 0
Servicing The Vehicle 0
Routine Maintenance 0
Rear Axle 0
Tires 0
Vehicle Cleaning And Care 0
Sun Top And Windshield 0
Hauling 0
T 0
HARDWARE 0
CAPACITIES AND REPLACEMENT PARTS 0
Fig 5 Capacities 0
Fig 6 Replacement Part 0
Fig 7 Torque Specifications and Bolt Grades 0
PERIODIC SERVICE SCHEDULE 0
3 – CHECK C&A – CHECK & ADJUST CL – CLEAN R – REPLACE 0
Fig 8 Periodic Service Schedule 0
B-SAFETY-Jan09pdf 0
NOTES, CAUTIONS AND WARNINGS 0
Address practices not related to personal injury 0
IMPORTANT SAFETY WARNING 0
MODIFICATIONS TO VEHICLE 0
GENERAL MAINTENANCE 0
BEFORE SERVICING THE VEHICLE 0
Additional Warnings 0
Fig 1 Attach Accessory Wires to Battery Pack 0
Fig 2 Batteries, Charger Receptacle & Controller 0
BATTERY REMOVAL & INSTALLATION 0
The following text, there are references to removing/installing bolts, etc Additional hardware (nuts, washers, etc) that is re 0
1 Turn vehicle key to the off position and remove the key 0
2 Using an insulated wrench, disconnect the main negative (-) battery cable, BL- 0
3 Using an insulated wrench, disconnect the main positive (+) battery cable, BL+ 0
4 Using an insulated wrench, disconnect and remove all other wires connected to the batteries 0
5 Remove the two pan head Torx screws, (one on each side) from the battery strap 0
6 Remove the battery hold down and the battery strap by loosening all three hex nuts until they are at the end of the J-bolt an 0
7 Remove the batteries using commercially available battery carrier straps (2 per battery) and a portable lifting device Remov 0
Fig 3 Battery Removal 0
8 Check the area surrounding the battery tray for corrosion If any corrosion is found, it should be immediately removed with a 0
9 Replace the batteries, starting with the battery located at the back of the battery tray (4), making sure that it is positioned as shown 0
0
Fig 4 Battery Placement & Orientation 0
10 With the J-bolts in the battery hold down and held in place by the hex nuts on the end of the threaded portion; carefully po 0
11 Install the two pan head Torx screws through the ends of the battery strap into the holes on the vehicle frame and tighten them to 80 – 97 in lbs (9 – 11 Nm) torque 0
12 Inspect all wires and terminals and clean any corrosion from the battery terminals or wire terminals with a solution of baking soda and water, use a wire brush to completely remove corrosion if required 0
13 Carefully replace the wires on the battery terminals as shown Make sure to reconnect the main negative (-) battery cable, BL-, from the controller last 0
Fig 5 Battery Hold Down 0
Fig 6 Battery Connections 0
14 Tighten all battery terminal hardware to 95 – 105 in lbs (11 – 12 Nm) torque 0
15 Protect the battery terminals and battery cable ends with a commercially available protective coating 0
LIFTING THE VEHICLE 0
Fig 7 Lifting Points 0
C-BODY-Jan09pdf 0
Fig 1 Body 0
GENERAL 0
Vehicle accessories, such as the sun top and windshield, need to be removed before removing many body components 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
Fig 2 Christmas Tree Rivet Removal 0
BODY COMPONENT REPLACEMENT 0
Front Bumper and Cowl Support (Ref Fig 3) 0
1 Remove two hex nuts (11) securing the top of the bumper to the front strut mounting bolts 0
2 Pull top of bumper (12) forward and off of the bolts then lift upward to clear the frame channel between the front struts and pull the lower edge of the bumper down and away from the vehicle 0
3 Remove the washers (13) 0
Fig 3 Front Bumper and Cowl Support 0
Rocker Panels (Ref Fig 4) 0
1 Remove the lower rocker panel (1) by removing three torx screws (3) 0
2 Remove the upper rocker panel (2) by removing the two remaining torx screw (3) 0
Fig 4 Rocker Panel Removal 0
Floor Mat (Ref Fig 5) (Ref Fig 6) 0
1 Remove six christmas tree rivets (5) securing the floor mat to the floorboard (4) (Ref Fig 5) 0
2 Pull edge of floor mat from under edge of instrument panel and lift over accelerator and brake pedals 0
I 0
Fig 5 Floor Mat Fastener Removal 0
Fig 6 Floor Mat 0
Cowl and Instrument Panel (Ref Fig 7) (Ref Fig 8) 0
1 Remove four torx screws (11) securing the trim panel (12) to the instrument panel (13) and cowl (14) 0
2 Locate the tab in the fender well area, under the cowl The tab extends from the instrument panel through a slot in the cowl, 0
3 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
4 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 7 Cowl and Instrument Panel Trim 0
5 Remove three self threading nuts (20) securing the cup holder assembly (15) to the instrument panel Remove the cup holder an 0
Fig 8 Instrument Panel and Cup Holder 0
6 Remove four torx screws (16) and flat washers (17) securing the instrument panel along its lower edge and the two torx screws (18) located near the top of the instrument panel; one on each side The instrument panel can now be removed 0
Front Splash Guard (Ref Fig 9) 0
1 Remove two christmas tree rivets (22) securing front splash guard (21) to vehicle(Ref Fig 2) 0
Fig 9 Front Splash Guard 0
Fig 10 Golf Car Rear Body, Sweater Basket, Rear Bumper & Fender Liner 0
Sweater Basket (Ref Fig 10) 0
1 Remove four torx screws (28) and flanged nuts (29) on the top edge of the sweater basket assembly (27) 0
2 Remove two torx screws (30) securing the back of the sweater basket to the seat back supports 0
3 Slide the sweater basket assembly (27) off the seat back supports 0
Seat Back Assembly 0
1 Remove four torx screws (26) that secure the seat back assembly (25) to the support struts 0
Fender Liner (Ref Fig 2) (Ref Fig 10) 0
1 Remove four christmas tree rivets (42) that secure the liner (41) to the frame of the vehicle Two christmas tree rivets are located on the lower front edge of the fender liner, the two remaining are located along the inside surface above the wheel 0
Rear Body (Ref Fig 10) 0
1 Raise and remove the seat bottom assembly from the vehicle Remove four torx screws (26) securing the seat back (25) to the seat back supports 0
2 Using an insulated wrench, disconnect the battery cable at the negative (-), BL-, battery terminal 0
3 Remove the two Torx head screws that secure the controller splash shield to the body on the passenger side of the vehicle 0
4 Remove the two strut covers (36) by sliding the covers up and off of the struts 0
5 Disconnect the wires from the charging receptacle to the battery and unplug the wire to the main wiring harness If vehicle is equipped with an on board battery charger skip this step 0
6 Remove two torx screws (33) securing each hinge plate (32) along the front edge of the rear body then remove both hinge plates 0
7 Remove two inner torx screws (34) from the back edge of seat opening in the rear body 0
8 Remove four torx screws (31) from the lower edge of the rear body, two on the driver side and two on the passenger side 0
9 Remove two torx screws (35) from the bagwell floor 0
10 Lift the rear body, pivot the seat opening upward and towards the back of the vehicle to clear the seat back supports 0
Rear Bumper (Ref Fig 10) 0
1 Remove two torx head screws (item 35) from the bag well floor If the rear body has been removed from the vehicle go to step 2 0
2 Remove four hex head bolts (37) securing the bumper to the vehicle frame 0
3 Pull the rear bumper backwards off the frame; lifting the rear edge of the body may make removal easier 0
Fig 11 2 + 2 Rear Facing Seat & Foot Rest 0
2 + 2 Rear Facing Seat & Foot Rest 0
1 Remove four hex head bolts (10) that secure the seat bottom to the hip restraints 0
2 Lift the seat bottom (11) up and remove it from the vehicle 0
Fig 12 Rear Facing Seat Bottom 0
3 Loosen the torx head bolts (23) and nuts (22) (Ref Fig 15) that secure the seat back mounting brackets and hip restraint to the seat back support (14) 0
4 Slide the seat back assembly (15) with the brackets attached towards the back of the vehicle and remove it from the vehicle 0
5 To separate the seat back assembly (15) from the mounting brackets (17) remove the four torx head screws (16), two from each bracket 0
Fig 13 Rear Facing Seat Back 0
6 Remove the hex head bolt (20) and nut (21) from the lower leg of the driver side hip restraint 0
Fig 14 Rear Facing Seat Hip Restraint 0
7 Remove the hex nuts (22) from the torx head bolts (23) that secure the driver side hip restraint to the seat back support 0
8 Hold or support the hip restraint before removing the torx head bolts (23), once these bolts are removed the hip restraint is free from the vehicle 0
Fig 15 Upper Hip Restraint Bolts 0
9 Repeat steps 6 – 8 for the removal of the passenger side hip restraint 0
10 Remove four torx head bolts (25) that secure the front seat back to the seat back support bracket 0
Fig 16 Front Seat Back 0
11 Remove two torx head bolts (28) from the bagwell floor 0
Fig 17 Rear Facing Seat Foot Rest 0
12 Loosen four hex head bolts (30) Support the rear foot rest (29) before removing the two bolts closest to the rear of the ve 0
Fig 18 Foot Rest Removal 0
13 Remove four hex head bolts (31) and nuts (32) that secure the seat back support (33) to the frame, slide the seat back support up until it clears the rear body 0
Fig 19 Seat Back Support 0
Floorboard 0
1 Remove the two Torx screws (44) securing the front seat support frame (45) to the floorboard (48) 0
2 Remove two Torx socket head cap screws (46) and washers (47) that secure the floorboard (48) to the vehicle frame 0
Fig 20 Front Seat Support and Floorboard 0
BODY CARE MAINTENANCE 0
Cleaning 0
1 Wet the body with a low pressure hose to rinse off any loose dust and dirt 0
2 Wash the vehicle with a solution of mild soap and water using a soft cotton cloth Do not use abrasive cleaners or solvents 0
3 Apply clear coat safe automotive car wax to revive lost luster as needed Test the wax on an inconspicuous area before applying to the entire vehicle Buff the wax by hand Do not use a power buffer to remove wax from the body panels 0
PAINTING 0
Light Scratches 0
1 Clean the area to be repaired with clean, clear water 0
2 Using 1200 grit sandpaper, water sand the entire area of the scratch in a circular motion, spraying with water as needed, until the original scratch is no longer visible 0
3 Wipe the area dry and visually inspect to be sure that the original scratch has completely disappeared 0
4 Using 1500 grit sandpaper, wet sand the area until all of the marks left by the 1200 grit sandpaper are gone, pay close attention to the edges of the sanded area 0
5 Using the buffer with the 3-M 39001 compound on the foam pad, turn the buffer on at slow speed Use a cris- crossed pattern t 0
6 Using the buffer with the 3-M 39003 or 3-M 05995 Polishing glaze (depending upon the color of the vehicle body) on the foam p 0
7 Wipe with a clean, soft cloth to remove any compound from the surrounding area Any dirt on the cloth may mar the surface 0
Minor Scratches 0
1 Thoroughly clean the surface to be repaired with alcohol and dry 0
2 Touch up damaged area with sequential coats (two coats minimum recommended, allowing 30 – 45 minutes between coats, increasin 0
3 Use 1200 grit “wet” sand paper to blend touch up area level with the rest of the part being repaired Use a polishing compound to renew gloss and to further blend and transition newly painted surface 0
4 Clean with alcohol and dry 0
5 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 0
6 Wax or polish with Carnauba base product, available at any automotive parts distributor 0
Larger Scratches 0
1 Thoroughly clean the surface to be repaired with alcohol and dry 0
2 Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type touch- up paint 0
3 Apply spray touch up paint in light, even, overlapping strokes Multiple coats may be applied to provide adequate coverage and finish Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best color match 0
4 After painting, allow to dry overnight Smooth the mask lines using 1200 grit “wet” sand paper to blend touch up area level w 0
5 Clean with alcohol and dry 0
6 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 0
7 Wax or polish with Carnauba base product, available at any automotive parts distributor 0
Complete Panel Repair 0
Most paint manufacturers can perform a computer paint match to assure accurate color matching 0
D-WHEELS Jan09pdf 0
WHEEL AND TIRE SERVICE 49
Tire condition should be inspected per the Periodic Service Schedule Inflation pressures should be checked when the tires are c 49
Use caution when inflating tires Due to the low volume of these small tires, over inflation can occur in a matter of seconds O 49
Tire Repair 49
The vehicle is fitted with low pressure tubeless tires mounted on one piece rims 49
Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel 49
If the tire is flat, remove the wheel and inflate the tire to the maximum recommended pressure for the tire Immerse the tire in water to locate the leak and mark with chalk Insert tire plug in accordance with manufacturer’s specifications 49
Wheel Installation 50
It is important to follow the ‘cross sequence’ pattern when installing lug nuts This will assure even seating of the wheel against the hub 50
With the valve stem to the outside, mount the wheel onto the hub Install lug nuts (1) finger tight; make sure that the tapered 50
Fig 1 Tire Mounting & Cross Sequence for Tightening 50
F-FR SUSP-STEER-Jan09pdf 0
Fig 1 Front Suspension and Steering 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
MAINTENANCE 0
Tire Wear Diagnosis 0
Fig 2 Tire Wear 0
Wheel Alignment (Ref Fig 3) (Ref Fig 4) 0
1 Lift the front of the vehicle and support on jack stands as instructed in the SAFETY section 0
2 Rotate each wheel and scribe a paint line around the circumference of the tire at the center of the tread pattern 0
3 Lower vehicle with the tires in the straight ahead position 0
4 Roll vehicle forward approximately five feet in order to allow the tires to take their normal running position 0
0
Fig 3 Wheel Alignment 0
5 Measure the distance between the paint lines at both the front and rear of the tires The measurement taken at the front of the tires should be 0″ – 1/8″ (0 – 3 mm) less than the rear measurement 0
6 To adjust the wheel alignment, loosen the tie rod jam nut (1) and turn the tie rods and equal number of turns until the correct alignment is achieved Failure to turn both tie rods the same number of turns will result in poor turning radius 0
7 Tighten the tie rod jam nuts (1) and torque as specified 0
Fig 4 Tie Rod Jam Nut 0
Hub Assembly (Ref Fig 5) 0
1 Remove the dust cap (1) by tapping around the cap flange using a flat blade screwdriver and a ball peen hammer 0
2 Remove the lock nut (2) Note: it is recommended that locking nuts be replaced after a maximum of 5 removals 0
3 Remove hub (3) by sliding it off of the spindle 0
4 Clean spindle (4) thoroughly with solvent and inspect spindle threads; if threads are damaged replace the spindle 0
Spindle Assembly (Ref Fig 5) 0
1 Remove the hub assembly as described in the previous section 0
2 Loosen the nut securing the tie rod end to the spindle arm until it is flush with the end of the tie rod end 0
3 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the hammer to release the tie rod end from the spindle arm 0
4 Remove the nut and the tie rod end from the spindle arm 0
5 Remove hex nut (9) and hex head bolt (8), remove the spindle assembly (4 & 5) 0
Struts (Ref Fig 5) 0
1 Loosen the nut securing the tie rod end to the spindle arm until it is flush with the end of the tie rod end 0
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the hammer to release the tie rod end from the spindle arm 0
3 Remove the nut and the tie rod end from the spindle arm 0
4 Remove hex nut (9) and hex head bolt (8); the spindle and hub assemblies (1 – 7) can then be removed as a single unit 0
5 Remove the hex head bolt (11) securing lower end of strut to A-arm (13) 0
6 Remove the hex nut (20) and the hex head bolt (19) securing the top of the strut to the frame 0
Fig 5 Hub, Spindle, Strut and A-Arm Assemblies 0
A-Arm Assembly (Ref Fig 5) 0
1 Remove the hex head bolt (11) securing the a-arm (13) to the strut 0
2 Remove bushings (14 & 16) from a-arm, being careful to retain sleeve (15) 0
3 Inspect the sleeve (15) for wear or pitting; replace if sleeve (15) shows signs of wear or pitting 0
4 Remove two hex head bolts (17 & 18) securing the a- arm to the frame brackets 0
Clipboard and Steering Wheel (Ref Fig 6) (Ref Fig 7) (Ref Fig 8) 0
To maintain correct orientation when replacing steering wheel, first turn wheels straight ahead 0
1 Pull straight up on the lower edge of the clipboard to release the two retaining tabs 0
2 Using thumb for leverage as shown, reach from underneath the steering wheel with fingertips to first pull down, and then push up to release the two top clipboard retaining tabs 0
0
Fig 6 Clipboard Removal 0
3 Loosen the steering wheel retaining nut two or three turns Do not remove nut at this time 0
4 Apply upward pressure to the steering wheel by placing a plastic faced hammer against the steering wheel retaining nut Strik 0
Fig 7 Loosen Steering Wheel 0
5 When steering wheel is loosened, remove steering wheel retaining nut (1) and steering wheel (3) 0
Installation 0
6 Coat steering shaft splines lightly with a commercially available anti-seize compound 0
7 Make sure that wheels are positioned straight ahead 0
8 Align the steering wheel (3) on the steering shaft and push into place 0
Fig 8 Steering Wheel 0
9 Install steering wheel retaining nut (2) 0
10 Inspect the four retaining tabs on the clipboard (1) for white stress lines If stress lines are present, replace clipboard with a new one 0
11 Carefully press the top two tabs into the matching slots in the steering wheel, then press the bottom two tabs into the matching slots in the steering wheel 0
Steering Column Assembly & Yoke (Ref Fig 9) (Ref Fig 10) (Ref Fig 11) 0
1 Disconnect wiring for turn signals if vehicle is so equipped, as described in the Electrical Wiring section of this manual 0
2 Remove the lower cross bolt (8) from the yoke 0
Fig 9 Lower Cross Bolt 0
3 Remove four torx head screws (9) securing steering column assembly to vehicle frame 0
Fig 10 Steering Column Assembly Screws 0
4 Loosen the upper cross bolt (10) on the yoke and slide the yoke upward on the intermediate shaft to disengage from the steering box pinion 0
5 Turn the steering column assembly CCW about 10 to disengage the locking tabs and lift steering column with intermediate shaft and yoke out of vehicle, making note of the location of the notch in the steering column mounting bracket (up or down) 0
6 To separate the yoke from the intermediate shaft remove the upper cross bolt (10) and nut (11) then pull the yoke off of the intermediate shaft splines 0
Fig 11 Upper Cross Bolt 0
7 Apply a commercially available anti seize compound to the splines of the intermediate shaft and install the yoke onto the shaft Do not tighten the upper cross bolt and nut 0
8 To install the steering column assembly align the locking tabs on the mounting bracket with the slots in the frame and turn t 0
9 Install the four Torx screws (9) finger tight and then tighten to the proper toque 0
10 Apply a commercially available anti-seize compound to the splines of the steering box pinion before installing the yoke Do not install the lower cross bolt (8) at this time 0
11 To align the steering wheel with the front wheels use the following procedure: 0
a) Install the front wheels if they have been removed 0
b) Remove the jack stands and lower the vehicle to the ground 0
c) Push vehicle backward about 5 feet and then forward about 5 feet 0
d) If the steering wheel is not oriented properly remove the yoke from the steering box pinion and turn the steering wheel to the correct orientation 0
e) Install the yoke on the spline of the steering box pinion 0
6 Install the lower cross bolt (13) through the un- threaded portion of the yoke, making sure that the lock washer (14) is in place, into the threaded side 0
7 Tighten the upper cross bolt (10) and nut (11), making sure that the lock washer (12) is in place, then tighten the lower cross bolt (13) to the proper torque 0
Rod End / Ball Joint 0
1 Loosen the nut securing the tie rod end to the spindle arm 0
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the ball peen hammer to release tie rod from spindle arm 0
3 Remove the nut and remove the tie rod end from the spindle arm 0
4 Measure the length of the threaded part of the rod end to the jam nut or count the number of turns that it takes to remove the rod end 0
5 Install the new rod end the same number of turns that were counted when removing the old rod end or to the same measured length of the threaded part of the rod end to the jam nut 0
6 Install the rod end into the spindle 0
7 Tighten the jam nut against the rod end 0
8 Replace the other rod end if necessary 0
9 Check the wheel alignment and correct if necessary The procedure for alignment is detailed at the beginning of this section 0
Steering Box (Ref Fig 12) 0
1 Loosen the nut securing the tie rod end to the spindle arm 0
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the ball peen hammer to release tie rod from spindle arm 0
3 Remove the nut and remove the tie rod end from the spindle arm 0
4 Repeat steps 3 through 5 for the remaining tie rod end 0
5 Remove the lower cross bolt securing the yoke to the steering box pinion 0
6 Loosen the upper cross bolt securing the yoke to the intermediate shaft 0
7 Remove the yoke from the steering box pinion by sliding it up the intermediate shaft 0
8 Remove three torx head screws (15) securing the steering box (16) to the vehicle frame 0
9 Remove steering box from the driver’s side of the vehicle 0
Fig 12 Steering Box 0
E-ELEC SPEED CONTROLLER-2Feb09pdf 0
Fig 1 Electronic Speed Control 0
GENERAL 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
Fig 2 Christmas Tree Rivet Removal 0
Fig 3 Pedal Cover 0
Accelerator Pedal Assembly 0
1 Remove four christmas tree rivets securing pedal cover to floorboard 0
2 Remove pedal cover 0
3 Remove three torx screws (2) securing accelerator pedal assembly (1) to the floorboard (Ref Fig 4) 0
4 Disconnect the wires from the rotary position sensor (5) and the throttle enable switch (12) 0
5 Remove the two Torx screws (4) from the rotary position sensor (5) and remove sensor 0
6 Remove the two Torx screws (8) from the throttle enable switch (7) and remove the switch 0
Installation 0
7 Align the slot in the rotary position sensor (5) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (4) Use Loctite® 242; according to product instructions; on the two Torx screws 0
8 Position the throttle enable switch (7) oriented as shown, secure in place with two Socket head cap screws (6) Use Loctite 242; according to product instructions; on the two Socket head cap screws 0
9 Reconnect electrical harness to rotary position sensor (5) and to the throttle enable switch connector (7) 0
10 Place pedal assembly in position on the floorboard and secure with three Torx screws (2) 0
Fig 4 Accelerator Pedal 0
11 Install the pedal cover, using new christmas tree rivets, replace the floormat and rocker panels 0
Solenoid Replacement (Ref Fig 5) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove three plastic rivets (4) securing the controller splash shield; two on the rear body and one from the controller heat sink, raise the splash shield and place it off to one side out of the way 0
3 Disconnect the red wire from the upper terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire to the main wiring harness by removing the upper hex nut (6) 0
4 Disconnect the red wire from the lower terminal on the solenoid to B+ on the controller by removing the lower hex nut (6) 0
5 Remove two hex head bolts (7) securing the solenoid to the controller heat sink 0
6 Cut and strip the insulation from the end of one black wire from the solenoid to the wire harness; using a butt splice connector and heat shrink tubing splice the replacement solenoid wire to the wire harness, repeat for the remaining wire 0
7 Secure the new solenoid to the controller heat sink with the two hex head bolts (7) Orient the solenoid with the wires on top as shown 0
8 Connect the red wire from the controller B+ to the lower terminal of the solenoid and the white wire to the resistor, secure in place using a hex nut (6) 0
9 Connect the red wire from the positive (+), BL+, battery terminal and the yellow wire from the wiring harness to the upper terminal of the solenoid, secure in place with a hex nut (6) 0
10 Reinstall the splash shield 0
Fig 5 Controller 0
Controller (Ref Fig 5) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
3 Remove two Torx head screws (4) securing the controller splash shield to the rear body and the christmas tree rivet (2) securing the splash shield to the controller heat sink; position splash shield off to one side to allow access to the controller 0
4 Disconnect the Red positive (+) battery cable from the upper terminal of the solenoid 0
5 Disconnect the Red wire from the controller B+ terminal to the lower terminal of the solenoid 0
6 Remove two hex head bolts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 0
7 Disconnect the 2 pin connector (14) from the wire harness 0
8 Disconnect the 3 pin connector (12) from the resistor control (13) connector 0
9 Disconnect the 23 pin connector (9) from controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
10 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 0
11 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 0
12 Remove the front two hex head bolts (10) securing the controller assembly to the floorboard and loosen the rear hex head bolt (10) Slide the controller towards the front of the car and lift it out 0
13 To install the controller, position it on the floorboard; making sure that all wires are not pinched or under the controller 0
14 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 0
15 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 0
16 Install the solenoid on the controller heat sink using two hex head bolts (7) Make sure that the black wires from the solenoid to the wire harness are located at the top of the solenoid 0
17 Install the Red wire to the B+ terminal of the controller (Do not over tighten the terminal screw (11) 0
18 Plug the 23 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
19 Check all wires to be sure they are connected to the proper terminal 0
20 Position the Splash Shield under the edge of the seat opening, install the christmas tree rivet (2) and the two Torx head screws (4) 0
21 Reconnect wires to the battery pack 0
G-MOTOR-13Jan09pdf 0
Fig 1 Motor 0
GENERAL 0
Motor 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 With an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Remove three plastic rivets securing the controller splash shield; two on the passenger side of the body at the seat opening and one from the controller 0
7 Disconnect motor wires from controller terminals, U, V and W, refer to the Speed Control section of this manual for torque complete information on these connections 0
8 Disconnect the main harness connector (31) to the motor brake 0
9 Disconnect main harness connector (32) to the motor temperature sensor and the main harness connector (33) to the motor sensor 0
0
Fig 2 Motor Connections 0
10 Pull the motor wires out through the bagwell 0
11 Remove the six hex head bolts (2) and split lock washers (3) securing the motor (1) to the axle and carefully slide the moto 0
Fig 3 Motor 0
12 Before installing the motor on the axle apply lubricant (80% molybdenum disulfide paste) to the input shaft spline The approved lubricants are: Dow Corning 77, Molykote (r) M-77 paste or Tribology TAS 100 EP 0
13 Carefully align the motor spline with the input shaft, orient the motor with the wires near the top and install the six hex 0
Fig 4 Motor Bolt Tightening Sequence 0
14 Connect the wires from the main harness to the motor brake, the motor sensor and the motor temperature sensor 0
15 Connect the wires from the motor to the controller; the green wire to terminal U, the yellow wire to terminal V and the blue 0
Fig 5 Motor to Controller Connections 0
16 Connect the negative (-) battery cable, BL-, to the battery pack 0
Motor Brake 0
REMOVAL 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Disconnect wire harness from motor brake 0
7 Remove three hex head bolts (32) and lock washers (33) from the motor brake assembly (31) 0
Fig 6 Motor Brake 0
INSTALLATION 0
1 Position the brake with the connector at the top as shown above and install the three hex head bolts (32) loosely 0
2 Connect the wire harness to the motor brake and move the Run/Tow switch to the ’TOW’ position This will provide power to the brake to align the disc material 0
3 Tighten the three hex head bolts evenly to the specified torque 0
4 Move the Run/Tow switch to the ’RUN’ position 0
H-BATTERIES AND CHARGING-Jan09pdf 0
Fig 1 Batteries and Charging Receptacle 0
SAFETY 0
Always observe the following warnings when working on or near batteries: 0
BATTERY 0
BATTERY MAINTENANCE 0
At Each Charging Cycle 0
Monthly 0
Electrolyte Level and Water 0
Fig 2 Correct Electrolyte Level 0
Fig 3 Water Purity Table 0
Fig 4 Automatic Watering Gun 0
The watering device should only be used if the electrolyte level is less than 1/2” (13 mm) above top of plates 0
Cleaning Batteries 0
Fig 5 Preparing Acid Neutralizing Solution 0
BATTERY REMOVAL & INSTALLATION 0
The following text, there are references to removing/installing bolts, etc Additional hardware (nuts, washers, etc) that is re 0
1 Turn vehicle key to the off position and remove the key 0
2 Using an insulated wrench, disconnect the main negative (-), BL-, battery cable 0
3 Using an insulated wrench, disconnect the main positive (+), BL+, battery cable 0
4 Using an insulated wrench, disconnect and remove all other wires connected to the batteries 0
5 Remove the two pan head Torx screws (one each side) securing the battery strap 0
6 Remove the battery hold down by loosening all three hex nuts until they are at the end of the J-bolt and unhooking the J-bolt 0
7 Remove the batteries using commercially available battery carrier straps (2 per battery) Remove the three front batteries (1 0
Fig 6 Battery Removal 0
8 Check the area surrounding the battery tray for corrosion If any corrosion is found, it should be immediately removed with a 0
9 Replace the batteries, starting with the battery located at the back of the battery tray (4), making sure that it is positioned as shown 0
Fig 7 Battery Placement & Orientation 0
10 With the J-bolts in the battery hold down and held in place by the hex nuts on the end of the threaded portion; carefully po 0
11 Install the two pan head Torx screws through the ends of the battery strap into the holes on the vehicle frame and tighten them to 80 – 97 in lbs (9 – 11 Nm) torque 0
Fig 8 Battery Components 0
12 Inspect all wires and terminals and clean any corrosion from the battery terminals or wire terminals with a solution of baking soda and water, use a wire brush to completely remove corrosion if required 0
13 Carefully replace the wires on the battery terminals as shown Make sure to reconnect the main negative (-) battery cable, BL-, from the controller last 0
14 Tighten all battery terminal hardware to 90 – 105 in lbs (10 – 12 Nm) torque 0
15 Protect the battery terminals and battery cable terminals wit a commercially available protective coating 0
0
Fig 9 Battery Connections 0
PROLONGED STORAGE 0
Fig 10 Freezing Point of Electrolyte 0
BATTERY CHARGING 0
In some portable chargers, there will be a rattle present in the body of the charger DC plug This rattle is caused by an intern 0
TROUBLESHOOTING 0
Hydrometer 0
Fig 11 Hydrometer 0
Do not perform a hydrometer test on a battery that has just been watered The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte 0
Using A Hydrometer 0
1 Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and not 0
2 Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without contacting the top or bottom of the cylinder 0
3 Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float 0
4 Add or subtract four points (004) to the reading for every 10° F (6° C) the electrolyte temperature is above or below 80° F 0
5 Test each cell and note the readings (corrected to 80° F or 27° C) A variation of fifty points between any two cell readings (example 1250 – 1200) indicates a problem with the low reading cell(s) 0
Fig 12 Hydrometer Temperature Correction 0
I-BATTERY CHARGER-Jan09pdf 0
CHARGER DESCRIPTION105
PORTABLE CHARGER INSTALLATION105
Fig 1 Charger Installation105
Looping the DC cord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished with charging The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away106
UNDERSTANDING THE CHARGER106
LED DISPLAY INFORMATION106
LED Operation Codes:106
LED Fault Code:106
MAINTENANCE INSTRUCTIONS106
1 For flooded lead-acid batteries, regularly check the water levels of each battery cell after charging and add distilled water106
2 Make sure the charger connections to the battery terminals are tight and clean Check for any deformations or cracks in the p106
3 Keep the cooling fins free of dirt and debris, do not expose the charger to oil, dirt, mud or to direct heavy water spray when cleaning equipment106
4 Inspect the plug of the battery charger and the vehicle receptacle housing for dirt or debris Clean the DC connector monthly or more often if needed106
K-Electrical Wiring-2Feb09pdf 0
Fig 1 Main Electrical Harness 0
MAIN WIRING HARNESS 0
1 Disconnect the main wiring harness from the battery pack using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run’ position, turn the key switch to reverse, 0
3 Locate the tab under the cowl that extends from the instrument panel through a slot in the cowl, squeeze the legs of the tab 0
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 2 Instrument Panel & Trim 0
6 Remove the wiring harness from the front splash shield retaining clips 0
7 If vehicle is equipped with brake lights, disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder 0
8 Remove the Diagnostic Plug from the bottom of the cup holder 0
9 Disconnect the plug to the throttle enable switch 0
10 Disconnect the plug from the rotary position sensor 0
11 Disconnect the plug from the brake enable switch 0
12 Disconnect the wires from the rotary position sensor 0
13 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
14 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
15 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
16 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
17 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and move it out of the way 0
18 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
19 Unplug the large 23 pin connector (3) from the controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
20 Disconnect the plug for the resistor, remove two screws that secure the sensor on top of the resistor 0
Fig 3 Controller 0
21 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through 0
Fig 4 Run / Tow Switch 0
22 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
Fig 5 Reverse Warning Indicator 0
23 Remove hex nuts (16) and disconnect the red wire to the positive battery, BL+, terminal (20) and the yellow wire (17) to the 0
Fig 6 Solenoid Removal 0
24 Remove two hex head bolts (22) securing the solenoid (18) to the controller heat sink 0
25 Unplug the connectors from the motor brake (23), the motor temperature sensor (24) and the motor sensor (25) 0
Fig 7 Motor Connections 0
26 Remove main wiring harness from the vehicle 0
27 Install new main wiring harness making sure that it follows the proper path 0
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1, 2 & 3) 0
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels 0
Fig 8 Harness Routing & Pedal Connections 0
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4) 0
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6) 0
e) Connect the wires to the brake pedal rotary position sensor (8) and the brake enable switch connector (9) 0
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10) 0
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel 0
h) Feed the connectors for the key switch, the optional fuel gauge/state of charge meter and the diagnostic plug through the ope 0
Fig 9 Cup Holder 0
i) Route the wires (14) for the key switch and the optional fuel gauge/state of charge meter through the guide (15) on the front 0
l 0
Fig 10 Front Splash Shield 0
j) Connect the wire harness to the key switch 0
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side 0
l) Plug the connector (20) for the charger receptacle into the connector on the main wiring harness 0
Fig 11 Charger Receptacle 0
m) Install the Red wire (23) to the B+ terminal of the controller (Do not over tighten the terminal screw (24)) 0
n) Install the solenoid (25) on the controller heat sink using two hex head bolts (26) Make sure that the black wires from the solenoid to the wire harness are located at the top of the solenoid 0
o) Connect the Red wire (23) from the controller B+ to the bottom terminal of the solenoid (25), using a slim wrench to keep the 0
0
Fig 12 Controller Connections 0
p) Plug the 23 pin connector (3) from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
0
Fig 13 23 Pin Connector 0
q) Plug the connectors for the motor brake (31), the motor temperature sensor (32) and the motor sensor (33) into the connectors on the motor and motor brake 0
0
Fig 14 Motor Connections 0
18 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10) 0
19 Press the fuse holder (12) into the hole on the controller splash shield 0
Fig 15 Reverse Warning Indicator & Fuse 0
20 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notc 0
Fig 16 Run / Tow Switch 0
21 Replace the controller splash shield and secure it to the body with two Torx head screws 0
22 Connect the negative battery wires using an insulated wrench 0
23 Connect the positive battery wires using an insulated wrench 0
24 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL COMPONENTS 0
Run / Tow Switch (Ref Fig 17 on page K-6) 0
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the switch and wires 0
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts 0
4 Cut the wires from the existing run/tow switch close to the switch 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness 0
6 Remove the upper nut and seal (7) from the new switch (8) 0
7 Install the switch (8) with the notch towards the RUN direction 0
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table 0
Fig 17 Run / Tow Switch 0
9 Install the splash shield using three plastic rivets to secure the shield to the body and the controller 0
Reverse Warning Indicator (Ref Fig 18 on page K-7) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires 0
3 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
4 Cut the wires close to the reverse warning indicator (11) 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (11) to the wire harness 0
6 Secure the new reverse warning indicator (11) to the splash shield with the torx head screws (10) 0
7 Reinstall the splash shield 0
Fig 18 Reverse Warning Indicator 0
State of Charge / Fuel Gauge Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel 0
Fig 19 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20) 0
3 Depress the tabs on the fuel gage/state of charge meter (20) and push the unit out of the trim panel (11) 0
Fig 20 Fuel Gage/State of Charge Meter 0
4 Insert the new fuel gage/state of charge meter (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the main harness (21) to the fuel gage/state of charge meter (20) 0
6 Push the instrument panel trim (11) into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Fig 21 Main Wiring Harness 0
Fig 22 Accessory Wiring Harness 0
Fig 23 Accessory Wiring Harness and Accessories 0
ACCESSORY WIRING HARNESS 0
Replacing the Accessory Wiring Harness 0
1 Using an insulated wrench disconnect the accessory harness from the battery pack 0
2 Unplug the red and purple wires from the brake light relay to the main harness 0
3 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn, fuel gage (state of charge meter) and brake lights 0
4 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder 0
5 Remove the three fuse holders from the controller splash shield 0
6 Disconnect the tail light wiring connectors 0
7 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
8 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
9 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
10 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
11 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
12 Remove the accessory wiring harness from the vehicle 0
13 Install new accessory wiring harness making sure that it follows the proper path 0
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that 0
b) Route the wires for the headlight switch through the opening in the instrument panel for the headlight switch 0
c) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle 0
d) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn 0
e) Connect the horn button connector to the accessory harness under the cup holder 0
f) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmas tree rivet (2) 0
0
Fig 24 Brake Light Relay 0
g) Connect the red and purple wires from the accessory harness to the matching wires from the main wire harness 0
h) Route the rest of the harness down through the cup holder and in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor 0
i) Route the wires and connector for the driver side brake light between the rear body and the battery pack and around the drive 0
j) Route the fuses and the passenger side brake light wires between the rear body and the battery pack 0
k) Snap the fuse holders into the holes on the controller splash shield 0
l) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light 0
13 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL ACCESSORIES 0
Head Light Replacement 0
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward 0
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward 0
3 Disconnect the accessory harness connector (5) from the headlight (3) and turn signal (4) 0
0
Fig 25 Headlight Assembly 0
4 To install the headlight assembly, connect the accessory harness connection (6) to the turn signal (4) and the accessory harness connection (5) to the headlight bulb (3) 0
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position 0
Head Light Bulb Replacement 0
1 Turn the headlight bulb (3) clockwise and pull to remove 0
2 Disconnect the accessory harness from the light bulb 0
3 Connect the accessory harness to the light bulb 0
4 Align the bulb with the opening in the back of the headlight assembly 0
5 Turn the bulb (3) counter clockwise until it stops 0
Turn signal Bulb Replacement 0
1 Grip the turn signal bulb housing (7) and turn to align with slot then pull backward to remove housing from headlight assembly 0
Fig 26 Turn Signal Bulb Replacement 0
2 Remove bulb from housing and replace with a new one 0
3 Align housing with slot and insert turn signal housing (7) into headlight assembly, turn to lock in place 0
Head Light Switch Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel 0
Fig 27 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the head light switch (13) 0
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11) 0
Fig 28 Head Light Switch 0
4 Insert the new head light switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the accessory harness (12) to the headlight switch (13) 0
6 Push the instrument panel trim into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Turn Signal Switch Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the connector from the turn signal switch harness to the main electrical harness 0
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder 0
4 Remove the plastic cover from the steering column 0
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw 0
6 Remove the turn signal switch assembly including the clamp 0
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column 0
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape 0
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column 0
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove 0
11 Route the wire harness under the floor mat to the cupholder 0
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet 0
13 Plug the turn signal wire harness connector into the accessory wire harness 0
Turn signal Flasher Unit Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the flasher unit from the turn signal wire harness 0
3 Install the new flasher unit in the wire harness receptacle 0
4 Replace the top part of the cup holder (ref Section B) 0
Tail Light Assembly Replacement 0
1 Remove the four Torx head screws (15) that secure the tail light assembly (16) to the rear body 0
2 Pull the tail light (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17) 0
Fig 29 Tail Light Assembly 0
3 Plug the new tail light assembly (15) into the accessory wire harness connector (16) and push the tail light assembly (16) into the opening 0
4 Install the four Torx head screws (15) 0
Tail Light Lens Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Install the new lens and secure in place with the two phillips head screws 0
Tail Light Bulb Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Remove the light bulb 0
3 Install the new light bulb 0
4 Install the lens and secure in place with the two phillips head screws 0
Horn Button Replacement 0
1 Remove the horn button cover using a flat blade to work the cover off of the switch 0
2 Pull the upper corner of the floormat down to expose the switch retaining nut 0
3 Remove the nut that secures the horn button 0
4 Remove the horn button switch from the floor1board 0
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch 0
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder 0
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame 0
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness 0
9 Replace the floormat and install the horn button cover 0
Horn Replacement 0
1 Disconnect the accessory wire harness from the horn 0
2 Remove the hex head bolt that secures the horn to the mounting bracket 0
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt 0
4 Connect the accessory wire harness to the horn 0
K-Electrical Wiring-2Feb09pdf 0
Fig 1 Main Electrical Harness 0
MAIN WIRING HARNESS 0
1 Disconnect the main wiring harness from the battery pack using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run’ position, turn the key switch to reverse, 0
3 Locate the tab under the cowl that extends from the instrument panel through a slot in the cowl, squeeze the legs of the tab 0
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 2 Instrument Panel & Trim 0
6 Remove the wiring harness from the front splash shield retaining clips 0
7 If vehicle is equipped with brake lights, disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder 0
8 Remove the Diagnostic Plug from the bottom of the cup holder 0
9 Disconnect the plug to the throttle enable switch 0
10 Disconnect the plug from the rotary position sensor 0
11 Disconnect the plug from the brake enable switch 0
12 Disconnect the wires from the rotary position sensor 0
13 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
14 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
15 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
16 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
17 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and move it out of the way 0
18 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
19 Unplug the large 23 pin connector (3) from the controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
20 Disconnect the plug for the resistor, remove two screws that secure the sensor on top of the resistor 0
Fig 3 Controller 0
21 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through 0
Fig 4 Run / Tow Switch 0
22 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
Fig 5 Reverse Warning Indicator 0
23 Remove hex nuts (16) and disconnect the red wire to the positive battery, BL+, terminal (20) and the yellow wire (17) to the 0
Fig 6 Solenoid Removal 0
24 Remove two hex head bolts (22) securing the solenoid (18) to the controller heat sink 0
25 Unplug the connectors from the motor brake (23), the motor temperature sensor (24) and the motor sensor (25) 0
Fig 7 Motor Connections 0
26 Remove main wiring harness from the vehicle 0
27 Install new main wiring harness making sure that it follows the proper path 0
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1, 2 & 3) 0
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels 0
Fig 8 Harness Routing & Pedal Connections 0
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4) 0
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6) 0
e) Connect the wires to the brake pedal rotary position sensor (8) and the brake enable switch connector (9) 0
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10) 0
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel 0
h) Feed the connectors for the key switch, the optional fuel gauge/state of charge meter and the diagnostic plug through the ope 0
Fig 9 Cup Holder 0
i) Route the wires (14) for the key switch and the optional fuel gauge/state of charge meter through the guide (15) on the front 0
l 0
Fig 10 Front Splash Shield 0
j) Connect the wire harness to the key switch 0
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side 0
l) Plug the connector (20) for the charger receptacle into the connector on the main wiring harness 0
Fig 11 Charger Receptacle 0
m) Install the Red wire (23) to the B+ terminal of the controller (Do not over tighten the terminal screw (24)) 0
n) Install the solenoid (25) on the controller heat sink using two hex head bolts (26) Make sure that the black wires from the solenoid to the wire harness are located at the top of the solenoid 0
o) Connect the Red wire (23) from the controller B+ to the bottom terminal of the solenoid (25), using a slim wrench to keep the 0
0
Fig 12 Controller Connections 0
p) Plug the 23 pin connector (3) from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
0
Fig 13 23 Pin Connector 0
q) Plug the connectors for the motor brake (31), the motor temperature sensor (32) and the motor sensor (33) into the connectors on the motor and motor brake 0
0
Fig 14 Motor Connections 0
18 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10) 0
19 Press the fuse holder (12) into the hole on the controller splash shield 0
Fig 15 Reverse Warning Indicator & Fuse 0
20 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notc 0
Fig 16 Run / Tow Switch 0
21 Replace the controller splash shield and secure it to the body with two Torx head screws 0
22 Connect the negative battery wires using an insulated wrench 0
23 Connect the positive battery wires using an insulated wrench 0
24 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL COMPONENTS 0
Run / Tow Switch (Ref Fig 17 on page K-6) 0
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the switch and wires 0
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts 0
4 Cut the wires from the existing run/tow switch close to the switch 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness 0
6 Remove the upper nut and seal (7) from the new switch (8) 0
7 Install the switch (8) with the notch towards the RUN direction 0
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table 0
Fig 17 Run / Tow Switch 0
9 Install the splash shield using three plastic rivets to secure the shield to the body and the controller 0
Reverse Warning Indicator (Ref Fig 18 on page K-7) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires 0
3 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
4 Cut the wires close to the reverse warning indicator (11) 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (11) to the wire harness 0
6 Secure the new reverse warning indicator (11) to the splash shield with the torx head screws (10) 0
7 Reinstall the splash shield 0
Fig 18 Reverse Warning Indicator 0
State of Charge / Fuel Gauge Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel 0
Fig 19 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20) 0
3 Depress the tabs on the fuel gage/state of charge meter (20) and push the unit out of the trim panel (11) 0
Fig 20 Fuel Gage/State of Charge Meter 0
4 Insert the new fuel gage/state of charge meter (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the main harness (21) to the fuel gage/state of charge meter (20) 0
6 Push the instrument panel trim (11) into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Fig 21 Main Wiring Harness 0
Fig 22 Accessory Wiring Harness 0
Fig 23 Accessory Wiring Harness and Accessories 0
ACCESSORY WIRING HARNESS 0
Replacing the Accessory Wiring Harness 0
1 Using an insulated wrench disconnect the accessory harness from the battery pack 0
2 Unplug the red and purple wires from the brake light relay to the main harness 0
3 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn, fuel gage (state of charge meter) and brake lights 0
4 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder 0
5 Remove the three fuse holders from the controller splash shield 0
6 Disconnect the tail light wiring connectors 0
7 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
8 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
9 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
10 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
11 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
12 Remove the accessory wiring harness from the vehicle 0
13 Install new accessory wiring harness making sure that it follows the proper path 0
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that 0
b) Route the wires for the headlight switch through the opening in the instrument panel for the headlight switch 0
c) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle 0
d) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn 0
e) Connect the horn button connector to the accessory harness under the cup holder 0
f) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmas tree rivet (2) 0
0
Fig 24 Brake Light Relay 0
g) Connect the red and purple wires from the accessory harness to the matching wires from the main wire harness 0
h) Route the rest of the harness down through the cup holder and in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor 0
i) Route the wires and connector for the driver side brake light between the rear body and the battery pack and around the drive 0
j) Route the fuses and the passenger side brake light wires between the rear body and the battery pack 0
k) Snap the fuse holders into the holes on the controller splash shield 0
l) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light 0
13 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL ACCESSORIES 0
Head Light Replacement 0
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward 0
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward 0
3 Disconnect the accessory harness connector (5) from the headlight (3) and turn signal (4) 0
0
Fig 25 Headlight Assembly 0
4 To install the headlight assembly, connect the accessory harness connection (6) to the turn signal (4) and the accessory harness connection (5) to the headlight bulb (3) 0
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position 0
Head Light Bulb Replacement 0
1 Turn the headlight bulb (3) clockwise and pull to remove 0
2 Disconnect the accessory harness from the light bulb 0
3 Connect the accessory harness to the light bulb 0
4 Align the bulb with the opening in the back of the headlight assembly 0
5 Turn the bulb (3) counter clockwise until it stops 0
Turn signal Bulb Replacement 0
1 Grip the turn signal bulb housing (7) and turn to align with slot then pull backward to remove housing from headlight assembly 0
Fig 26 Turn Signal Bulb Replacement 0
2 Remove bulb from housing and replace with a new one 0
3 Align housing with slot and insert turn signal housing (7) into headlight assembly, turn to lock in place 0
Head Light Switch Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel 0
Fig 27 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the head light switch (13) 0
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11) 0
Fig 28 Head Light Switch 0
4 Insert the new head light switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the accessory harness (12) to the headlight switch (13) 0
6 Push the instrument panel trim into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Turn Signal Switch Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the connector from the turn signal switch harness to the main electrical harness 0
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder 0
4 Remove the plastic cover from the steering column 0
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw 0
6 Remove the turn signal switch assembly including the clamp 0
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column 0
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape 0
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column 0
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove 0
11 Route the wire harness under the floor mat to the cupholder 0
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet 0
13 Plug the turn signal wire harness connector into the accessory wire harness 0
Turn signal Flasher Unit Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the flasher unit from the turn signal wire harness 0
3 Install the new flasher unit in the wire harness receptacle 0
4 Replace the top part of the cup holder (ref Section B) 0
Tail Light Assembly Replacement 0
1 Remove the four Torx head screws (15) that secure the tail light assembly (16) to the rear body 0
2 Pull the tail light (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17) 0
Fig 29 Tail Light Assembly 0
3 Plug the new tail light assembly (15) into the accessory wire harness connector (16) and push the tail light assembly (16) into the opening 0
4 Install the four Torx head screws (15) 0
Tail Light Lens Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Install the new lens and secure in place with the two phillips head screws 0
Tail Light Bulb Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Remove the light bulb 0
3 Install the new light bulb 0
4 Install the lens and secure in place with the two phillips head screws 0
Horn Button Replacement 0
1 Remove the horn button cover using a flat blade to work the cover off of the switch 0
2 Pull the upper corner of the floormat down to expose the switch retaining nut 0
3 Remove the nut that secures the horn button 0
4 Remove the horn button switch from the floor1board 0
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch 0
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder 0
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame 0
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness 0
9 Replace the floormat and install the horn button cover 0
Horn Replacement 0
1 Disconnect the accessory wire harness from the horn 0
2 Remove the hex head bolt that secures the horn to the mounting bracket 0
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt 0
4 Connect the accessory wire harness to the horn 0
L-REAR SUSPENSION-Jan09pdf 0
Fig 1 Rear Suspension 0
GENERAL 0
In the following text, there are references to removing/installing hardware (nuts, bolts, screws, washers, etc) Hardware that 0
SHOCK ABSORBER (Ref Fig 2) 0
1 Remove the two Torx head screws that secure the rear access panel 0
2 Remove the rear access panel 0
3 Raise the rear of the vehicle in accordance with the instructions provided in Section B of this manual and support the rear of the vehicles on the outer ends of the rear bumper 0
4 Remove the hex head bolt (5) and washer (4) from the lower end of the shock absorber 0
5 Remove the hex head bolt (1) and washer (2) from the upper end of the shock absorber 0
Fig 2 Shock Absorber 0
6 Install the hex head bolt (1) and washer (2) for the upper shock mount, make sure that the shock (3) is oriented as shown 0
7 Install the hex head bolt (5) and washer (4) through the lower end of the shock (3) into the mounting bracket on the axle 0
REAR LEAF SPRING (Ref Fig 3) 0
If both leaf springs are to be replaced and the rear axle is not being removed, it is important to remove and replace one leaf spring at a time It is recommended that leaf springs be replaced in pairs 0
Removal 0
1 Raise the rear of the vehicle in accordance with the instructions provided in Section B of this manual 0
2 Place a floor jack under the center section of the rear axle and raise the jack just enough to place a second set of jack stands under the axle tubes 0
3 Remove the two hex nuts (3) from the U-bolt (1) on the axle allowing the leaf spring plate (2) to slide off of the U-bolt 0
4 Remove the hex head bolts (15) and nuts (11) from the shackle plates (12) at the rear of the frame Remove the flanged urethane bushings (13) and spacers (14) as well 0
5 Remove the hex head bolt (7) and nut (4) from the forward leaf spring mounting bracket The leaf spring (16) can now be removed from the vehicle 0
6 Remove the flanged urethane bushings (6) and the spacer (5) from the leaf spring 0
Installation 0
7 Apply a commercially available anti-seize compound to the large flanged urethane bushings (6) 0
8 Install the large flanged urethane bushings (6) and spacer (5) in the end of the leaf spring (16) and place the leaf spring in the forward mounting bracket 0
9 Install the hex head bolt (7) and nut (4) to secure the forward end of the leaf spring in the bracket 0
10 Apply a commercially available anti-seize compound to the flanged urethane bushings (13) 0
11 Install one set of the smaller flanged urethane bushings (13) and spacer (14) in the rear frame mounting holes 0
12 Position the shackle plates (12) over the bushings and install the hex head bolt (15) and nut (11) 0
13 Install the remaining pair of flanged urethane bushings (13) and spacer (14) in the leaf spring (16) Position the leaf spring between the shackle plates (12) and install the hex head bolt (15) and nut (11) 0
14 Align the pin on the leaf spring (16) with the hole in the axle bracket and install the leaf spring plate (2) on to the U-bolt (1) Secure plate in place with two hex nuts (3) and tighten both nuts equally to the specified torque 0
15 Torque all hardware as specified making sure that the leaf spring pin remains aligned with the holes in the axle mounting bracket and the leaf spring mounting plate 0
Fig 3 Rear Leaf Spring 0
M-REAR AXLE-Jan09pdf 0
Fig 1 Rear Axle 0
REAR AXLE MAINTENANCE 0
Checking the Torque to Rotate 0
1 Remove the driver side rear wheel as noted in section D of this manual 0
2 Remove the cotter pin from the castle nut 0
3 With the socket and torque wrench apply pressure in a clockwise motion If the axle hub moves at 60 ft lbs or less replace t 0
Replacing the Lubricant 0
1 Remove bolts securing the oil pan 0
2 Using the rigid gasket scraper and the hammer separate the oil pan from the axle 0
3 Remove all traces of the old gasket material from the both surfaces and from the bolt holes 0
4 Clean oil pan after emptying the old oil 0
5 Apply Permatex RTV or equivalent to the gasket flange on the oil pan according to product instructions 0
6 Install the oil pan, tightening the bolts finger tight and then tighten to the proper torque value in a cross bolt pattern 0
7 Remove the driver side rear wheel as shown in the Tire and Wheel section of this manual 0
8 Remove the driver side rear hub as shown in the rear hub in the next section 0
9 Remove the driver side axle shaft as shown in the next section 0
10 Thread flexible tubing into the axle tube, past the seal and into the gear area 0
11 Connect the flexible tubing to the fluid pump 0
12 Fill with 25 oz of Mobile 424 lubricant slowly 0
13 Install the axle as shown in the next section 0
14 Install the rear hub as shown in the next section 0
15 Install the rear wheel as shown in the Tire and Wheel section of this manual 0
REAR AXLE DISASSEMBLY 0
0
It is recommended that whenever a bearing seal or ’O’ ring is removed, it be replaced with a new one regardless of the mileage Always wipe the seals and ’O’ rings with a light oil before installing 0
Rear Hub 0
1 Remove cotter pin (1) 0
2 Remove castle nut (2) and flat washer(3) 0
3 Remove hub (4) from axle splines (5) 0
Fig 2 Hub 0
4 Coat the splines of the axle shaft (5) with a Dow-Corning Moly Coat TM77 anti-seize compound 0
5 Install hub (4) onto the axle shaft splines (5) 0
6 Install the flat washer (3) and the castle nut (2) onto the axle 0
7 Tighten castle nut (2) to specified torque If cotter pin (1) can not pass through the hole in the axle shaft continue to tig 0
Axle Shaft, Bearing and Seal Removal and Disassembly 0
1 Remove the outer snap ring from the axle tube 0
Fig 3 Outer Snap Ring 0
2 Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube 0
Fig 4 Remove Axle Shaft 0
3 Remove the bearing by supporting the inner race of the bearing on an arbor press bed and applying pressure to the threaded end of the axle shaft 0
Fig 5 Press Bearing from Shaft 0
4 Remove the inner snap ring 0
5 Remove the oil seal using a seal puller 0
Fig 6 Oil Seal Removal 0
6 Install the new oil seal using the seal installer (E-Z-GO P/N 18739-G1) to drive the seal into its correct position 0
Fig 7 Seal Installation 0
7 Install the inner snap ring 0
8 Carefully insert the axle shaft and bearing through the oil seal Rotate the shaft until the spline engages with the differential side gears 0
9 Install the outer snap ring 0
N-WEATHER PROTECTION-Jan09pdf 0
Fig 1 Top and Windshield 0
TOP AND WINDSHIELD 0
Trailering 0
WINDSHIELD 0
1 Remove two torx head screws (1) from the lower portion of the windshield 0
2 Release the rubber latches (2) and fold the top portion of the windshield down 0
3 Carefully pull the outer edge of the windshield sash (3) forward and slide the flat screw driver into the opening Pull towards the front of the vehicle separating the sash from the front strut Repeat for the other side 0
4 To reinstall the windshield, hang the windshield on the front strut using the rubber latches (2) on the top portion of the windshield 0
5 Align the holes in the lower section with the holes in the front strut Alignment guides (long thin screw driver or bolts) may be helpful in keeping the holes aligned as the windshield is carefully pushed onto the front strut 0
6 Install two torx head screws (1) carefully, do not over tighten 0
Fig 2 Windshield 0
GOLF CAR TOP 0
Removal 0
1 Remove six flanged hex nuts (1) and the hex bolts (2) securing the top to the struts 0
2 Lift the top off of the struts and set it aside 0
3 Remove the access cover (5) by sliding a flat screwdriver under the edge of it and prying it away from the instrument panel, repeat for the other side 0
4 Remove the two hex head bolts (6) from each side that secure the front strut to the vehicle, lift the strut up until it clears the instrument panel and cowl 0
5 Remove the rubber grommets (7) from the front strut holes if they did not come off with the struts 0
6 Remove four flanged hex nuts (3) from inside the sweater basket then remove the four hex head bolts (4) that slide through the rear top strut, lift the strut up to clear the sweater basket Repeat for the other side 0
Installation 0
1 Place the rubber grommets (7) into the holes in the front cowl making sure that they are oriented properly for each side The grommet should follow the contour of the body 0
2 Position the front strut with the bend angled to the rear of the vehicle, slide the strut through the grommets and into posit 0
3 Position the rear struts so that they are bent to the outside of the vehicle and the top legs point to the front of the vehic 0
4 Place the top onto the struts and install six hex head bolts (2) down through the top and struts, place the nuts (1) on finger tight 0
5 Make sure that the grommets (7) on the front strut are in place 0
6 Tighten all fasteners to the proper torque 0
7 Replace the access covers (5) in the instrument panel 0
Fig 3 Golf Car Top 0
2 + 2 TOP 0
Removal 0
1 Remove four hex nuts (10) and the hex bolts (8) securing the rear of the top (3) to the struts (5 & 6) 0
2 Remove two hex nuts (10) and hex bolts (13) with spacers (12) securing the top (3) at the front to the strut (4) 0
Fig 4 2 + 2 Top 0
3 Lift the top (3) off of the struts and set it aside 0
4 Remove the access cover (1) by sliding a flat screwdriver under the edge of it and prying it away from the instrument panel, repeat for the other side 0
5 Remove the two hex head bolts (11) from each side that secure the front strut to the vehicle, lift the strut (4) up until it clears the instrument panel and cowl 0
6 Remove the rubber grommets (14 & 15) from the front strut holes if they did not come off with the struts 0
7 Remove two hex bolts (9) from one rear strut (5 or 6) then, repeat for the other side 0
Installation 0
1 Place the rubber grommets (14 & 15) into the holes in the front cowl making sure that they are oriented properly for each side The grommet should follow the contour of the body 0
2 Position the front strut (4) with the bend angled to the rear of the vehicle, slide the strut through the grommets and into p 0
3 Position the rear struts (5 & 6) so that they are bent to the outside of the vehicle and the top legs point to the rear of th 0
4 Place the top onto the struts and install two hex head bolts (13) and spacers (12) at the front through the struts, place the nuts (10) only finger tight 0
5 Install four hex head bolts (8) and hex nuts (10) through the rear struts (5 & 6) only finger tight 0
6 Make sure that the grommets (14 & 15) on the front strut (4) are in place 0
7 Tighten all fasteners to the proper torque 0
8 Replace the access covers (1) in the instrument panel 0
N-WEATHER PROTECTION-Jan09pdf 0
Fig 1 Top and Windshield153
TOP AND WINDSHIELD153
Trailering153
WINDSHIELD154
1 Remove two torx head screws (1) from the lower portion of the windshield154
2 Release the rubber latches (2) and fold the top portion of the windshield down154
3 Carefully pull the outer edge of the windshield sash (3) forward and slide the flat screw driver into the opening Pull towards the front of the vehicle separating the sash from the front strut Repeat for the other side154
4 To reinstall the windshield, hang the windshield on the front strut using the rubber latches (2) on the top portion of the windshield154
5 Align the holes in the lower section with the holes in the front strut Alignment guides (long thin screw driver or bolts) may be helpful in keeping the holes aligned as the windshield is carefully pushed onto the front strut154
6 Install two torx head screws (1) carefully, do not over tighten154
Fig 2 Windshield154
GOLF CAR TOP154
Removal154
1 Remove six flanged hex nuts (1) and the hex bolts (2) securing the top to the struts154
2 Lift the top off of the struts and set it aside154
3 Remove the access cover (5) by sliding a flat screwdriver under the edge of it and prying it away from the instrument panel, repeat for the other side154
4 Remove the two hex head bolts (6) from each side that secure the front strut to the vehicle, lift the strut up until it clears the instrument panel and cowl154
5 Remove the rubber grommets (7) from the front strut holes if they did not come off with the struts154
6 Remove four flanged hex nuts (3) from inside the sweater basket then remove the four hex head bolts (4) that slide through the rear top strut, lift the strut up to clear the sweater basket Repeat for the other side154
Installation154
1 Place the rubber grommets (7) into the holes in the front cowl making sure that they are oriented properly for each side The grommet should follow the contour of the body154
2 Position the front strut with the bend angled to the rear of the vehicle, slide the strut through the grommets and into posit154
3 Position the rear struts so that they are bent to the outside of the vehicle and the top legs point to the front of the vehic154
4 Place the top onto the struts and install six hex head bolts (2) down through the top and struts, place the nuts (1) on finger tight155
5 Make sure that the grommets (7) on the front strut are in place155
6 Tighten all fasteners to the proper torque155
7 Replace the access covers (5) in the instrument panel155
Fig 3 Golf Car Top155
2 + 2 TOP156
Removal156
1 Remove four hex nuts (10) and the hex bolts (8) securing the rear of the top (3) to the struts (5 & 6)156
2 Remove two hex nuts (10) and hex bolts (13) with spacers (12) securing the top (3) at the front to the strut (4)156
Fig 4 2 + 2 Top156
3 Lift the top (3) off of the struts and set it aside157
4 Remove the access cover (1) by sliding a flat screwdriver under the edge of it and prying it away from the instrument panel, repeat for the other side157
5 Remove the two hex head bolts (11) from each side that secure the front strut to the vehicle, lift the strut (4) up until it clears the instrument panel and cowl157
6 Remove the rubber grommets (14 & 15) from the front strut holes if they did not come off with the struts157
7 Remove two hex bolts (9) from one rear strut (5 or 6) then, repeat for the other side157
Installation157
1 Place the rubber grommets (14 & 15) into the holes in the front cowl making sure that they are oriented properly for each side The grommet should follow the contour of the body157
2 Position the front strut (4) with the bend angled to the rear of the vehicle, slide the strut through the grommets and into p157
3 Position the rear struts (5 & 6) so that they are bent to the outside of the vehicle and the top legs point to the rear of th157
4 Place the top onto the struts and install two hex head bolts (13) and spacers (12) at the front through the struts, place the nuts (10) only finger tight157
5 Install four hex head bolts (8) and hex nuts (10) through the rear struts (5 & 6) only finger tight157
6 Make sure that the grommets (14 & 15) on the front strut (4) are in place157
7 Tighten all fasteners to the proper torque157
8 Replace the access covers (1) in the instrument panel157
O-Diagnostics and Troubleshooting-Jan09pdf 0
HOW TO USE THE HAND HELD DIAGNOSTIC UNIT161
Fig 1 Hand Held Diagnostic Unit161
MENUS161
DIAGNOSTICS REPORT (real time read only)161
1 BATTERY VOLTAGE: displayed as ’VOLTAGE’, the next line displays ’HIGH’, the actual voltage or ’LOW’ in tenths of a volt161
162
2 CALCULATED BATTERY CURRENT: displayed as ’CURRENT’, the next line displays calculated current as ’LOW’, the actual number in DC Amps or as ’HIGH’162
3 STATE OF CHARGE: displayed as ’SOC’, the next line displays the state of charge for the battery pack as ’NORMAL’ or ’LOW BATT’162
4 THROTTLE SENSOR VOLTAGE: displayed as ’THROTVOLT’, the next line displays the sensor voltage as ’LOW’, ’NORMAL’ or ’HIGH’162
5 THROTTLE SWITCH POSITION: displayed as ’THROTTLESW’, the next line displays the switch voltage as ’NORMAL’ or ’HIGH’162
162
6 BRAKE SENSOR VOLTAGE: displayed as ’BRAKEVOLT’, the next line displays the sensor voltage as ’LOW’, ’NORMAL’ or ’HIGH’162
7 BRAKE SWITCH POSITION: displayed as ’BRAKE SW’ the next line displays the switch voltage as ’NORMAL’ or ’HIGH’162
162
8 MOTOR COMMAND SPEED: displayed as ’CMDSPEED’, the next line displays the speed in RPMs (revolutions per minute) that is being requested of the motor by the pedal position162
9 MOTOR ACTUAL SPEED: displayed as ’ACTSPEED’, the next line displays the actual motor speed in RPMs162
162
10 MOTOR CURRENT: displayed as ’AC CURRENT’, the next line displays the AC current in Amps162
11 MOTOR TEMPERATURE: displayed as ’MOTORTEMP’, the next line displays the internal motor temperature in C162
12 FORWARD SWITCH: displayed as ’FWD SWITCH’, the next line displays the switch position as ’ON’ or ’OFF’162
13 REVERSE SWITCH: displayed as ’REV SWITCH’, the next line displays the direction selection as ’ON’ or ’OFF’162
14 RUN TOW SWITCH POSITION: displayed as ’RUN TOW SW’, the next line displays the position of the run/tow switch as ’RUN’ or ’TOW’162
162
15 REVERSE WARNING BUZZER: displayed as ’BUZZER’, the next line displays the buzzer state as ’ON’ or ’OFF’162
16 SOLENOID: displayed as ’SOLENOID’, the next line displays the solenoid state as ’ON’ or ’OFF163
’163
17 ELECTRIC BRAKE CURRENT: displayed as ’EBRAKECURR’, the next line displays the brake current as a three place decimal in Amps; the brake current displayed below is 3 milliAmps163
BATTERY AND WARRANTY (read only)163
163
1 STATE OF BATTERY CHARGE: displayed as ’SOCBATT’, the next line displays the battery pack state of charge; the battery pack state of charge shown below is 85%163
2 TOTAL AMP-HOURS: displayed as ’TOTAL AH’, this is the total Amp-Hours used for the life of the car163
3 TOTAL MINUTES: displayed as ’TOTAL’, this is the total running time of the vehicle, the next line displays the hours163
163
4 TOTAL ROUNDS: displayed as ’EST TOTAL RNDS’, the next line displays the number of rounds as calculated based on 42 minutes running time per round played163
5 CHARGE CONSUMED: displayed as ’CHARGE’, the next line displays the total charge consumed in kw-hrs163
163
163
ERROR MESSAGES164
164
WARNING MESSAGES164
SETTING TOP SPEED AND PERFORMANCE PROFILES (read and write)164
COURSE ENERGY CONSUMPTION (read only)164
DIGITAL VOLT OHM METER172
Fig 2 DVOM172
TROUBLESHOOTING172
ACCESSORY WIRING HARNESS172
POWER SUPPLY173
Check For Loose or Bare Wires173
If any DVOM readings indicate a faulty wire, it is recommended that the condition of the terminals and wire junction be examined173
Check Battery Condition173
P-LIGHTNING AND GROUND-Jan09pdf 0
1 Grounding Requirements177
2 Ground Systems177
3 Lightning Protection Requirements177
4 Equipment Fault and Personal Safety System177
5 Ground Network Requirements177
6 External Grounding Requirements178
7 Materials178
8 Earth Electrode System178
9 Lightning Protection System178
10 Equipment Fault and Personal Safety System179
Q-Specification-Jan09pdf 0
RXV ELECTRIC – FLEET VEHICLE SPECIFICATIONS183
RXV ELECTRIC – FREEDOM VEHICLE SPECIFICATIONS184
RXV ELECTRIC – SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS185
Fig 1 Fleet & Freedom Vehicle Dimensions186
Fig 2 Shuttle 2 + 2 Vehicle Dimensions187
Fig 3 Vehicle Incline Specifications and Turning Diameter188
Fig 4 Powerwise QE 48V Charger189
B-SAFETY-Jan09pdf 0
NOTICES, CAUTIONS, WARNINGS AND DANGERS 0
Address practices not related to personal injury 0
IMPORTANT SAFETY WARNING 0
MODIFICATIONS TO VEHICLE 0
GENERAL MAINTENANCE 0
BEFORE SERVICING THE VEHICLE 0
Additional Warnings 0
Fig 1 Attach Accessory Wires to Battery Pack 0
Fig 2 Batteries, Charger Receptacle & Controller 0
BATTERY REMOVAL & INSTALLATION 0
The following text, there are references to removing/installing bolts, etc Additional hardware (nuts, washers, etc) that is re 0
1 Turn vehicle key to the off position and remove the key 0
2 Using an insulated wrench, disconnect the main negative (-) battery cable, BL- 0
3 Using an insulated wrench, disconnect the main positive (+) battery cable, BL+ 0
4 Using an insulated wrench, disconnect and remove all other wires connected to the batteries 0
5 Remove the two pan head Torx screws, (one on each side) from the battery strap 0
6 Remove the battery hold down and the battery strap by loosening all three hex nuts until they are at the end of the J-bolt an 0
7 Remove the batteries using commercially available battery carrier straps (2 per battery) and a portable lifting device Remov 0
Fig 3 Battery Removal 0
8 Check the area surrounding the battery tray for corrosion If any corrosion is found, it should be immediately removed with a 0
9 Replace the batteries, starting with the battery located at the back of the battery tray (4), making sure that it is positioned as shown 0
0
Fig 4 Battery Placement & Orientation 0
10 With the J-bolts in the battery hold down and held in place by the hex nuts on the end of the threaded portion; carefully po 0
11 Install the two pan head Torx screws through the ends of the battery strap into the holes on the vehicle frame and tighten them to 80 – 97 in lbs (9 – 11 Nm) torque 0
12 Inspect all wires and terminals and clean any corrosion from the battery terminals or wire terminals with a solution of baking soda and water, use a wire brush to completely remove corrosion if required 0
13 Carefully replace the wires on the battery terminals as shown Make sure to reconnect the main negative (-) battery cable, BL-, from the controller last 0
Fig 5 Battery Hold Down 0
Fig 6 Battery Connections 0
14 Tighten all battery terminal hardware to 95 – 105 in lbs (11 – 12 Nm) torque 0
15 Protect the battery terminals and battery cable ends with a commercially available protective coating 0
LIFTING THE VEHICLE 0
Fig 7 Lifting Points 0
C-BODY-Jan09pdf 0
Fig 1 Body 33
GENERAL 33
Vehicle accessories, such as the sun top and windshield, need to be removed before removing many body components 33
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 33
Fig 2 Christmas Tree Rivet Removal 33
BODY COMPONENT REPLACEMENT 34
Front Bumper and Cowl Support (Ref Fig 3) 34
1 Remove two hex nuts (11) securing the top of the bumper to the front strut mounting bolts 34
2 Pull top of bumper (12) forward and off of the bolts then lift upward to clear the frame channel between the front struts and pull the lower edge of the bumper down and away from the vehicle 34
3 Remove the washers (13) 34
Fig 3 Front Bumper and Cowl Support 34
Rocker Panels (Ref Fig 4) 34
1 Remove the lower rocker panel (1) by removing three torx screws (3) 34
2 Remove the upper rocker panel (2) by removing the two remaining torx screw (3) 34
Fig 4 Rocker Panel Removal 34
Floor Mat (Ref Fig 5) (Ref Fig 6) 34
1 Remove six christmas tree rivets (5) securing the floor mat to the floorboard (4) (Ref Fig 5) 34
2 Pull edge of floor mat from under edge of instrument panel and lift over accelerator and brake pedals 34
I 35
Fig 5 Floor Mat Fastener Removal 35
Fig 6 Floor Mat 35
Cowl and Instrument Panel (Ref Fig 7) (Ref Fig 8) 35
1 Remove four torx screws (11) securing the trim panel (12) to the instrument panel (13) and cowl (14) 35
2 Locate the tab in the fender well area, under the cowl The tab extends from the instrument panel through a slot in the cowl, 35
3 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 35
4 Disconnect wires to the instruments located in the trim panel then remove the trim panel 35
Fig 7 Cowl and Instrument Panel Trim 35
5 Remove three self threading nuts (20) securing the cup holder assembly (15) to the instrument panel Remove the cup holder an 36
Fig 8 Instrument Panel and Cup Holder 36
6 Remove four torx screws (16) and flat washers (17) securing the instrument panel along its lower edge and the two torx screws (18) located near the top of the instrument panel; one on each side The instrument panel can now be removed 36
Front Splash Guard (Ref Fig 9) 36
1 Remove two christmas tree rivets (22) securing front splash guard (21) to vehicle(Ref Fig 2) 36
Fig 9 Front Splash Guard 36
Fig 10 Golf Car Rear Body, Sweater Basket, Rear Bumper & Fender Liner 37
Sweater Basket (Ref Fig 10) 37
1 Remove four torx screws (28) and flanged nuts (29) on the top edge of the sweater basket assembly (27) 37
2 Remove two torx screws (30) securing the back of the sweater basket to the seat back supports 37
3 Slide the sweater basket assembly (27) off the seat back supports 37
Seat Back Assembly 37
1 Remove four torx screws (26) that secure the seat back assembly (25) to the support struts 37
Fender Liner (Ref Fig 2) (Ref Fig 10) 38
1 Remove four christmas tree rivets (42) that secure the liner (41) to the frame of the vehicle Two christmas tree rivets are located on the lower front edge of the fender liner, the two remaining are located along the inside surface above the wheel 38
Rear Body (Ref Fig 10) 38
1 Raise and remove the seat bottom assembly from the vehicle Remove four torx screws (26) securing the seat back (25) to the seat back supports 38
2 Using an insulated wrench, disconnect the battery cable at the negative (-), BL-, battery terminal 38
3 Remove the two Torx head screws that secure the controller splash shield to the body on the passenger side of the vehicle 38
4 Remove the two strut covers (36) by sliding the covers up and off of the struts 38
5 Disconnect the wires from the charging receptacle to the battery and unplug the wire to the main wiring harness If vehicle is equipped with an on board battery charger skip this step 38
6 Remove two torx screws (33) securing each hinge plate (32) along the front edge of the rear body then remove both hinge plates 38
7 Remove two inner torx screws (34) from the back edge of seat opening in the rear body 38
8 Remove four torx screws (31) from the lower edge of the rear body, two on the driver side and two on the passenger side 38
9 Remove two torx screws (35) from the bagwell floor 38
10 Lift the rear body, pivot the seat opening upward and towards the back of the vehicle to clear the seat back supports 38
Rear Bumper (Ref Fig 10) 38
1 Remove two torx head screws (item 35) from the bag well floor If the rear body has been removed from the vehicle go to step 2 38
2 Remove four hex head bolts (37) securing the bumper to the vehicle frame 38
3 Pull the rear bumper backwards off the frame; lifting the rear edge of the body may make removal easier 38
Fig 11 2 + 2 Rear Facing Seat & Foot Rest 39
2 + 2 Rear Facing Seat & Foot Rest 39
1 Remove four hex head bolts (10) that secure the seat bottom to the hip restraints 39
2 Lift the seat bottom (11) up and remove it from the vehicle 39
Fig 12 Rear Facing Seat Bottom 39
3 Loosen the torx head bolts (23) and nuts (22) (Ref Fig 15) that secure the seat back mounting brackets and hip restraint to the seat back support (14) 40
4 Slide the seat back assembly (15) with the brackets attached towards the back of the vehicle and remove it from the vehicle 40
5 To separate the seat back assembly (15) from the mounting brackets (17) remove the four torx head screws (16), two from each bracket 40
Fig 13 Rear Facing Seat Back 40
6 Remove the hex head bolt (20) and nut (21) from the lower leg of the driver side hip restraint 40
Fig 14 Rear Facing Seat Hip Restraint 40
7 Remove the hex nuts (22) from the torx head bolts (23) that secure the driver side hip restraint to the seat back support 40
8 Hold or support the hip restraint before removing the torx head bolts (23), once these bolts are removed the hip restraint is free from the vehicle 40
Fig 15 Upper Hip Restraint Bolts 40
9 Repeat steps 6 – 8 for the removal of the passenger side hip restraint 40
10 Remove four torx head bolts (25) that secure the front seat back to the seat back support bracket 40
Fig 16 Front Seat Back 40
11 Remove two torx head bolts (28) from the bagwell floor 40
Fig 17 Rear Facing Seat Foot Rest 40
12 Loosen four hex head bolts (30) Support the rear foot rest (29) before removing the two bolts closest to the rear of the ve 40
Fig 18 Foot Rest Removal 41
13 Remove four hex head bolts (31) and nuts (32) that secure the seat back support (33) to the frame, slide the seat back support up until it clears the rear body 41
Fig 19 Seat Back Support 41
Floorboard 42
1 Remove the two Torx screws (44) securing the front seat support frame (45) to the floorboard (48) 42
2 Remove two Torx socket head cap screws (46) and washers (47) that secure the floorboard (48) to the vehicle frame 42
Fig 20 Front Seat Support and Floorboard 42
BODY CARE MAINTENANCE 43
Cleaning 43
1 Wet the body with a low pressure hose to rinse off any loose dust and dirt 43
2 Wash the vehicle with a solution of mild soap and water using a soft cotton cloth Do not use abrasive cleaners or solvents 43
3 Apply clear coat safe automotive car wax to revive lost luster as needed Test the wax on an inconspicuous area before applying to the entire vehicle Buff the wax by hand Do not use a power buffer to remove wax from the body panels 43
PAINTING 43
Light Scratches 43
1 Clean the area to be repaired with clean, clear water 43
2 Using 1200 grit sandpaper, water sand the entire area of the scratch in a circular motion, spraying with water as needed, until the original scratch is no longer visible 43
3 Wipe the area dry and visually inspect to be sure that the original scratch has completely disappeared 43
4 Using 1500 grit sandpaper, wet sand the area until all of the marks left by the 1200 grit sandpaper are gone, pay close attention to the edges of the sanded area 43
5 Using the buffer with the 3-M 39001 compound on the foam pad, turn the buffer on at slow speed Use a cris- crossed pattern t 43
6 Using the buffer with the 3-M 39003 or 3-M 05995 Polishing glaze (depending upon the color of the vehicle body) on the foam p 43
7 Wipe with a clean, soft cloth to remove any compound from the surrounding area Any dirt on the cloth may mar the surface 43
Minor Scratches 43
1 Thoroughly clean the surface to be repaired with alcohol and dry 44
2 Touch up damaged area with sequential coats (two coats minimum recommended, allowing 30 – 45 minutes between coats, increasin 44
3 Use 1200 grit “wet” sand paper to blend touch up area level with the rest of the part being repaired Use a polishing compound to renew gloss and to further blend and transition newly painted surface 44
4 Clean with alcohol and dry 44
5 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 44
6 Wax or polish with Carnauba base product, available at any automotive parts distributor 44
Larger Scratches 44
1 Thoroughly clean the surface to be repaired with alcohol and dry 44
2 Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type touch- up paint 44
3 Apply spray touch up paint in light, even, overlapping strokes Multiple coats may be applied to provide adequate coverage and finish Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best color match 44
4 After painting, allow to dry overnight Smooth the mask lines using 1200 grit “wet” sand paper to blend touch up area level w 44
5 Clean with alcohol and dry 44
6 (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish 44
7 Wax or polish with Carnauba base product, available at any automotive parts distributor 44
Complete Panel Repair 44
Most paint manufacturers can perform a computer paint match to assure accurate color matching 44
F-FR SUSP-STEER-Jan09pdf 0
Fig 1 Front Suspension and Steering 71
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 71
MAINTENANCE 71
Tire Wear Diagnosis 71
Fig 2 Tire Wear 72
Wheel Alignment (Ref Fig 3) (Ref Fig 4) 72
1 Lift the front of the vehicle and support on jack stands as instructed in the SAFETY section 72
2 Rotate each wheel and scribe a paint line around the circumference of the tire at the center of the tread pattern 72
3 Lower vehicle with the tires in the straight ahead position 72
4 Roll vehicle forward approximately five feet in order to allow the tires to take their normal running position 72
72
Fig 3 Wheel Alignment 72
5 Measure the distance between the paint lines at both the front and rear of the tires The measurement taken at the front of the tires should be 0″ – 1/8″ (0 – 3 mm) less than the rear measurement 72
6 To adjust the wheel alignment, loosen the tie rod jam nut (1) and turn the tie rods and equal number of turns until the correct alignment is achieved Failure to turn both tie rods the same number of turns will result in poor turning radius 73
7 Tighten the tie rod jam nuts (1) and torque as specified 73
Fig 4 Tie Rod Jam Nut 73
Hub Assembly (Ref Fig 5) 73
1 Remove the dust cap (1) by tapping around the cap flange using a flat blade screwdriver and a ball peen hammer 73
2 Remove the lock nut (2) Note: it is recommended that locking nuts be replaced after a maximum of 5 removals 73
3 Remove hub (3) by sliding it off of the spindle 73
4 Clean spindle (4) thoroughly with solvent and inspect spindle threads; if threads are damaged replace the spindle 73
Spindle Assembly (Ref Fig 5) 73
1 Remove the hub assembly as described in the previous section 73
2 Loosen the nut securing the tie rod end to the spindle arm until it is flush with the end of the tie rod end 73
3 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the hammer to release the tie rod end from the spindle arm 73
4 Remove the nut and the tie rod end from the spindle arm 73
5 Remove hex nut (9) and hex head bolt (8), remove the spindle assembly (4 & 5) 73
Struts (Ref Fig 5) 74
1 Loosen the nut securing the tie rod end to the spindle arm until it is flush with the end of the tie rod end 74
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the hammer to release the tie rod end from the spindle arm 74
3 Remove the nut and the tie rod end from the spindle arm 74
4 Remove hex nut (9) and hex head bolt (8); the spindle and hub assemblies (1 – 7) can then be removed as a single unit 74
5 Remove the hex head bolt (11) securing lower end of strut to A-arm (13) 74
6 Remove the hex nut (20) and the hex head bolt (19) securing the top of the strut to the frame 74
Fig 5 Hub, Spindle, Strut and A-Arm Assemblies 75
A-Arm Assembly (Ref Fig 5) 75
1 Remove the hex head bolt (11) securing the a-arm (13) to the strut 75
2 Remove bushings (14 & 16) from a-arm, being careful to retain sleeve (15) 75
3 Inspect the sleeve (15) for wear or pitting; replace if sleeve (15) shows signs of wear or pitting 75
4 Remove two hex head bolts (17 & 18) securing the a- arm to the frame brackets 75
Clipboard and Steering Wheel (Ref Fig 6) (Ref Fig 7) (Ref Fig 8) 76
To maintain correct orientation when replacing steering wheel, first turn wheels straight ahead 76
1 Pull straight up on the lower edge of the clipboard to release the two retaining tabs 76
2 Using thumb for leverage as shown, reach from underneath the steering wheel with fingertips to first pull down, and then push up to release the two top clipboard retaining tabs 76
76
Fig 6 Clipboard Removal 76
3 Loosen the steering wheel retaining nut two or three turns Do not remove nut at this time 76
4 Apply upward pressure to the steering wheel by placing a plastic faced hammer against the steering wheel retaining nut Strik 76
Fig 7 Loosen Steering Wheel 76
5 When steering wheel is loosened, remove steering wheel retaining nut (1) and steering wheel (3) 76
Installation 76
6 Coat steering shaft splines lightly with a commercially available anti-seize compound 76
7 Make sure that wheels are positioned straight ahead 76
8 Align the steering wheel (3) on the steering shaft and push into place 76
Fig 8 Steering Wheel 76
9 Install steering wheel retaining nut (2) 76
10 Inspect the four retaining tabs on the clipboard (1) for white stress lines If stress lines are present, replace clipboard with a new one 76
11 Carefully press the top two tabs into the matching slots in the steering wheel, then press the bottom two tabs into the matching slots in the steering wheel 77
Steering Column Assembly & Yoke (Ref Fig 9) (Ref Fig 10) (Ref Fig 11) 77
1 Disconnect wiring for turn signals if vehicle is so equipped, as described in the Electrical Wiring section of this manual 77
2 Remove the lower cross bolt (8) from the yoke 77
Fig 9 Lower Cross Bolt 77
3 Remove four torx head screws (9) securing steering column assembly to vehicle frame 77
Fig 10 Steering Column Assembly Screws 77
4 Loosen the upper cross bolt (10) on the yoke and slide the yoke upward on the intermediate shaft to disengage from the steering box pinion 77
5 Turn the steering column assembly CCW about 10 to disengage the locking tabs and lift steering column with intermediate shaft and yoke out of vehicle, making note of the location of the notch in the steering column mounting bracket (up or down) 77
6 To separate the yoke from the intermediate shaft remove the upper cross bolt (10) and nut (11) then pull the yoke off of the intermediate shaft splines 77
Fig 11 Upper Cross Bolt 77
7 Apply a commercially available anti seize compound to the splines of the intermediate shaft and install the yoke onto the shaft Do not tighten the upper cross bolt and nut 77
8 To install the steering column assembly align the locking tabs on the mounting bracket with the slots in the frame and turn t 78
9 Install the four Torx screws (9) finger tight and then tighten to the proper toque 78
10 Apply a commercially available anti-seize compound to the splines of the steering box pinion before installing the yoke Do not install the lower cross bolt (8) at this time 78
11 To align the steering wheel with the front wheels use the following procedure: 78
a) Install the front wheels if they have been removed 78
b) Remove the jack stands and lower the vehicle to the ground 78
c) Push vehicle backward about 5 feet and then forward about 5 feet 78
d) If the steering wheel is not oriented properly remove the yoke from the steering box pinion and turn the steering wheel to the correct orientation 78
e) Install the yoke on the spline of the steering box pinion 78
6 Install the lower cross bolt (13) through the un- threaded portion of the yoke, making sure that the lock washer (14) is in place, into the threaded side 78
7 Tighten the upper cross bolt (10) and nut (11), making sure that the lock washer (12) is in place, then tighten the lower cross bolt (13) to the proper torque 78
Rod End / Ball Joint 78
1 Loosen the nut securing the tie rod end to the spindle arm 78
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the ball peen hammer to release tie rod from spindle arm 78
3 Remove the nut and remove the tie rod end from the spindle arm 78
4 Measure the length of the threaded part of the rod end to the jam nut or count the number of turns that it takes to remove the rod end 78
5 Install the new rod end the same number of turns that were counted when removing the old rod end or to the same measured length of the threaded part of the rod end to the jam nut 78
6 Install the rod end into the spindle 78
7 Tighten the jam nut against the rod end 78
8 Replace the other rod end if necessary 78
9 Check the wheel alignment and correct if necessary The procedure for alignment is detailed at the beginning of this section 78
Steering Box (Ref Fig 12) 78
1 Loosen the nut securing the tie rod end to the spindle arm 78
2 Using a ball joint separator as a lever, apply pressure to the ball joint and tap the spindle arm sharply with the ball peen hammer to release tie rod from spindle arm 78
3 Remove the nut and remove the tie rod end from the spindle arm 78
4 Repeat steps 3 through 5 for the remaining tie rod end 79
5 Remove the lower cross bolt securing the yoke to the steering box pinion 79
6 Loosen the upper cross bolt securing the yoke to the intermediate shaft 79
7 Remove the yoke from the steering box pinion by sliding it up the intermediate shaft 79
8 Remove three torx head screws (15) securing the steering box (16) to the vehicle frame 79
9 Remove steering box from the driver’s side of the vehicle 79
Fig 12 Steering Box 79
K-Electrical Wiring-2Feb09pdf 0
Fig 1 Main Electrical Harness 0
MAIN WIRING HARNESS 0
1 Disconnect the main wiring harness from the battery pack using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run’ position, turn the key switch to reverse, 0
3 Locate the tab under the cowl that extends from the instrument panel through a slot in the cowl, squeeze the legs of the tab 0
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 2 Instrument Panel & Trim 0
6 Remove the wiring harness from the front splash shield retaining clips 0
7 If vehicle is equipped with brake lights, disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder 0
8 Remove the Diagnostic Plug from the bottom of the cup holder 0
9 Disconnect the plug to the throttle enable switch 0
10 Disconnect the plug from the rotary position sensor 0
11 Disconnect the plug from the brake enable switch 0
12 Disconnect the wires from the rotary position sensor 0
13 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
14 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
15 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
16 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
17 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and move it out of the way 0
18 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
19 Unplug the large 23 pin connector (3) from the controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
20 Disconnect the plug for the resistor, remove two screws that secure the sensor on top of the resistor 0
Fig 3 Controller 0
21 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through 0
Fig 4 Run / Tow Switch 0
22 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
Fig 5 Reverse Warning Indicator 0
23 Remove hex nuts (16) and disconnect the red wire to the positive battery, BL+, terminal (20) and the yellow wire (17) to the 0
Fig 6 Solenoid Removal 0
24 Remove two hex head bolts (22) securing the solenoid (18) to the controller heat sink 0
25 Unplug the connectors from the motor brake (23), the motor temperature sensor (24) and the motor sensor (25) 0
Fig 7 Motor Connections 0
26 Remove main wiring harness from the vehicle 0
27 Install new main wiring harness making sure that it follows the proper path 0
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1, 2 & 3) 0
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels 0
Fig 8 Harness Routing & Pedal Connections 0
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4) 0
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6) 0
e) Connect the wires to the brake pedal rotary position sensor (8) and the brake enable switch connector (9) 0
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10) 0
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel 0
h) Feed the connectors for the key switch, the optional fuel gauge/state of charge meter and the diagnostic plug through the ope 0
Fig 9 Cup Holder 0
i) Route the wires (14) for the key switch and the optional fuel gauge/state of charge meter through the guide (15) on the front 0
l 0
Fig 10 Front Splash Shield 0
j) Connect the wire harness to the key switch 0
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side 0
l) Plug the connector (20) for the charger receptacle into the connector on the main wiring harness 0
Fig 11 Charger Receptacle 0
m) Install the Red wire (23) to the B+ terminal of the controller (Do not over tighten the terminal screw (24)) 0
n) Install the solenoid (25) on the controller heat sink using two hex head bolts (26) Make sure that the black wires from the solenoid to the wire harness are located at the top of the solenoid 0
o) Connect the Red wire (23) from the controller B+ to the bottom terminal of the solenoid (25), using a slim wrench to keep the 0
0
Fig 12 Controller Connections 0
p) Plug the 23 pin connector (3) from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
0
Fig 13 23 Pin Connector 0
q) Plug the connectors for the motor brake (31), the motor temperature sensor (32) and the motor sensor (33) into the connectors on the motor and motor brake 0
0
Fig 14 Motor Connections 0
18 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10) 0
19 Press the fuse holder (12) into the hole on the controller splash shield 0
Fig 15 Reverse Warning Indicator & Fuse 0
20 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notc 0
Fig 16 Run / Tow Switch 0
21 Replace the controller splash shield and secure it to the body with two Torx head screws 0
22 Connect the negative battery wires using an insulated wrench 0
23 Connect the positive battery wires using an insulated wrench 0
24 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL COMPONENTS 0
Run / Tow Switch (Ref Fig 17 on page K-6) 0
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the switch and wires 0
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts 0
4 Cut the wires from the existing run/tow switch close to the switch 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness 0
6 Remove the upper nut and seal (7) from the new switch (8) 0
7 Install the switch (8) with the notch towards the RUN direction 0
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table 0
Fig 17 Run / Tow Switch 0
9 Install the splash shield using three plastic rivets to secure the shield to the body and the controller 0
Reverse Warning Indicator (Ref Fig 18 on page K-7) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires 0
3 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
4 Cut the wires close to the reverse warning indicator (11) 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (11) to the wire harness 0
6 Secure the new reverse warning indicator (11) to the splash shield with the torx head screws (10) 0
7 Reinstall the splash shield 0
Fig 18 Reverse Warning Indicator 0
State of Charge / Fuel Gauge Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel 0
Fig 19 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20) 0
3 Depress the tabs on the fuel gage/state of charge meter (20) and push the unit out of the trim panel (11) 0
Fig 20 Fuel Gage/State of Charge Meter 0
4 Insert the new fuel gage/state of charge meter (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the main harness (21) to the fuel gage/state of charge meter (20) 0
6 Push the instrument panel trim (11) into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Fig 21 Main Wiring Harness 0
Fig 22 Accessory Wiring Harness 0
Fig 23 Accessory Wiring Harness and Accessories 0
ACCESSORY WIRING HARNESS 0
Replacing the Accessory Wiring Harness 0
1 Using an insulated wrench disconnect the accessory harness from the battery pack 0
2 Unplug the red and purple wires from the brake light relay to the main harness 0
3 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn, fuel gage (state of charge meter) and brake lights 0
4 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder 0
5 Remove the three fuse holders from the controller splash shield 0
6 Disconnect the tail light wiring connectors 0
7 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
8 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
9 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
10 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
11 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
12 Remove the accessory wiring harness from the vehicle 0
13 Install new accessory wiring harness making sure that it follows the proper path 0
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that 0
b) Route the wires for the headlight switch through the opening in the instrument panel for the headlight switch 0
c) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle 0
d) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn 0
e) Connect the horn button connector to the accessory harness under the cup holder 0
f) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmas tree rivet (2) 0
0
Fig 24 Brake Light Relay 0
g) Connect the red and purple wires from the accessory harness to the matching wires from the main wire harness 0
h) Route the rest of the harness down through the cup holder and in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor 0
i) Route the wires and connector for the driver side brake light between the rear body and the battery pack and around the drive 0
j) Route the fuses and the passenger side brake light wires between the rear body and the battery pack 0
k) Snap the fuse holders into the holes on the controller splash shield 0
l) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light 0
13 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL ACCESSORIES 0
Head Light Replacement 0
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward 0
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward 0
3 Disconnect the accessory harness connector (5) from the headlight (3) and turn signal (4) 0
0
Fig 25 Headlight Assembly 0
4 To install the headlight assembly, connect the accessory harness connection (6) to the turn signal (4) and the accessory harness connection (5) to the headlight bulb (3) 0
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position 0
Head Light Bulb Replacement 0
1 Turn the headlight bulb (3) clockwise and pull to remove 0
2 Disconnect the accessory harness from the light bulb 0
3 Connect the accessory harness to the light bulb 0
4 Align the bulb with the opening in the back of the headlight assembly 0
5 Turn the bulb (3) counter clockwise until it stops 0
Turn signal Bulb Replacement 0
1 Grip the turn signal bulb housing (7) and turn to align with slot then pull backward to remove housing from headlight assembly 0
Fig 26 Turn Signal Bulb Replacement 0
2 Remove bulb from housing and replace with a new one 0
3 Align housing with slot and insert turn signal housing (7) into headlight assembly, turn to lock in place 0
Head Light Switch Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel 0
Fig 27 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the head light switch (13) 0
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11) 0
Fig 28 Head Light Switch 0
4 Insert the new head light switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the accessory harness (12) to the headlight switch (13) 0
6 Push the instrument panel trim into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Turn Signal Switch Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the connector from the turn signal switch harness to the main electrical harness 0
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder 0
4 Remove the plastic cover from the steering column 0
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw 0
6 Remove the turn signal switch assembly including the clamp 0
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column 0
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape 0
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column 0
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove 0
11 Route the wire harness under the floor mat to the cupholder 0
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet 0
13 Plug the turn signal wire harness connector into the accessory wire harness 0
Turn signal Flasher Unit Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the flasher unit from the turn signal wire harness 0
3 Install the new flasher unit in the wire harness receptacle 0
4 Replace the top part of the cup holder (ref Section B) 0
Tail Light Assembly Replacement 0
1 Remove the four Torx head screws (15) that secure the tail light assembly (16) to the rear body 0
2 Pull the tail light (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17) 0
Fig 29 Tail Light Assembly 0
3 Plug the new tail light assembly (15) into the accessory wire harness connector (16) and push the tail light assembly (16) into the opening 0
4 Install the four Torx head screws (15) 0
Tail Light Lens Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Install the new lens and secure in place with the two phillips head screws 0
Tail Light Bulb Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Remove the light bulb 0
3 Install the new light bulb 0
4 Install the lens and secure in place with the two phillips head screws 0
Horn Button Replacement 0
1 Remove the horn button cover using a flat blade to work the cover off of the switch 0
2 Pull the upper corner of the floormat down to expose the switch retaining nut 0
3 Remove the nut that secures the horn button 0
4 Remove the horn button switch from the floor1board 0
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch 0
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder 0
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame 0
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness 0
9 Replace the floormat and install the horn button cover 0
Horn Replacement 0
1 Disconnect the accessory wire harness from the horn 0
2 Remove the hex head bolt that secures the horn to the mounting bracket 0
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt 0
4 Connect the accessory wire harness to the horn 0
A1_Model_Info-Jan09pdf 0
E-Z-GO Division of TEXTRON Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice 3
E-Z-GO Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual 3
GENERAL INFORMATION 4
SERVICE AND REPAIR MANUAL 3
ELECTRIC POWERED 3
GOLF CARS & PERSONAL VEHICLES 3
RXV FLEET GOLF CAR 3
RXV FREEDOM GOLF CAR 3
RXV SHUTTLE 2+2 3
STARTING MID-MODEL YEAR 2009 3
(MANUFACTURED BEGINNING FEBRUARY 23, 2009) 3
BATTERY PROLONGED STORAGE 4
E-ELEC SPEED CONTROLLER-16Feb09pdf 0
Fig 1 Electronic Speed Control 0
GENERAL 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
Fig 2 Christmas Tree Rivet Removal 0
Fig 3 Pedal Cover 0
Accelerator Pedal Assembly 0
1 Remove four christmas tree rivets securing pedal cover to floorboard 0
2 Remove pedal cover 0
3 Remove three torx screws (2) securing accelerator pedal assembly (1) to the floorboard (Ref Fig 4) 0
4 Disconnect the wires from the rotary position sensor (5) and the throttle enable switch (12) 0
5 Remove the two Torx screws (4) from the rotary position sensor (5) and remove sensor 0
6 Remove the two Torx screws (8) from the throttle enable switch (7) and remove the switch 0
Installation 0
7 Align the slot in the rotary position sensor (5) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (4) Use Loctite® 242; according to product instructions; on the two Torx screws 0
8 Position the throttle enable switch (7) oriented as shown, secure in place with two Socket head cap screws (6) Use Loctite 242; according to product instructions; on the two Socket head cap screws 0
9 Reconnect electrical harness to rotary position sensor (5) and to the throttle enable switch connector (7) 0
10 Place pedal assembly in position on the floorboard and secure with three Torx screws (2) 0
Fig 4 Accelerator Pedal 0
11 Install the pedal cover, using new christmas tree rivets, replace the floormat and rocker panels 0
Solenoid Replacement (Ref Fig 5) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove three plastic rivets (4) securing the controller splash shield; two on the rear body and one from the controller heat sink, raise the splash shield and place it off to one side out of the way 0
3 Disconnect the red wire from the upper terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire to the main wiring harness by removing the upper hex nut (6) 0
4 Disconnect the red wire from the lower terminal on the solenoid to B+ on the controller by removing the lower hex nut (6) 0
5 Remove two hex head bolts (7) securing the solenoid to the controller heat sink 0
6 Cut and strip the insulation from the end of one black wire from the solenoid to the wire harness; using a butt splice connector and heat shrink tubing splice the replacement solenoid wire to the wire harness, repeat for the remaining wire 0
7 Secure the new solenoid to the controller heat sink with the two hex head bolts (7) Orient the solenoid with the wires on top as shown 0
8 Connect the red wire from the controller B+ to the lower terminal of the solenoid and the white wire to the resistor, secure in place using a hex nut (6) 0
9 Connect the red wire from the positive (+), BL+, battery terminal and the yellow wire from the wiring harness to the upper terminal of the solenoid, secure in place with a hex nut (6) 0
10 Reinstall the splash shield 0
Fig 5 Controller 0
Controller (Ref Fig 5) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
3 Remove two Torx head screws (4) securing the controller splash shield to the rear body and the christmas tree rivet (2) securing the splash shield to the controller heat sink; position splash shield off to one side to allow access to the controller 0
4 Disconnect the Red positive (+) battery cable from the upper terminal of the solenoid 0
5 Disconnect the Red wire from the controller B+ terminal to the lower terminal of the solenoid 0
6 Remove two hex head bolts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 0
7 Disconnect the 2 pin connector (14) from the wire harness 0
8 Disconnect the 3 pin connector (12) from the resistor control (13) connector 0
9 Disconnect the 23 pin connector (9) from controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
10 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 0
11 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 0
12 Remove the front two hex head bolts (10) securing the controller assembly to the floorboard and loosen the rear hex head bolt (10) Slide the controller towards the front of the car and lift it out 0
13 To install the controller, position it on the floorboard; making sure that all wires are not pinched or under the controller 0
14 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 0
15 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 0
16 Install the solenoid on the controller heat sink using two hex head bolts (7) Make sure that the black wires from the solenoid to the wire harness are located at the top of the solenoid 0
17 Install the Red wire to the B+ terminal of the controller (Do not over tighten the terminal screw (11) 0
18 Plug the 23 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
19 Check all wires to be sure they are connected to the proper terminal 0
20 Position the Splash Shield under the edge of the seat opening, install the christmas tree rivet (2) and the two Torx head screws (4) 0
21 Reconnect wires to the battery pack 0
J-BRAKES-16FEB09pdf 0
Fig 1 Brake Pedal111
GENERAL111
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was111
Fig 2 Christmas Tree Rivet Removal111
Brake Pedal Assembly111
1 Remove four christmas tree rivets (20) securing pedal cover (21) to floorboard112
2 Remove pedal cover (21)112
Fig 3 Pedal Cover112
3 Mark the position of the retaining nut (12) on the threaded portion of the pedal return spring rod112
4 Loosen the retaining nut (12) to release the spring tension112
5 Disconnect the brake pedal return spring (2) by removing the E-ring (3) and the clevis pin (1)112
6 Remove four socket head hex screws (6) securing the brake pedal assembly to the floorboard (Ref Fig 5)112
7 Disconnect the wires from the rotary position sensor (8) and the brake enable switch (9)112
8 Remove the two Torx screws (6) from the rotary position sensor (7) and remove sensor112
9 Remove the two Socket head cap screws (11) from the throttle enable switch (10) and remove the switch112
10 Align the slot in the rotary position sensor (8) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (9) Use Loctite® 242, according to product instructions, with the two Torx screws (8)112
Fig 4 Brake Pedal Return Spring112
Fig 5 Brake Pedal112
11 Position the brake switch (10) oriented as shown, secure in place with two Socket head cap screws (11) Use Loctite 242, according to product instructions, with the two Socket head cap screws (11)112
12 Reconnect electrical harness to rotary position sensor (8) and to the brake switch (10)113
13 Place pedal assembly (5) in position on the floorboard and secure with four socket head hex screws (6)113
14 Install the clevis pin (1) through the brake pedal return spring arm (2) and secure with the E-clip (3)113
15 Tighten the return spring retaining nut (12) to the position marked113
16 Install the pedal cover (21), using new christmas tree rivets (20), replace the floormat and rocker panels‘113
M-REAR AXLE-APR9pdf 0
Fig 1 Rear Axle 0
REAR AXLE MAINTENANCE 0
Checking the Torque to Rotate 0
1 Remove the driver side rear wheel as noted in section D of this manual 0
2 Remove the cotter pin from the castle nut 0
3 With the socket and torque wrench apply pressure in a clockwise motion If the axle hub moves at 60 ft lbs or less replace t 0
Replacing the Lubricant 0
1 Remove bolts securing the oil pan 0
2 Using the rigid gasket scraper and the hammer separate the oil pan from the axle 0
3 Remove all traces of the old gasket material from the both surfaces and from the bolt holes 0
4 Clean oil pan after emptying the old oil 0
5 Apply Permatex RTV or equivalent to the gasket flange on the oil pan according to product instructions 0
6 Install the oil pan, tightening the bolts finger tight and then tighten to the proper torque value in a cross bolt pattern 0
7 Check axle for Fill plug, if a fill plug is present skip steps 8-16 and follow the fill procedure for axles with fill plugs 0
8 Remove the driver side rear wheel as shown in the Tire and Wheel section of this manual 0
9 Remove the driver side rear hub as shown in the rear hub in the next section 0
10 Remove the driver side axle shaft as shown in the next section 0
11 Thread flexible tubing into the axle tube, past the seal and into the gear area 0
12 Connect the flexible tubing to the fluid pump 0
13 Fill with 25 oz of Mobile 424 lubricant slowly 0
14 Install the axle as shown in the next section 0
15 Install the rear hub as shown in the next section 0
16 Install the rear wheel as shown in the Tire and Wheel section of this manual 0
Fill Procedure For Axles Fitted With Fill Plugs 0
Fig 2 FILL PLUG 0
REAR AXLE DISASSEMBLY 0
0
It is recommended that whenever a bearing seal or ’O’ ring is removed, it be replaced with a new one regardless of the mileage Always wipe the seals and ’O’ rings with a light oil before installing 0
Rear Hub 0
1 Remove cotter pin (1) 0
2 Remove castle nut (2) and flat washer(3) 0
3 Remove hub (4) from axle splines (5) 0
Fig 3 Hub 0
4 Coat the splines of the axle shaft (5) with a Dow-Corning Moly Coat TM77 anti-seize compound 0
5 Install hub (4) onto the axle shaft splines (5) 0
6 Install the flat washer (3) and the castle nut (2) onto the axle 0
7 Tighten castle nut (2) to specified torque If cotter pin (1) can not pass through the hole in the axle shaft continue to tig 0
Axle Shaft, Bearing and Seal Removal and Disassembly 0
1 Remove the outer snap ring from the axle tube 0
Fig 4 Outer Snap Ring 0
2 Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube 0
Fig 5 Remove Axle Shaft 0
3 Remove the bearing by supporting the inner race of the bearing on an arbor press bed and applying pressure to the threaded end of the axle shaft 0
Fig 6 Press Bearing from Shaft 0
4 Remove the inner snap ring 0
5 Remove the oil seal using a seal puller 0
Fig 7 Oil Seal Removal 0
6 Install the new oil seal using the seal installer (E-Z-GO P/N 18739-G1) to drive the seal into its correct position 0
Fig 8 Seal Installation 0
7 Install the inner snap ring 0
8 Carefully insert the axle shaft and bearing through the oil seal Rotate the shaft until the spline engages with the differential side gears 0
9 Install the outer snap ring 0
A3-GENERAL INFO-May09pdf 0
SERIAL NUMBER LOCATION 0
Fig 1 Serial Number Location on Steering Column 0
Fig 2 Serial Number on Front Frame 0
Fig 3 Serial Number on Rear Frame 0
0
Fig 4 Initial Service Chart 0
Towing 0
If a vehicle is towed in excess of 15 mph the motor brake will engage and slow the vehicle down 0
The RUN/TOW switch should always be returned to the ’RUN’ or (on CE vehicles) position after towing the vehicle If the switch is left in the ’TOW’ or (on CE vehicles) position for an extended period of time it will drain the batteries 0
Fig 5 Run/Tow Switch 0
PARKING BRAKE 0
Servicing The Vehicle 0
Routine Maintenance 0
Rear Axle 0
Tires 0
Vehicle Cleaning And Care 0
Sun Top And Windshield 0
Hauling 0
T 0
HARDWARE 0
CAPACITIES AND REPLACEMENT PARTS 0
Fig 6 Capacities 0
Fig 7 Replacement Part 0
Fig 8 Torque Specifications and Bolt Grades 0
PERIODIC SERVICE SCHEDULE 0
3 – CHECK C&A – CHECK & ADJUST CL – CLEAN R – REPLACE 0
Fig 9 Periodic Service Schedule 0
M-REAR AXLE-APR9pdf 0
Fig 1 Rear Axle145
REAR AXLE MAINTENANCE145
Checking the Torque to Rotate145
1 Remove the driver side rear wheel as noted in section D of this manual145
2 Remove the cotter pin from the castle nut145
3 With the socket and torque wrench apply pressure in a clockwise motion If the axle hub moves at 60 ft lbs or less replace t145
Replacing the Lubricant145
1 Remove bolts securing the oil pan146
2 Using the rigid gasket scraper and the hammer separate the oil pan from the axle146
3 Remove all traces of the old gasket material from the both surfaces and from the bolt holes146
4 Clean oil pan after emptying the old oil146
5 Apply Permatex RTV or equivalent to the gasket flange on the oil pan according to product instructions146
6 Install the oil pan, tightening the bolts finger tight and then tighten to the proper torque value in a cross bolt pattern146
7 Check axle for Fill plug, if a fill plug is present skip steps 8-16 and follow the fill procedure for axles with fill plugs146
8 Remove the driver side rear wheel as shown in the Tire and Wheel section of this manual146
9 Remove the driver side rear hub as shown in the rear hub in the next section146
10 Remove the driver side axle shaft as shown in the next section146
11 Thread flexible tubing into the axle tube, past the seal and into the gear area146
12 Connect the flexible tubing to the fluid pump146
13 Fill with 25 oz of Mobile 424 lubricant slowly146
14 Install the axle as shown in the next section146
15 Install the rear hub as shown in the next section146
16 Install the rear wheel as shown in the Tire and Wheel section of this manual146
Fill Procedure For Axles Fitted With Fill Plugs146
Fig 2 FILL PLUG146
REAR AXLE DISASSEMBLY146
146
It is recommended that whenever a bearing seal or ’O’ ring is removed, it be replaced with a new one regardless of the mileage Always wipe the seals and ’O’ rings with a light oil before installing146
Rear Hub147
1 Remove cotter pin (1)147
2 Remove castle nut (2) and flat washer(3)147
3 Remove hub (4) from axle splines (5)147
Fig 3 Hub147
4 Coat the splines of the axle shaft (5) with a Dow-Corning Moly Coat TM77 anti-seize compound147
5 Install hub (4) onto the axle shaft splines (5)147
6 Install the flat washer (3) and the castle nut (2) onto the axle147
7 Tighten castle nut (2) to specified torque If cotter pin (1) can not pass through the hole in the axle shaft continue to tig147
Axle Shaft, Bearing and Seal Removal and Disassembly147
1 Remove the outer snap ring from the axle tube147
Fig 4 Outer Snap Ring147
2 Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube147
Fig 5 Remove Axle Shaft147
3 Remove the bearing by supporting the inner race of the bearing on an arbor press bed and applying pressure to the threaded end of the axle shaft147
Fig 6 Press Bearing from Shaft148
4 Remove the inner snap ring148
5 Remove the oil seal using a seal puller148
Fig 7 Oil Seal Removal148
6 Install the new oil seal using the seal installer (E-Z-GO P/N 18739-G1) to drive the seal into its correct position148
Fig 8 Seal Installation148
7 Install the inner snap ring148
8 Carefully insert the axle shaft and bearing through the oil seal Rotate the shaft until the spline engages with the differential side gears148
9 Install the outer snap ring148
G-MOTOR-08AUG09pdf 0
Bearing Encoder 0
REMOVAL 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Remove the motor brake and motor from the axle shaft (See previous section instructions for the removal) 0
7 Remove the snap ring (N) and wave washer (O) that secures the motor shaft to the motor end cap 0
8 Tap on the motor shaft with a rubber mallet to disengage the shaft from the encoder bearing 0
9 Remove four long hex head bolts (L) and washers (M) from the motor, retain the bolts and washers for use in reassembling the motor as shown 0
10 Tap the corners or ears of the end cap to disengage the end cap flange from the motor housing 0
11 Remove four phillips head screws (7) and washers (5) that secure the encoder bearing retaining plates (6) 0
12 Remove the phillips head screw (4) and wire clip (2) from the inside of the end cap 0
13 Using a mallet or hammer, tap the encoder bearing (1) from the outside of the end cap to remove it from the bore Be careful to avoid damage to the bearing bore in the end cap 0
INSTALLATION 0
1 Position the encoder bearing (1) with the wires aligned with the recess in the inside of the end cap 0
2 Seat the encoder bearing into the end cap bore by tapping around the outer edge of the bearing Avoid tapping on the encoder, make sure to tap only on the rim of the bearing, use a brass drift or rod if necessary 0
3 Secure the encoder bearing with the retainer plates (6), screws (7), washers(5) 0
4 Fix the clip (2) to the bearing cable and secure the clip to the motor end plate with the screw (4), washer (3) (removed in step 12 under Removal section) as shown below 0
5 Tighten all the hardware to the specified torque value 0
6 Re-install motor end cap back to the stator and secure with the bolts (L) and washers (M) (removed in step 9 under removal section), tighten to specified torque value 0
Fig 1 Motor 0
GENERAL 0
Motor 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 With an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Remove three plastic rivets securing the controller splash shield; two on the passenger side of the body at the seat opening and one from the controller 0
7 Disconnect motor wires from controller terminals, U, V and W, refer to the Speed Control section of this manual for torque complete information on these connections 0
8 Disconnect the main harness connector (31) to the motor brake 0
9 Disconnect main harness connector (32) to the motor temperature sensor and the main harness connector (33) to the motor sensor 0
0
Fig 2 Motor Connections 0
10 Pull the motor wires out through the bagwell 0
11 Remove the six hex head bolts (2) and split lock washers (3) securing the motor (1) to the axle and carefully slide the moto 0
Fig 3 Motor 0
12 Before installing the motor on the axle apply lubricant (80% molybdenum disulfide paste) to the input shaft spline The approved lubricants are: Dow Corning 77, Molykote (r) M-77 paste or Tribology TAS 100 EP 0
13 Carefully align the motor spline with the input shaft, orient the motor with the wires near the top and install the six hex 0
Fig 4 Motor Bolt Tightening Sequence 0
14 Connect the wires from the main harness to the motor brake, the motor sensor and the motor temperature sensor 0
15 Connect the wires from the motor to the controller; the green wire to terminal U, the yellow wire to terminal V and the blue 0
Fig 5 Motor to Controller Connections 0
16 Connect the negative (-) battery cable, BL-, to the battery pack 0
Motor Brake 0
REMOVAL 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Disconnect wire harness from motor brake 0
7 Remove three hex head bolts (32) and lock washers (33) from the motor brake assembly (31) 0
Fig 6 Motor Brake 0
INSTALLATION 0
1 Position the brake with the connector at the top as shown above and install the three hex head bolts (32) loosely 0
2 Connect the wire harness to the motor brake and move the Run/Tow switch to the ’TOW’ position This will provide power to the brake to align the disc material 0
3 Tighten the three hex head bolts evenly to the specified torque 0
4 Move the Run/Tow switch to the ’RUN’ position 0
E-ELEC SPEED CONTROLLER- 12Jan10pdf 0
Fig 1 Electronic Speed Control 0
GENERAL 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, was 0
Fig 2 Christmas Tree Rivet Removal 0
Fig 3 Pedal Cover 0
Accelerator Pedal Assembly 0
1 Remove four christmas tree rivets securing pedal cover to floorboard 0
2 Remove pedal cover 0
3 Remove three torx screws (2) securing accelerator pedal assembly (1) to the floorboard (Ref Fig 4) 0
4 Disconnect the wires from the rotary position sensor (5) and the throttle enable switch (12) 0
5 Remove the two Torx screws (4) from the rotary position sensor (5) and remove sensor 0
6 Remove the two Torx screws (8) from the throttle enable switch (7) and remove the switch 0
Installation 0
7 Align the slot in the rotary position sensor (5) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (4) Use Loctite® 242; according to product instructions; on the two Torx screws 0
8 Position the throttle enable switch (7) oriented as shown, secure in place with two Torx screws (6) Use Loctite 242; accordi 0
9 Place pedal assembly in position on the floorboard and secure with three Torx screws (2) 0
Fig 4 Accelerator Pedal 0
10 Install the pedal cover, using new christmas tree rivets, replace the floormat and rocker panels 0
Solenoid Replacement 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove the controller splash shield; some vehicles will have two torx head screws and one christmas tree rivet, the remaining 0
1 Disconnect the red wire from the upper terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire to the main wiring harness by removing the upper hex nut (5) 0
2 Disconnect the red wire from the lower terminal on the solenoid to B+ on the controller by removing the lower hex nut (6) 0
3 Remove two hex head nuts (7) securing the solenoid to the controller heat sink 0
4 Cut the two wires from the solenoid to the wire harness and strip approximately 1/2″ (13 mm) of insulation from the ends of the wires from the harness 0
5 Insert the stripped wires from the harness into ends of the ring terminals and crimp both ends 0
Fig 5 Old Style Rectangular Solenoid 0
Round Solenoid Removal 0
1 Disconnect the red wire (13) from the front terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire (14) to the main wiring harness by removing the front hex nut (6) 0
2 Disconnect the red wire (11) from the back terminal on the solenoid (4) to B+ on the controller and and white wire (12) from resistor by removing the back hex nut (5) 0
3 Disconnect the red wire (9) and black wire (8) from the terminals by removing smaller hex nuts (15) 0
4 Remove two hex head nuts (10) securing the solenoid (4) to the controller heat sink 0
Solenoid Installation 0
1 Secure the solenoid (4) to the controller heat sink with the two hex head nuts (10) 0
2 Reconnect the red wire (9) and black wire (8) from harness to solenoid (4) as shown and secure in place with two smaller hex nuts (15) 0
3 Reconnect the red wire (11) from the controller B+ to the back terminal of the solenoid (4) and the white wire (12) to the resistor, secure in place using a hex nut (5) Be sure to place larger terminal wires first on studs with smaller wires on last 0
4 Connect the red wire (13) from the positive (+), BL+, battery terminal and the yellow wire (14) from the wiring harness to th 0
Fig 6 Round Solenoid 0
5 Reinstall the electronic controller shield as before 0
6 Reinstall three christmas tree rivets (1) to secure the shield to the body and the controller 0
7 Connect the negative (-) cable to the battery 0
Controller 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
3 Remove three christmas tree rivets (4) securing the controller splash shield to the rear body and to the controller heat sink; position splash shield off to one side to allow access to the controller 0
Fig 7 Controller Splash Shield Cover 0
4 Disconnect the Red positive (+) battery cable from the front terminal of the solenoid 0
5 Disconnect the Red wire from the controller B+ terminal to the back terminal of the solenoid 0
6 Remove two hex head nuts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 0
7 Disconnect the 2 pin connector (14) from the wire harness 0
8 Disconnect the 3 pin connector (12) from the resistor control (13) connector 0
9 Disconnect the 23 pin connector (9) from controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
10 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 0
11 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 0
12 Remove the front two hex head bolts (10) securing the controller assembly to the floorboard and loosen the rear hex head bolt (10) Slide the controller towards the front of the car and lift it out 0
Fig 8 Solenoid Connections 0
Installation 0
13 To install the controller, position it on the floorboard; making sure that all wires are not pinched or under the controller 0
14 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 0
15 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 0
16 Install the solenoid on the controller heat sink using two hex head nuts (7) Reconnect the Red positive (+) battery cable t 0
17 Install the Red wire to the B+ terminal of the controller (Do not over tighten the terminal screw (11) 0
18 Plug the 23 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
19 Check all wires to be sure they are connected to the proper terminal 0
20 Position the Splash Shield under the edge of the seat opening, install the three christmas tree rivets (4) 0
21 Reconnect wires to the battery pack Replace any worn or damaged hardware as required 0
K-Electrical Wiring-12jan10pdf 0
Fig 1 Main Electrical Harness 0
MAIN WIRING HARNESS 0
1 Disconnect the main wiring harness from the battery pack using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run’ position, turn the key switch to reverse, 0
3 Locate the tab under the cowl that extends from the instrument panel through a slot in the cowl, squeeze the legs of the tab 0
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 2 Instrument Panel & Trim 0
6 Remove the wiring harness from the front splash shield retaining clips 0
7 If vehicle is equipped with brake lights, disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder 0
8 Remove the Diagnostic Plug from the bottom of the cup holder 0
9 Disconnect the plug to the throttle enable switch 0
10 Disconnect the plug from the rotary position sensor 0
11 Disconnect the plug from the brake enable switch 0
12 Disconnect the wires from the rotary position sensor 0
13 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
14 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
15 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
16 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
17 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and move it out of the way 0
18 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
19 Unplug the large 23 pin connector (3) from the controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
20 Disconnect the plug for the resistor, remove two screws that secure the sensor on top of the resistor 0
Fig 3 Controller 0
21 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through 0
Fig 4 Run / Tow Switch 0
22 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
Fig 5 Reverse Warning Indicator 0
23 Determine which solenoid is installed Two types of solenoid have been used for this vehicle, on early vehicles the solenoid 0
24 HARDWIRED RECTANGULAR: Disconnect all wires from the terminal posts and remove two hex nuts (7) securing the solenoid to the controller heatsink 0
Fig 6 Old Style Rectangular Solenoid 0
25 ROUND: Remove two larger hex nuts (16) from the larger terminal posts and disconnect red wire from controller B+ terminal an 0
Fig 7 Solenoid Connections 0
26 Unplug the connectors from the motor brake (31), the motor temperature sensor (32) and the motor sensor (33) 0
Fig 8 Motor Connections 0
27 Remove main wiring harness from the vehicle 0
28 Install new main wiring harness making sure that it follows the proper path 0
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1, 2 & 3) 0
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels 0
Fig 9 Harness Routing & Pedal Connections 0
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4) 0
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6) 0
e) Connect the wires to the brake pedal rotary position sensor (8) and the brake enable switch connector (9) 0
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10) 0
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel 0
h) Feed the connectors for the key switch, the optional fuel gauge/state of charge meter and the diagnostic plug through the ope 0
Fig 10 Cup Holder 0
i) Route the wires (14) for the key switch and the optional fuel gauge/state of charge meter through the guide (15) on the front 0
l 0
Fig 11 Front Splash Shield 0
j) Connect the wire harness to the key switch 0
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side 0
l) Plug the connector (20) for the charger receptacle into the connector on the main wiring harness 0
Fig 12 Charger Receptacle 0
m) A new solenoid will ONLY be installed if the old one was connected directly to the wire harness (hard wired) Install solenoid (18) on the controller heat sink using two nuts (22) 0
n) Reconnect the black wire (23) and red wire (24) to the solenoid (18) as shown and secure in place with small hex nuts (28) 0
o) Connect the Red wire from the controller B+ and the white wire (17) from the resistor to the back terminal of the solenoid (1 0
p) Connect the Red wire (20) from the positive (+), BL+, battery terminal and the yellow wire (21) from the wiring harness to th 0
0
Fig 13 Controller Connections 0
q) Plug the 23 pin connector (3) from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
0
Fig 14 23 Pin Connector 0
r) Plug the connectors for the motor brake (31), the motor temperature sensor (32) and the motor sensor (33) into the connectors on the motor and motor brake 0
0
Fig 15 Motor Connections 0
29 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10) 0
30 Press the fuse holder (12) into the hole on the controller splash shield 0
Fig 16 Reverse Warning Indicator & Fuse 0
31 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notc 0
Fig 17 Run / Tow Switch 0
32 Replace the controller splash shield and secure it to the body with two Torx head screws 0
33 Connect the negative battery wires using an insulated wrench 0
34 Connect the positive battery wires using an insulated wrench 0
35 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL COMPONENTS 0
Run / Tow Switch (Ref Fig 18 on page K-7) 0
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the switch and wires 0
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts 0
4 Cut the wires from the existing run/tow switch close to the switch 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness 0
6 Remove the upper nut and seal (7) from the new switch (8) 0
7 Install the switch (8) with the notch towards the RUN direction 0
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table 0
Fig 18 Run / Tow Switch 0
9 Install the splash shield using three plastic rivets to secure the shield to the body and the controller 0
Reverse Warning Indicator (Ref Fig 19 on page K-7) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires 0
3 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
4 Cut the wires close to the reverse warning indicator (11) 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (11) to the wire harness 0
6 Secure the new reverse warning indicator (11) to the splash shield with the torx head screws (10) 0
7 Reinstall the splash shield 0
Fig 19 Reverse Warning Indicator 0
State of Charge / Fuel Gauge Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel 0
Fig 20 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20) 0
3 Depress the tabs on the fuel gage/state of charge meter (20) and push the unit out of the trim panel (11) 0
Fig 21 Fuel Gage/State of Charge Meter 0
4 Insert the new fuel gage/state of charge meter (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the main harness (21) to the fuel gage/state of charge meter (20) 0
6 Push the instrument panel trim (11) into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Fig 22 Main Wiring Harness 0
Fig 23 Accessory Wiring Harness 0
Fig 24 Accessory Wiring Harness and Accessories 0
ACCESSORY WIRING HARNESS 0
Replacing the Accessory Wiring Harness 0
1 Using an insulated wrench disconnect the accessory harness from the battery pack 0
2 Unplug the red and purple wires from the brake light relay to the main harness 0
3 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn, fuel gage (state of charge meter) and brake lights 0
4 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder 0
5 Remove the three fuse holders from the controller splash shield 0
6 Disconnect the tail light wiring connectors 0
7 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
8 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
9 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
10 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
11 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
12 Remove the accessory wiring harness from the vehicle 0
13 Install new accessory wiring harness making sure that it follows the proper path 0
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that 0
b) Route the wires for the headlight switch through the opening in the instrument panel for the headlight switch 0
c) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle 0
d) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn 0
e) Connect the horn button connector to the accessory harness under the cup holder 0
f) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmas tree rivet (2) 0
0
Fig 25 Brake Light Relay 0
g) Connect the red and purple wires from the accessory harness to the matching wires from the main wire harness 0
h) Route the rest of the harness down through the cup holder and in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor 0
i) Route the wires and connector for the driver side brake light between the rear body and the battery pack and around the drive 0
j) Route the fuses and the passenger side brake light wires between the rear body and the battery pack 0
k) Snap the fuse holders into the holes on the controller splash shield 0
l) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light 0
13 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL ACCESSORIES 0
Head Light Replacement 0
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward 0
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward 0
3 Disconnect the accessory harness connector (5) from the headlight (3) and turn signal (4) 0
0
Fig 26 Headlight Assembly 0
4 To install the headlight assembly, connect the accessory harness connection (6) to the turn signal (4) and the accessory harness connection (5) to the headlight bulb (3) 0
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position 0
Head Light Bulb Replacement 0
1 Turn the headlight bulb (3) clockwise and pull to remove 0
2 Disconnect the accessory harness from the light bulb 0
3 Connect the accessory harness to the light bulb 0
4 Align the bulb with the opening in the back of the headlight assembly 0
5 Turn the bulb (3) counter clockwise until it stops 0
Turn signal Bulb Replacement 0
1 Grip the turn signal bulb housing (7) and turn to align with slot then pull backward to remove housing from headlight assembly 0
Fig 27 Turn Signal Bulb Replacement 0
2 Remove bulb from housing and replace with a new one 0
3 Align housing with slot and insert turn signal housing (7) into headlight assembly, turn to lock in place 0
Head Light Switch Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel 0
Fig 28 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the head light switch (13) 0
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11) 0
Fig 29 Head Light Switch 0
4 Insert the new head light switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the accessory harness (12) to the headlight switch (13) 0
6 Push the instrument panel trim into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Turn Signal Switch Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the connector from the turn signal switch harness to the main electrical harness 0
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder 0
4 Remove the plastic cover from the steering column 0
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw 0
6 Remove the turn signal switch assembly including the clamp 0
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column 0
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape 0
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column 0
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove 0
11 Route the wire harness under the floor mat to the cupholder 0
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet 0
13 Plug the turn signal wire harness connector into the accessory wire harness 0
Turn signal Flasher Unit Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the flasher unit from the turn signal wire harness 0
3 Install the new flasher unit in the wire harness receptacle 0
4 Replace the top part of the cup holder (ref Section B) 0
Tail Light Assembly Replacement 0
1 Remove the four Torx head screws (15) that secure the tail light assembly (16) to the rear body 0
2 Pull the tail light (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17) 0
Fig 30 Tail Light Assembly 0
3 Plug the new tail light assembly (15) into the accessory wire harness connector (16) and push the tail light assembly (16) into the opening 0
4 Install the four Torx head screws (15) 0
Tail Light Lens Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Install the new lens and secure in place with the two phillips head screws 0
Tail Light Bulb Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Remove the light bulb 0
3 Install the new light bulb 0
4 Install the lens and secure in place with the two phillips head screws 0
Horn Button Replacement 0
1 Remove the horn button cover using a flat blade to work the cover off of the switch 0
2 Pull the upper corner of the floormat down to expose the switch retaining nut 0
3 Remove the nut that secures the horn button 0
4 Remove the horn button switch from the floor1board 0
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch 0
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder 0
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame 0
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness 0
9 Replace the floormat and install the horn button cover 0
Horn Replacement 0
1 Disconnect the accessory wire harness from the horn 0
2 Remove the hex head bolt that secures the horn to the mounting bracket 0
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt 0
4 Connect the accessory wire harness to the horn 0
A3-GENERAL INFO-Mar10pdf 0
SERIAL NUMBER LOCATION 0
Fig 1 Serial Number Location on Steering Column 0
Fig 2 Serial Number on Front Frame 0
Fig 3 Serial Number on Rear Frame 0
0
Fig 4 Initial Service Chart 0
Towing 0
If a vehicle is towed in excess of 15 mph the motor brake will engage and slow the vehicle down 0
The RUN/TOW switch should always be returned to the ’RUN’ or (on CE vehicles) position after towing the vehicle If the switch is left in the ’TOW’ or (on CE vehicles) position for an extended period of time it will drain the batteries 0
Fig 5 Run/Tow Switch 0
PARKING BRAKE 0
Servicing The Vehicle 0
Routine Maintenance 0
Rear Axle 0
Tires 0
Vehicle Cleaning And Care 0
Sun Top And Windshield 0
Hauling 0
T 0
HARDWARE 0
CAPACITIES AND REPLACEMENT PARTS 0
Fig 6 Capacities 0
Fig 7 Replacement Part 0
Fig 8 Torque Specifications and Bolt Grades 0
PERIODIC SERVICE SCHEDULE 0
3 – CHECK C&A – CHECK & ADJUST CL – CLEAN R – REPLACE 0
Fig 9 Periodic Service Schedule 0
L-REAR SUSPENSION-Jan09pdf 0
Fig 1 Rear Suspension139
GENERAL139
In the following text, there are references to removing/installing hardware (nuts, bolts, screws, washers, etc) Hardware that 139
SHOCK ABSORBER (Ref Fig 2)139
1 Remove the two Torx head screws that secure the rear access panel140
2 Remove the rear access panel140
3 Raise the rear of the vehicle in accordance with the instructions provided in Section B of this manual and support the rear of the vehicles on the outer ends of the rear bumper140
4 Remove the hex head bolt (5) and washer (4) from the lower end of the shock absorber140
5 Remove the hex head bolt (1) and washer (2) from the upper end of the shock absorber140
Fig 2 Shock Absorber140
6 Install the hex head bolt (1) and washer (2) for the upper shock mount, make sure that the shock (3) is oriented as shown140
7 Install the hex head bolt (5) and washer (4) through the lower end of the shock (3) into the mounting bracket on the axle140
REAR LEAF SPRING (Ref Fig 3)140
If both leaf springs are to be replaced and the rear axle is not being removed, it is important to remove and replace one leaf spring at a time It is recommended that leaf springs be replaced in pairs 140
Removal140
1 Raise the rear of the vehicle in accordance with the instructions provided in Section B of this manual140
2 Place a floor jack under the center section of the rear axle and raise the jack just enough to place a second set of jack stands under the axle tubes140
3 Remove the two hex nuts (3) from the U-bolt (1) on the axle allowing the leaf spring plate (2) to slide off of the U-bolt140
4 Remove the hex head bolts (15) and nuts (11) from the shackle plates (12) at the rear of the frame Remove the flanged urethane bushings (13) and spacers (14) as well140
5 Remove the hex head bolt (7) and nut (4) from the forward leaf spring mounting bracket The leaf spring (16) can now be removed from the vehicle140
6 Remove the flanged urethane bushings (6) and the spacer (5) from the leaf spring141
Installation141
7 Apply a commercially available anti-seize compound to the large flanged urethane bushings (6)141
8 Install the large flanged urethane bushings (6) and spacer (5) in the end of the leaf spring (16) and place the leaf spring in the forward mounting bracket141
9 Install the hex head bolt (7) and nut (4) to secure the forward end of the leaf spring in the bracket141
10 Apply a commercially available anti-seize compound to the flanged urethane bushings (13)141
11 Install one set of the smaller flanged urethane bushings (13) and spacer (14) in the rear frame mounting holes141
12 Position the shackle plates (12) over the bushings and install the hex head bolt (15) and nut (11)141
13 Install the remaining pair of flanged urethane bushings (13) and spacer (14) in the leaf spring (16) Position the leaf spring between the shackle plates (12) and install the hex head bolt (15) and nut (11)141
14 Align the pin on the leaf spring (16) with the hole in the axle bracket and install the leaf spring plate (2) on to the U-bolt (1) Secure plate in place with two hex nuts (3) and tighten both nuts equally to the specified torque141
15 Torque all hardware as specified making sure that the leaf spring pin remains aligned with the holes in the axle mounting bracket and the leaf spring mounting plate141
Fig 3 Rear Leaf Spring141
G-MOTOR-08 july 2010pdf 0
Bearing Encoder 0
REMOVAL 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Remove the motor brake and motor from the axle shaft (See previous section instructions for the removal) 0
7 Remove the snap ring (N) and wave washer (O) that secures the motor shaft to the motor end cap 0
8 Tap on the motor shaft with a rubber mallet to disengage the shaft from the encoder bearing 0
9 Remove four long hex head bolts (L) and washers (M) from the motor, retain the bolts and washers for use in reassembling the motor as shown 0
10 Tap the corners or ears of the end cap to disengage the end cap flange from the motor housing 0
11 Remove four phillips head screws (7) and washers (5) that secure the encoder bearing retaining plates (6) 0
12 Remove the phillips head screw (4) and wire clip (2) from the inside of the end cap 0
13 Using a mallet or hammer, tap the encoder bearing (1) from the outside of the end cap to remove it from the bore Be careful to avoid damage to the bearing bore in the end cap 0
INSTALLATION 0
1 Position the encoder bearing (1) with the wires aligned with the recess in the inside of the end cap 0
2 Seat the encoder bearing into the end cap bore by tapping around the outer edge of the bearing Avoid tapping on the encoder, make sure to tap only on the rim of the bearing, use a brass drift or rod if necessary 0
3 Secure the encoder bearing with the retainer plates (6), screws (7), washers(5) 0
4 Fix the clip (2) to the bearing cable and secure the clip to the motor end plate with the screw (4), washer (3) (removed in step 12 under Removal section) as shown below 0
5 Tighten all the hardware to the specified torque value 0
6 Re-install motor end cap back to the stator and secure with the bolts (L) and washers (M) (removed in step 9 under removal section), tighten to specified torque value 0
O 0
Fig 1 Motor 0
GENERAL 0
Motor 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 With an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Remove three plastic rivets securing the controller splash shield; two on the passenger side of the body at the seat opening and one from the controller 0
7 Disconnect motor wires from controller terminals, U, V and W, refer to the Speed Control section of this manual for torque complete information on these connections 0
8 Disconnect the main harness connector (31) from the motor brake and main harness connector (32) from the motor temperature sensor as shown below 0
9 Two different electric motors have been used on the vehicle, the harness connections depend on which motor is installed on th 0
10 OLD MOTOR: Disconnect the main harness connector (33) from the motor sensor as shown 0
0
Fig 2 Motor Connections (Early Vehicles) 0
11 NEW MOTOR: Disconnect one end of the adaptor from the motor sensor harness, disconect the other end of the adaptor harness from the harness connector as shown in detail 0
Fig 3 Motor Connections (Later Vehicles) 0
12 Pull the motor wires out through the bagwell 0
13 Remove the six hex head bolts (2) and split lock washers (3) securing the motor (1) to the axle and carefully slide the moto 0
Fig 4 Motor 0
14 Before installing the motor on the axle apply lubricant (80% molybdenum disulfide paste) to the input shaft spline The approved lubricants are: Dow Corning 77, Molykote (r) M-77 paste or Tribology TAS 100 EP 0
15 Carefully align the motor spline with the input shaft, orient the motor with the wires near the top and install the six hex 0
Fig 5 Motor Bolt Tightening Sequence 0
16 Connect the wires from the main harness to the motor brake (31), the motor sensor (33) and the motor temperature sensor (32) 0
17 Connect the wires from the motor to the controller; the green wire to terminal U, the yellow wire to terminal V and the blue 0
Fig 6 Motor to Controller Connections 0
18 Connect the negative (-) battery cable, BL-, to the battery pack 0
Motor Brake 0
REMOVAL 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Disconnect wire harness from motor brake 0
7 Remove three hex head bolts (32) and lock washers (33) from the motor brake assembly (31) 0
Fig 7 Motor Brake 0
INSTALLATION 0
1 Position the brake with the connector at the top as shown above and install the three hex head bolts (32) loosely 0
2 Connect the wire harness to the motor brake and move the Run/Tow switch to the ’TOW’ position This will provide power to the brake to align the disc material 0
3 Tighten the three hex head bolts evenly to the specified torque 0
4 Move the Run/Tow switch to the ’RUN’ position 0
G-MOTOR-08 july 2010pdf 0
Bearing Encoder 0
REMOVAL 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Remove the motor brake and motor from the axle shaft (See previous section instructions for the removal) 0
7 Remove the snap ring (N) and wave washer (O) that secures the motor shaft to the motor end cap 0
8 Tap on the motor shaft with a rubber mallet to disengage the shaft from the encoder bearing 0
9 Remove four long hex head bolts (L) and washers (M) from the motor, retain the bolts and washers for use in reassembling the motor as shown 0
10 Tap the corners or ears of the end cap to disengage the end cap flange from the motor housing 0
11 Remove four phillips head screws (7) and washers (5) that secure the encoder bearing retaining plates (6) 0
12 Remove the phillips head screw (4) and wire clip (2) from the inside of the end cap 0
13 Using a mallet or hammer, tap the encoder bearing (1) from the outside of the end cap to remove it from the bore Be careful to avoid damage to the bearing bore in the end cap 0
INSTALLATION 0
1 Position the encoder bearing (1) with the wires aligned with the recess in the inside of the end cap 0
2 Seat the encoder bearing into the end cap bore by tapping around the outer edge of the bearing Avoid tapping on the encoder, make sure to tap only on the rim of the bearing, use a brass drift or rod if necessary 0
3 Secure the encoder bearing with the retainer plates (6), screws (7), washers(5) 0
4 Fix the clip (2) to the bearing cable and secure the clip to the motor end plate with the screw (4), washer (3) (removed in step 12 under Removal section) as shown below 0
5 Tighten all the hardware to the specified torque value 0
6 Re-install motor end cap back to the stator and secure with the bolts (L) and washers (M) (removed in step 9 under removal section), tighten to specified torque value 0
O 0
Fig 1 Motor 0
GENERAL 0
Motor 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 With an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Remove three plastic rivets securing the controller splash shield; two on the passenger side of the body at the seat opening and one from the controller 0
7 Disconnect motor wires from controller terminals, U, V and W, refer to the Speed Control section of this manual for torque complete information on these connections 0
8 Disconnect the main harness connector (31) from the motor brake and main harness connector (32) from the motor temperature sensor as shown below 0
9 Two different electric motors have been used on the vehicle, the harness connections depend on which motor is installed on th 0
10 OLD MOTOR: Disconnect the main harness connector (33) from the motor sensor as shown 0
0
Fig 2 Motor Connections (Early Vehicles) 0
11 NEW MOTOR: Disconnect one end of the adaptor from the motor sensor harness, disconect the other end of the adaptor harness from the harness connector as shown in detail 0
Fig 3 Motor Connections (Later Vehicles) 0
12 Pull the motor wires out through the bagwell 0
13 Remove the six hex head bolts (2) and split lock washers (3) securing the motor (1) to the axle and carefully slide the moto 0
Fig 4 Motor 0
14 Before installing the motor on the axle apply lubricant (80% molybdenum disulfide paste) to the input shaft spline The approved lubricants are: Dow Corning 77, Molykote (r) M-77 paste or Tribology TAS 100 EP 0
15 Carefully align the motor spline with the input shaft, orient the motor with the wires near the top and install the six hex 0
Fig 5 Motor Bolt Tightening Sequence 0
16 Connect the wires from the main harness to the motor brake (31), the motor sensor (33) and the motor temperature sensor (32) 0
17 Connect the wires from the motor to the controller; the green wire to terminal U, the yellow wire to terminal V and the blue 0
Fig 6 Motor to Controller Connections 0
18 Connect the negative (-) battery cable, BL-, to the battery pack 0
Motor Brake 0
REMOVAL 0
1 Chock the rear wheels of the vehicle 0
2 Raise and remove seat bottom 0
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 0
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wa 0
5 Remove the two Torx head screws and the rear access cover from the bagwell area 0
6 Disconnect wire harness from motor brake 0
7 Remove three hex head bolts (32) and lock washers (33) from the motor brake assembly (31) 0
Fig 7 Motor Brake 0
INSTALLATION 0
1 Position the brake with the connector at the top as shown above and install the three hex head bolts (32) loosely 0
2 Connect the wire harness to the motor brake and move the Run/Tow switch to the ’TOW’ position This will provide power to the brake to align the disc material 0
3 Tighten the three hex head bolts evenly to the specified torque 0
4 Move the Run/Tow switch to the ’RUN’ position 0
K-Electrical Wiring-07JULY2010pdf 0
Fig 1 Main Electrical Harness 0
MAIN WIRING HARNESS 0
1 Disconnect the main wiring harness from the battery pack using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run’ position, turn the key switch to reverse, 0
3 Locate the tab under the cowl that extends from the instrument panel through a slot in the cowl, squeeze the legs of the tab 0
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with b 0
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 2 Instrument Panel & Trim 0
6 Remove the wiring harness from the front splash shield retaining clips 0
7 If vehicle is equipped with brake lights, disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder 0
8 Remove the Diagnostic Plug from the bottom of the cup holder 0
9 Disconnect the plug to the throttle enable switch 0
10 Disconnect the plug from the rotary position sensor 0
11 Disconnect the plug from the brake enable switch 0
12 Disconnect the wires from the rotary position sensor 0
13 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
14 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
15 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
16 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
17 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and move it out of the way 0
18 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
19 Unplug the large 23 pin connector (3) from the controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
20 Disconnect the plug for the resistor, remove two screws that secure the sensor on top of the resistor 0
Fig 3 Controller 0
21 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through 0
Fig 4 Run / Tow Switch 0
22 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
Fig 5 Reverse Warning Indicator 0
23 Determine which solenoid is installed Two types of solenoid have been used for this vehicle, on early vehicles the solenoid 0
24 HARDWIRED RECTANGULAR: Disconnect all wires from the terminal posts and remove two hex nuts (7) securing the solenoid to the 0
Fig 6 Old Style Rectangular Solenoid 0
25 ROUND: Remove two larger hex nuts (16) from the larger terminal posts and disconnect red wire from controller B+ terminal an 0
Fig 7 Solenoid Connections 0
26 Two different main wire harness have been used on this vehicle Determine which main wire harness is installed on the vehicl 0
27 OLD WIRE HARNESS: Disconnect all the main harness connectors from the motor brake (31), motor temperature sensor (32) and motor sensor (33) as shown below 0
Fig 8 Motor Connections (Early Vehicles) 0
28 NEW WIRE HARNESS: Disconnect the connectors of motor brake (31), the temperature sensor (32) from the main harness connector 0
a) OLD STYLE MOTOR: Disconnect male connector end of the adaptor harness from the female connector of the motor sensor harness, unplug the other end of the adaptor harness connector from the connector of the main harness as shown in detail below 0
Fig 9 Old Style Motor Connections (later Vehicles) 0
b) NEW STYLE MOTOR: Disconnect one end of the adaptor harness from the motor sensor harness, disconnect the other end of the adaptor harness from the main wire harness connector as shown in detail below 0
Fig 10 New Style Motor Connections (later Vehicles) 0
29 Remove main wiring harness from the vehicle 0
30 Install new main wiring harness making sure that it follows the proper path 0
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1, 2 & 3) 0
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels 0
Fig 11 Harness Routing & Pedal Connections 0
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4) 0
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6) 0
e) Connect the wires to the brake pedal rotary position sensor (8) and the brake enable switch connector (9) 0
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10) 0
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel 0
h) Feed the connectors for the key switch, the optional fuel gauge/state of charge meter and the diagnostic plug through the ope 0
Fig 12 Cup Holder 0
i) Route the wires (14) for the key switch and the optional fuel gauge/state of charge meter through the guide (15) on the front 0
l 0
Fig 13 Front Splash Shield 0
j) Connect the wire harness to the key switch 0
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side 0
l) Plug the connector (20) for the charger receptacle into the connector on the main wiring harness 0
Fig 14 Charger Receptacle 0
m) A new solenoid will ONLY be installed if the old one was connected directly to the wire harness (hard wired) Install solenoid (18) on the controller heat sink using two nuts (22) 0
n) Reconnect the black wire (23) and red wire (24) to the solenoid (18) as shown and secure in place with small hex nuts (28) 0
o) Connect the Red wire from the controller B+ and the white wire (17) from the resistor to the back terminal of the solenoid (1 0
p) Connect the Red wire (20) from the positive (+), BL+, battery terminal and the yellow wire (21) from the wiring harness to th 0
0
Fig 15 Controller Connections 0
q) Plug the 23 pin connector (3) from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
0
Fig 16 23 Pin Connector 0
r) Plug the connectors for the motor brake (31), the motor temperature sensor (32) on the motor and motor brake 0
s) OLD STYLE WIRE HARNESS: Plug the motor sensor (33) connector to the main wire harness connector as shown below 0
0
Fig 17 Motor Connections (Early Vehicles) 0
t) NEW STYLE WIRE HARNESS: Plug male connector end of the adaptor harness into the female connector on the motor sensor harness 0
Fig 18 Old Style Motor Connections (Later Vehicles) 0
u) Connect one end of the adaptor harness to the motor sensor harness, connect the other end of the adaptor harness to the main wire harness connector as shown in detail below 0
Fig 19 New Style Motor Connections (later Vehicles) 0
31 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10) 0
32 Press the fuse holder (12) into the hole on the controller splash shield 0
Fig 20 Reverse Warning Indicator & Fuse 0
33 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notc 0
34 Replace the controller splash shield and secure it to the body with two Torx head screws 0
35 Connect the negative battery wires using an insulated wrench 0
36 Connect the positive battery wires using an insulated wrench 0
37 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL COMPONENTS 0
Run / Tow Switch (Ref Fig 21 on page K-8) 0
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the switch and wires 0
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts 0
4 Cut the wires from the existing run/tow switch close to the switch 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness 0
6 Remove the upper nut and seal (7) from the new switch (8) 0
7 Install the switch (8) with the notch towards the RUN direction 0
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table 0
Fig 21 Run / Tow Switch 0
9 Install the splash shield using three plastic rivets to secure the shield to the body and the controller 0
Reverse Warning Indicator (Ref Fig 22 on page K-9) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires 0
3 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
4 Cut the wires close to the reverse warning indicator (11) 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (11) to the wire harness 0
6 Secure the new reverse warning indicator (11) to the splash shield with the torx head screws (10) 0
7 Reinstall the splash shield 0
Fig 22 Reverse Warning Indicator 0
State of Charge / Fuel Gauge Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel 0
Fig 23 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20) 0
3 Depress the tabs on the fuel gage/state of charge meter (20) and push the unit out of the trim panel (11) 0
Fig 24 Fuel Gage/State of Charge Meter 0
4 Insert the new fuel gage/state of charge meter (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the main harness (21) to the fuel gage/state of charge meter (20) 0
6 Push the instrument panel trim (11) into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Fig 25 Main Wiring Harness 0
Fig 26 Accessory Wiring Harness 0
Fig 27 Accessory Wiring Harness and Accessories 0
ACCESSORY WIRING HARNESS 0
Replacing the Accessory Wiring Harness 0
1 Using an insulated wrench disconnect the accessory harness from the battery pack 0
2 Unplug the red and purple wires from the brake light relay to the main harness 0
3 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn, fuel gage (state of charge meter) and brake lights 0
4 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder 0
5 Remove the three fuse holders from the controller splash shield 0
6 Disconnect the tail light wiring connectors 0
7 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
8 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
9 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
10 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
11 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
12 Remove the accessory wiring harness from the vehicle 0
13 Install new accessory wiring harness making sure that it follows the proper path 0
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that 0
b) Route the wires for the headlight switch through the opening in the instrument panel for the headlight switch 0
c) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle 0
d) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn 0
e) Connect the horn button connector to the accessory harness under the cup holder 0
f) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmas tree rivet (2) 0
0
Fig 28 Brake Light Relay 0
g) Connect the red and purple wires from the accessory harness to the matching wires from the main wire harness 0
h) Route the rest of the harness down through the cup holder and in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor 0
i) Route the wires and connector for the driver side brake light between the rear body and the battery pack and around the drive 0
j) Route the fuses and the passenger side brake light wires between the rear body and the battery pack 0
k) Snap the fuse holders into the holes on the controller splash shield 0
l) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light 0
13 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL ACCESSORIES 0
Head Light Replacement 0
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward 0
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward 0
3 Disconnect the accessory harness connector (5) from the headlight (3) and turn signal (4) 0
0
Fig 29 Headlight Assembly 0
4 To install the headlight assembly, connect the accessory harness connection (6) to the turn signal (4) and the accessory harness connection (5) to the headlight bulb (3) 0
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position 0
Head Light Bulb Replacement 0
1 Turn the headlight bulb (3) clockwise and pull to remove 0
2 Disconnect the accessory harness from the light bulb 0
3 Connect the accessory harness to the light bulb 0
4 Align the bulb with the opening in the back of the headlight assembly 0
5 Turn the bulb (3) counter clockwise until it stops 0
Turn signal Bulb Replacement 0
1 Grip the turn signal bulb housing (7) and turn to align with slot then pull backward to remove housing from headlight assembly 0
Fig 30 Turn Signal Bulb Replacement 0
2 Remove bulb from housing and replace with a new one 0
3 Align housing with slot and insert turn signal housing (7) into headlight assembly, turn to lock in place 0
Head Light Switch Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel 0
Fig 31 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the head light switch (13) 0
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11) 0
Fig 32 Head Light Switch 0
4 Insert the new head light switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the accessory harness (12) to the headlight switch (13) 0
6 Push the instrument panel trim into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Turn Signal Switch Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the connector from the turn signal switch harness to the main electrical harness 0
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder 0
4 Remove the plastic cover from the steering column 0
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw 0
6 Remove the turn signal switch assembly including the clamp 0
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column 0
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape 0
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column 0
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove 0
11 Route the wire harness under the floor mat to the cupholder 0
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet 0
13 Plug the turn signal wire harness connector into the accessory wire harness 0
Turn signal Flasher Unit Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the flasher unit from the turn signal wire harness 0
3 Install the new flasher unit in the wire harness receptacle 0
4 Replace the top part of the cup holder (ref Section B) 0
Tail Light Assembly Replacement 0
1 Remove the four Torx head screws (15) that secure the tail light assembly (16) to the rear body 0
2 Pull the tail light (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17) 0
Fig 33 Tail Light Assembly 0
3 Plug the new tail light assembly (15) into the accessory wire harness connector (16) and push the tail light assembly (16) into the opening 0
4 Install the four Torx head screws (15) 0
Tail Light Lens Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Install the new lens and secure in place with the two phillips head screws 0
Tail Light Bulb Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Remove the light bulb 0
3 Install the new light bulb 0
4 Install the lens and secure in place with the two phillips head screws 0
Horn Button Replacement 0
1 Remove the horn button cover using a flat blade to work the cover off of the switch 0
2 Pull the upper corner of the floormat down to expose the switch retaining nut 0
3 Remove the nut that secures the horn button 0
4 Remove the horn button switch from the floor1board 0
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch 0
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder 0
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame 0
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness 0
9 Replace the floormat and install the horn button cover 0
Horn Replacement 0
1 Disconnect the accessory wire harness from the horn 0
2 Remove the hex head bolt that secures the horn to the mounting bracket 0
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt 0
4 Connect the accessory wire harness to the horn 0
A3-GENERAL INFO-FEB11pdf 0
SERIAL NUMBER LOCATION 0
Fig 1 Serial Number Location on Steering Column 0
Fig 2 Serial Number on Front Frame 0
Fig 3 Serial Number on Rear Frame 0
0
Fig 4 Initial Service Chart 0
Towing 0
If a vehicle is towed in excess of 15 mph the motor brake will engage and slow the vehicle down 0
The RUN/TOW switch should always be returned to the ’RUN/ STORAGE’ or (on CE vehicles) position after towing the vehicle If the switch is left in the ’TOW’ or (on CE vehicles) position for an extended period of time it will drain the batteries 0
Fig 5 Run/Tow Switch 0
PARKING BRAKE 0
Servicing The Vehicle 0
Routine Maintenance 0
Rear Axle 0
Tires 0
Vehicle Cleaning And Care 0
Sun Top And Windshield 0
Hauling 0
T 0
HARDWARE 0
CAPACITIES AND REPLACEMENT PARTS 0
Fig 6 Capacities 0
Fig 7 Replacement Part 0
Fig 8 Torque Specifications and Bolt Grades 0
PERIODIC SERVICE SCHEDULE 0
3 – CHECK C&A – CHECK & ADJUST CL – CLEAN R – REPLACE 0
Fig 9 Periodic Service Schedule 0
A3-GENERAL INFO-DEC 11pdf 0
SERIAL NUMBER LOCATION 13
Fig 1 Serial Number Location on Steering Column 13
Fig 2 Serial Number on Front Frame 13
Fig 3 Serial Number on Rear Frame 13
13
Fig 4 Initial Service Chart 13
Towing 14
If a vehicle is towed in excess of 15 mph the motor brake will engage and slow the vehicle down 14
The RUN/TOW switch should always be returned to the ’RUN/ STORAGE’ or (on CE vehicles) position after towing the vehicle If the switch is left in the ’TOW’ or (on CE vehicles) position for an extended period of time it will drain the batteries 14
Fig 5 Run/Tow Switch 14
PARKING BRAKE 15
Servicing The Vehicle 15
Routine Maintenance 15
Rear Axle 16
Tires 16
Vehicle Cleaning And Care 16
Sun Top And Windshield 16
Hauling 16
T 17
HARDWARE 17
CAPACITIES AND REPLACEMENT PARTS 17
Fig 6 Capacities 17
Fig 7 Replacement Part 17
Fig 8 Torque Specifications and Bolt Grades 17
PERIODIC SERVICE SCHEDULE 0
P – CHECK C&A – CHECK & ADJUST CL – CLEAN R – REPLACE 0
Fig 9 Periodic Service Schedule 0
G-MOTOR-Dec 2011pdf 0
Bearing Encoder 87
REMOVAL 87
1 Chock the rear wheels of the vehicle 87
2 Raise and remove seat bottom 87
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 87
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run/Storage position, turn the key switch to reverse, wait for the reverse warning indicator to become silent turn the key switch to the off position and remove the key f 87
5 Remove the two Torx head screws and the rear access cover from the bagwell area 87
6 Remove the motor brake and motor from the axle shaft (See previous section instructions for the removal) 87
7 Remove the snap ring (N) and wave washer (O) that secures the motor shaft to the motor end cap 87
8 Tap on the motor shaft with a rubber mallet to disengage the shaft from the encoder bearing 87
9 Remove four long hex head bolts (L) and washers (M) from the motor, retain the bolts and washers for use in reassembling the motor as shown 87
10 Tap the corners or ears of the end cap to disengage the end cap flange from the motor housing 87
11 Remove four phillips head screws (7) and washers (5) that secure the encoder bearing retaining plates (6) 87
12 Remove the phillips head screw (4) and wire clip (2) from the inside of the end cap 87
13 Using a mallet or hammer, tap the encoder bearing (1) from the outside of the end cap to remove it from the bore Be careful to avoid damage to the bearing bore in the end cap 87
INSTALLATION 87
1 Position the encoder bearing (1) with the wires aligned with the recess in the inside of the end cap 87
2 Seat the encoder bearing into the end cap bore by tapping around the outer edge of the bearing Avoid tapping on the encoder, make sure to tap only on the rim of the bearing, use a brass drift or rod if necessary 87
3 Secure the encoder bearing with the retainer plates (6), screws (7), washers(5) 87
4 Fix the clip (2) to the bearing cable and secure the clip to the motor end plate with the screw (4), washer (3) (removed in step 12 under Removal section) as shown below 87
5 Tighten all the hardware to the specified torque value 88
6 Re-install motor end cap back to the stator and secure with the bolts (L) and washers (M) (removed in step 9 under removal section), tighten to specified torque value 88
O 83
Fig 1 Motor 83
GENERAL 83
Motor 83
1 Chock the rear wheels of the vehicle 83
2 Raise and remove seat bottom 83
3 With an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 83
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run/Storage position, turn the key switch to reverse, wait for the reverse warning indicator to become silent turn the key switch to the off position and remove the key f 83
5 Remove the two Torx head screws and the rear access cover from the bagwell area 83
6 Remove three plastic rivets securing the controller splash shield; two on the passenger side of the body at the seat opening and one from the controller 83
7 Disconnect motor wires from controller terminals, U, V and W, refer to the Speed Control section of this manual for torque complete information on these connections 83
8 Disconnect the main harness connector (31) from the motor brake and main harness connector (32) from the motor temperature sensor as shown below 83
9 Two different electric motors have been used on the vehicle, the harness connections depend on which motor is installed on the vehicle The early motor has two sets of bundled wires routed from under the housing on the motor near the electric brak 83
10 OLD MOTOR: Disconnect the main harness connector (33) from the motor sensor as shown 84
84
Fig 2 Motor Connections (Early Vehicles) 84
11 NEW MOTOR: Disconnect one end of the adaptor from the motor sensor harness, disco ne ct the other end of the adaptor harness from the harness connector as shown in detail 84
Fig 3 Motor Connections (Later Vehicles) 84
12 Pull the motor wires out through the bagwell 84
13 Remove the six hex head bolts (2) and split lock washers (3) securing the motor (1) to the axle and carefully slide the motor straight out from the axle splines Note: a drive belt or woven strap may be used as a sling to help support the motor d 84
Fig 4 Motor 84
Fig 5 Air Blast Cleaning 85
14 Using air blower, blow compressed air and clean the motor coupler as shown in Fig 5 And use a scriber to scrap of any rust deposits 85
15 Apply Anti-seize Compound inside the coupler (approx 1 tablespoon) towards the bottom Coat all of the splinesThe recommended anti-seize is Loctite Silver grade or equivalent 85
16 Before installing the motor on the axle apply lubricant (80% molybdenum disulfide paste) to the input shaft spline The approved lubricants are: Dow Corning 77, Molykote (r) M-77 paste or Tribology TAS 100 EP 85
17 Carefully align the motor spline with the input shaft, orient the motor with the wires near the top and install the six hex head bolts (2) and split lock washers (3) finger tight Tighten the hex head bolts (2) in a cross pattern to the specified 85
Fig 6 Motor Bolt Tightening Sequence 85
18 Connect the wires from the main harness to the motor brake (31), the motor sensor (33) and the motor temperature sensor (32) 85
19 Connect the wires from the motor to the controller; the green wire to terminal U, the yellow wire to terminal V and the blue wire to terminal W Install the terminal screws (27) finger tight, then torque as specified Do not over tighten the term 85
Fig 7 Motor to Controller Connections 85
20 Connect the negative (-) battery cable, BL-, to the battery pack 85
Motor Brake 86
REMOVAL 86
1 Chock the rear wheels of the vehicle 86
2 Raise and remove seat bottom 86
3 Using an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery 86
4 Drain the stored energy from the controller Place the Run/Tow switch in the Run/Storage position, turn the key switch to reverse, wait for the reverse warning indicator to become silent turn the key switch to the off position and remove the key f 86
5 Remove the two Torx head screws and the rear access cover from the bagwell area 86
6 Disconnect wire harness from motor brake 86
7 Remove three hex head bolts (32) and lock washers (33) from the motor brake assembly (31) 86
Fig 8 Motor Brake 86
INSTALLATION 86
1 Position the brake with the connector at the top as shown above and install the three hex head bolts (32) loosely 86
2 Connect the wire harness to the motor brake and move the Run/Tow switch to the ’TOW’ position This will provide power to the brake to align the disc material 86
3 Tighten the three hex head bolts evenly to the specified torque 86
4 Move the Run/Tow switch to the ’RUN/STORAGE’ position 86
E-ELEC SPEED CONTROLLER- 15Mar12pdf 0
Fig 1 Electronic Speed Control 0
GENERAL 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, washers, etc) that are removed must always be installed in their original positions unless otherwise specified Non-specifie 0
Fig 2 Christmas Tree Rivet Removal 0
Fig 3 Pedal Cover 0
Accelerator Pedal Assembly 0
1 Remove four christmas tree rivets securing pedal cover to floorboard 0
2 Remove pedal cover 0
3 Remove three torx screws (2) securing accelerator pedal assembly (1) to the floorboard (Ref Fig 4) 0
4 Disconnect the wires from the rotary position sensor (5) and the throttle enable switch (12) 0
5 Remove the two Torx screws (4) from the rotary position sensor (5) and remove sensor 0
6 Remove the two Torx screws (8) from the throttle enable switch (7) and remove the switch 0
Installation 0
7 Align the slot in the rotary position sensor (5) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (4) Use Loctite® 242; according to product instructions; on the two Torx screws 0
8 Position the throttle enable switch (7) oriented as shown, secure in place with two Torx screws (6) Use Loctite 242; according to product instructions; on the two Torx screwsReconnect electrical harness to rotary position sensor (5) and to the t 0
9 Place pedal assembly in position on the floorboard and secure with three Torx screws (2) 0
Fig 4 Accelerator Pedal 0
10 Install the pedal cover, using new christmas tree rivets, replace the floormat and rocker panels 0
Solenoid Replacement 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove the controller splash shield; some vehicles will have two torx head screws and one christmas tree rivet, the remaining vehicles will have three christas tree rivets securing the splash shield in place After removing the fasteners place the 0
1 Disconnect the red wire from the upper terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire to the main wiring harness by removing the upper hex nut (5) 0
2 Disconnect the red wire from the lower terminal on the solenoid to B+ on the controller by removing the lower hex nut (6) 0
3 Remove two hex head nuts (7) securing the solenoid to the controller heat sink 0
4 Cut the two wires from the solenoid to the wire harness and strip approximately 1/2″ (13 mm) of insulation from the ends of the wires from the harness 0
5 Insert the stripped wires from the harness into ends of the ring terminals and crimp both ends 0
Fig 5 Old Style Rectangular Solenoid 0
Round Solenoid Removal 0
1 Disconnect the red wire (13) from the front terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire (14) to the main wiring harness by removing the front hex nut (6) 0
2 Disconnect the red wire (11) from the back terminal on the solenoid (4) to B+ on the controller and and white wire (12) from resistor by removing the back hex nut (5) 0
3 Disconnect the red wire (9) and black wire (8) from the terminals by removing smaller hex nuts (15) 0
4 Remove two hex head nuts (10) securing the solenoid (4) to the controller heat sink 0
Solenoid Installation 0
1 Secure the solenoid (4) to the controller heat sink with the two hex head nuts (10) 0
2 Reconnect the red wire (9) and black wire (8) from harness to solenoid (4) as shown and secure in place with two smaller hex nuts (15) 0
3 Reconnect the red wire (11) from the controller B+ to the back terminal of the solenoid (4) and the white wire (12) to the resistor, secure in place using a hex nut (5) Be sure to place larger terminal wires first on studs with smaller wires on last 0
4 Connect the red wire (13) from the positive (+), BL+, battery terminal and the yellow wire (14) from the wiring harness to the front terminal of the solenoid (4), secure in place with a hex nut (6) Be sure to place larger terminal wires first on 0
Fig 6 Round Solenoid 0
5 Reinstall the electronic controller shield as before 0
6 Reinstall three christmas tree rivets (1) to secure the shield to the body and the controller 0
7 Connect the negative (-) cable to the battery 0
Controller 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wait for the reverse warning indicator to become silent, turn the key switch to the off position and remove the key from the 0
3 Remove three christmas tree rivets (4) securing the controller splash shield to the rear body and to the controller heat sink; position splash shield off to one side to allow access to the controller 0
Fig 7 Controller Splash Shield Cover 0
4 Disconnect the Red positive (+) battery cable from the front terminal of the solenoid 0
5 Disconnect the Red wire from the controller B+ terminal to the back terminal of the solenoid 0
6 Remove two hex head nuts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 0
7 Disconnect the 2 pin connector (14) from the wire harness 0
8 Disconnect the 3 pin connector (12) from the resistor control (13) connector 0
9 Disconnect the 23 pin connector (9) from controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
10 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 0
11 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 0
12 Remove the front two hex head bolts (10) securing the controller assembly to the floorboard and loosen the rear hex head bolt (10) Slide the controller towards the front of the car and lift it out 0
Fig 8 Solenoid Connections 0
Installation 0
13 To install the controller, position it on the floorboard; making sure that all wires are not pinched or under the controller feet; and slide it to the back aligning the slot under the head of the hex head bolt (10) Install the two hex head bolts 0
14 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 0
15 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 0
16 Install the solenoid on the controller heat sink using two hex head nuts (7) Reconnect the Red positive (+) battery cable to the front terminal of the solenoid Make sure that the red wire (17) and black wire (18) from the wire harness to the so 0
17 Install the Red wire to the B+ terminal of the controller (Do not over tighten the terminal screw (11) 0
18 Plug the 23 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
19 Check all wires to be sure they are connected to the proper terminal 0
20 Position the Splash Shield under the edge of the seat opening, install the three christmas tree rivets (4) 0
21 Reconnect wires to the battery pack Replace any worn or damaged hardware as required 0
For New Controller Post production 23rd Jan 2012 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wait for the reverse warning indicator to become silent, turn the key switch to the off position and remove the key from the 0
3 Remove three christmas tree rivets (4) securing the controller splash shield to the rear body and to the controller heat sink; position splash shield off to one side to allow access to the controller 0
4 Disconnect the Red positive (+) battery cable from the front terminal of the solenoid 0
5 Disconnect the Bus bar from the controller B+ terminal to the back terminal of the solenoid 0
6 Remove two hex head nuts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 0
7 Disconnect the 2 pin connector (14) from the wire harness 0
8 Disconnect the 35 pin connector (9) from controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
9 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 0
10 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 0
11 Remove the four hex head bolts (10) securing the controller assembly to the bracket Slide the controller towards the front of the car and lift it out 0
Fig 9 New Controller and Solenoid 0
Installation 0
12 To install the controller, position it on the floorboard; making sure that all wires are not pinched or under the controller feet; and slide it to the back aligning the slot under the head of the hex head bolt (10) Install the two hex head bolts 0
13 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 0
14 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 0
15 Install the solenoid on the controller heat sink using two hex head bolts (7) Reconnect the Red positive (+) battery cable to the front terminal of the solenoid Make sure that the red wire (17) and black wire (18) from the wire harness to the s 0
16 Install the Bus bar to the B+ terminal of the controller to the terminal of solenoid as shown (Do not over tighten the terminal screw (11) 0
17 Plug the 35 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
18 Connect the 2 pin connector (14) from the wire harness 0
19 Check all wires to be sure they are connected to the proper terminal 0
20 Position the Splash Shield under the edge of the seat opening, install the three christmas tree rivets (4) 0
21 Reconnect wires to the battery pack Replace any worn or damaged hardware as required 0
K-Electrical Wiring-15MAR2012pdf 0
Fig 1 Main Electrical Harness 0
MAIN WIRING HARNESS 0
1 Disconnect the main wiring harness from the battery pack using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run/Storage’ position, turn the key switch to reverse, wait for the reverse warning indicator to become silent then turn the key switch to the off position and remov 0
3 Locate the tab under the cowl that extends from the instrument panel through a slot in the cowl, squeeze the legs of the tab together and push to the back of the vehicle while pulling forward on the cowl Repeat for the other side — at this poin 0
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with both hands and pull away from the instrument panel (13); move to the other side of the vehicle and grip the ball holder on 0
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel 0
Fig 2 Instrument Panel & Trim 0
6 Remove the wiring harness from the front splash shield retaining clips 0
7 If vehicle is equipped with brake lights, disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder 0
8 Remove the Diagnostic Plug from the bottom of the cup holder 0
9 Disconnect the plug to the throttle enable switch 0
10 Disconnect the plug from the rotary position sensor 0
11 Disconnect the plug from the brake enable switch 0
12 Disconnect the wires from the rotary position sensor 0
13 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
14 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
15 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
16 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
17 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and move it out of the way 0
18 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
19 Unplug the large 23 (35 for new controller) pin connector (3) from the controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
20 Disconnect the plug for the resistor, remove two screws that secure the sensor on top of the resistor 0
Fig 3 Controller 0
Fig 4 New Controller 0
21 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through the splash shield CE vehicles will have a key switch in place of the toggle switch, unscrew the top ring to release the 0
Fig 5 Run / Tow Switch 0
22 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
Fig 6 Reverse Warning Indicator 0
23 Determine which solenoid is installed Two types of solenoid have been used for this vehicle, on early vehicles the solenoid was rectangular and hardwired into the wire harness, later vehicles have the round solenoid where all wires are connected 0
24 HARDWIRED RECTANGULAR: Disconnect all wires from the terminal posts and remove two hex nuts (7) securing the solenoid to the controller heatsink If the vehicle has the hardwired rectangular solenoid a new round solenoid will need to be purchased 0
Fig 7 Old Style Rectangular Solenoid 0
25 ROUND: Remove two larger hex nuts (16) from the larger terminal posts and disconnect red wire from controller B+ terminal (Bus bar for new controller) and white wire (17) from the resistor, red wire (20) from BL+, battery terminal, and yellow wir 0
Fig 8 Solenoid Connections 0
Fig 9 New Solenoid Connections 0
26 Two different main wire harness have been used on this vehicle Determine which main wire harness is installed on the vehicle On early vehicles the motor sensor connected directly to the main wire harness connector, later vehicles have the main 0
27 OLD WIRE HARNESS: Disconnect all the main harness connectors from the motor brake (31), motor temperature sensor (32) and motor sensor (33) as shown below 0
Fig 10 Motor Connections (Early Vehicles) 0
28 NEW WIRE HARNESS: Disconnect the connectors of motor brake (31), the temperature sensor (32) from the main harness connectors Two different electric motors have been used on the vehicle, the harness connections depend on which motor is installed 0
a) OLD STYLE MOTOR: Disconnect male connector end of the adaptor harness from the female connector of the motor sensor harness, unplug the other end of the adaptor harness connector from the connector of the main harness as shown in detail below 0
Fig 11 Old Style Motor Connections (later Vehicles) 0
b) NEW STYLE MOTOR: Disconnect one end of the adaptor harness from the motor sensor harness, disconnect the other end of the adaptor harness from the main wire harness connector as shown in detail below 0
Fig 12 New Style Motor Connections (later Vehicles) 0
29 Remove main wiring harness from the vehicle 0
30 Install new main wiring harness making sure that it follows the proper path 0
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1, 2 & 3) 0
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels 0
Fig 13 Harness Routing & Pedal Connections 0
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4) 0
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6) 0
e) Connect the wires to the brake pedal rotary position sensor (8) and the brake enable switch connector (9) 0
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10) 0
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel 0
h) Feed the connectors for the key switch, the optional fuel gauge/state of charge meter and the diagnostic plug through the opening in the cup holder base (12) Place the diagnostic plug (13) into the cup holder base and route the connectors for the 0
Fig 14 Cup Holder 0
i) Route the wires (14) for the key switch and the optional fuel gauge/state of charge meter through the guide (15) on the front splash shield and the connectors for the key switch and the optional fuel gauge/state of charge meter through the opening 0
l 0
Fig 15 Front Splash Shield 0
j) Connect the wire harness to the key switch 0
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side 0
l) Plug the connector (20) for the charger receptacle into the connector on the main wiring harness 0
Fig 16 Charger Receptacle 0
m) A new solenoid will ONLY be installed if the old one was connected directly to the wire harness (hard wired) Install solenoid (18) on the controller heat sink using two nuts (22) 0
n) Reconnect the black wire (23) and red wire (24) to the solenoid (18) as shown and secure in place with small hex nuts (28) 0
o) Connect the Red wire from the controller B+ and the white wire (17) from the resistor to the back terminal of the solenoid (18) and secure in place using a hex nut (16) Be sure to place larger terminal wires first on studs and smaller wires on la 0
p) Connect the Red wire (20) from the positive (+), BL+, battery terminal and the yellow wire (21) from the wiring harness to the front terminal on the solenoid, secure in place with hex nut (16) as shown Be sure to place larger terminal wires first 0
0
Fig 17 Controller Connections 0
Fig 18 New Controller Connections 0
q) Plug the 23 (35 for new controller) pin connector (3) from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
0
Fig 19 23 Pin Connector 0
Fig 20 35 Pin Connector 0
r) Plug the connectors for the motor brake (31), the motor temperature sensor (32) on the motor and motor brake 0
s) OLD STYLE WIRE HARNESS: Plug the motor sensor (33) connector to the main wire harness connector as shown below 0
0
Fig 21 Motor Connections (Early Vehicles) 0
t) NEW STYLE WIRE HARNESS: Plug male connector end of the adaptor harness into the female connector on the motor sensor harness Plug the other end of the adaptor harness connector into the connector of main harness, push in firmly and make sure that 0
Fig 22 Old Style Motor Connections (Later Vehicles) 0
u) Connect one end of the adaptor harness to the motor sensor harness, connect the other end of the adaptor harness to the main wire harness connector as shown in detail below 0
Fig 23 New Style Motor Connections (later Vehicles) 0
31 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10) 0
32 Press the fuse holder (12) into the hole on the controller splash shield 0
Fig 24 Reverse Warning Indicator & Fuse 0
33 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notch towards the RUN/ STORAGE direction Install the upper nut (5) finger tight and torque as specified in the torque table, 0
34 Replace the controller splash shield and secure it to the body with two Torx head screws 0
35 Connect the negative battery wires using an insulated wrench 0
36 Connect the positive battery wires using an insulated wrench 0
37 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL COMPONENTS 0
Run / Tow Switch (Ref Fig 25 on page K-9) 0
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the switch and wires 0
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts 0
4 Cut the wires from the existing run/tow switch close to the switch 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness 0
6 Remove the upper nut and seal (7) from the new switch (8) 0
7 Install the switch (8) with the notch towards the RUN/ STORAGE direction 0
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table 0
Fig 25 Run / Tow Switch 0
9 Install the splash shield using three plastic rivets to secure the shield to the body and the controller 0
Reverse Warning Indicator (Ref Fig 26 on page K-10) 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires 0
3 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield 0
4 Cut the wires close to the reverse warning indicator (11) 0
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (11) to the wire harness 0
6 Secure the new reverse warning indicator (11) to the splash shield with the torx head screws (10) 0
7 Reinstall the splash shield 0
Fig 26 Reverse Warning Indicator 0
State of Charge / Fuel Gauge Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel 0
Fig 27 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20) 0
3 Depress the tabs on the fuel gage/state of charge meter (20) and push the unit out of the trim panel (11) 0
Fig 28 Fuel Gage/State of Charge Meter 0
4 Insert the new fuel gage/state of charge meter (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the main harness (21) to the fuel gage/state of charge meter (20) 0
6 Push the instrument panel trim (11) into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Fig 31 Main Wiring Harness 0
Fig 32 Accessory Wiring Harness 0
Fig 33 Accessory Wiring Harness and Accessories 0
ACCESSORY WIRING HARNESS 0
Replacing the Accessory Wiring Harness 0
1 Using an insulated wrench disconnect the accessory harness from the battery pack 0
2 Unplug the red and purple wires from the brake light relay to the main harness 0
3 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn, fuel gage (state of charge meter) and brake lights 0
4 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder 0
5 Remove the three fuse holders from the controller splash shield 0
6 Disconnect the tail light wiring connectors 0
7 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard 0
8 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support 0
9 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard 0
10 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper 0
11 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard 0
12 Remove the accessory wiring harness from the vehicle 0
13 Install new accessory wiring harness making sure that it follows the proper path 0
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that the wires tagged ’Driver Side’ are routed to the driver’s side of the vehicle and the wires tagged ’Passenger Sid 0
b) Route the wires for the headlight switch through the opening in the instrument panel for the headlight switch 0
c) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle 0
d) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn 0
e) Connect the horn button connector to the accessory harness under the cup holder 0
f) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmas tree rivet (2) 0
0
Fig 34 Brake Light Relay 0
g) Connect the red and purple wires from the accessory harness to the matching wires from the main wire harness 0
h) Route the rest of the harness down through the cup holder and in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor 0
i) Route the wires and connector for the driver side brake light between the rear body and the battery pack and around the driver’s side of the battery pack to the splash shield Secure the wires in the guides on the splash shield and connect to th 0
j) Route the fuses and the passenger side brake light wires between the rear body and the battery pack 0
k) Snap the fuse holders into the holes on the controller splash shield 0
l) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light 0
13 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness 0
REPLACING ELECTRICAL ACCESSORIES 0
Head Light Replacement 0
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward 0
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward 0
3 Disconnect the accessory harness connector (5) from the headlight (3) and turn signal (4) 0
0
Fig 35 Headlight Assembly 0
4 To install the headlight assembly, connect the accessory harness connection (6) to the turn signal (4) and the accessory harness connection (5) to the headlight bulb (3) 0
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position 0
Head Light Bulb Replacement 0
1 Turn the headlight bulb (3) clockwise and pull to remove 0
2 Disconnect the accessory harness from the light bulb 0
3 Connect the accessory harness to the light bulb 0
4 Align the bulb with the opening in the back of the headlight assembly 0
5 Turn the bulb (3) counter clockwise until it stops 0
Turn signal Bulb Replacement 0
1 Grip the turn signal bulb housing (7) and turn to align with slot then pull backward to remove housing from headlight assembly 0
Fig 36 Turn Signal Bulb Replacement 0
2 Remove bulb from housing and replace with a new one 0
3 Align housing with slot and insert turn signal housing (7) into headlight assembly, turn to lock in place 0
Head Light Switch Replacement 0
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel 0
Fig 37 Trim Panel Hardware 0
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the head light switch (13) 0
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11) 0
Fig 38 Head Light Switch 0
4 Insert the new head light switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place 0
5 Connect the accessory harness (12) to the headlight switch (13) 0
6 Push the instrument panel trim into place making sure that no wires are pinched 0
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl 0
Turn Signal Switch Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the connector from the turn signal switch harness to the main electrical harness 0
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder 0
4 Remove the plastic cover from the steering column 0
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw 0
6 Remove the turn signal switch assembly including the clamp 0
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column 0
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape 0
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column 0
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove 0
11 Route the wire harness under the floor mat to the cupholder 0
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet 0
13 Plug the turn signal wire harness connector into the accessory wire harness 0
Turn signal Flasher Unit Replacement 0
1 Remove the top part of the cup holder (ref Section B) 0
2 Unplug the flasher unit from the turn signal wire harness 0
3 Install the new flasher unit in the wire harness receptacle 0
4 Replace the top part of the cup holder (ref Section B) 0
Tail Light Assembly Replacement 0
1 Remove the four Torx head screws (15) that secure the tail light assembly (16) to the rear body 0
2 Pull the tail light (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17) 0
Fig 39 Tail Light Assembly 0
3 Plug the new tail light assembly (15) into the accessory wire harness connector (16) and push the tail light assembly (16) into the opening 0
4 Install the four Torx head screws (15) 0
Tail Light Lens Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Install the new lens and secure in place with the two phillips head screws 0
Tail Light Bulb Replacement 0
1 Remove the two phillips head screws that secure the lens to the tail light assembly 0
2 Remove the light bulb 0
3 Install the new light bulb 0
4 Install the lens and secure in place with the two phillips head screws 0
Horn Button Replacement 0
1 Remove the horn button cover using a flat blade to work the cover off of the switch 0
2 Pull the upper corner of the floormat down to expose the switch retaining nut 0
3 Remove the nut that secures the horn button 0
4 Remove the horn button switch from the floor1board 0
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch 0
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder 0
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame 0
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness 0
9 Replace the floormat and install the horn button cover 0
Horn Replacement 0
1 Disconnect the accessory wire harness from the horn 0
2 Remove the hex head bolt that secures the horn to the mounting bracket 0
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt 0
4 Connect the accessory wire harness to the horn 0
Fig 29 0
Fig 30 0
K-Electrical Wiring-22MAR2012pdf 0
Fig 1 Main Electrical Harness117
MAIN WIRING HARNESS117
1 Disconnect the main wiring harness from the battery pack using an insulated wrench117
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run/Storage’ position, turn the key switch to reverse, wait for the reverse warning indicator to become silent then turn the key switch to the off position and remov117
3 Locate the tab under the cowl that extends from the instrument panel through a slot in the cowl, squeeze the legs of the tab together and push to the back of the vehicle while pulling forward on the cowl Repeat for the other side — at this poin117
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with both hands and pull away from the instrument panel (13); move to the other side of the vehicle and grip the ball holder on 117
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel118
Fig 2 Instrument Panel & Trim118
6 Remove the wiring harness from the front splash shield retaining clips118
7 If vehicle is equipped with brake lights, disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder118
8 Remove the Diagnostic Plug from the bottom of the cup holder118
9 Disconnect the plug to the throttle enable switch118
10 Disconnect the plug from the rotary position sensor118
11 Disconnect the plug from the brake enable switch118
12 Disconnect the wires from the rotary position sensor118
13 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard118
14 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support118
15 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard118
16 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper118
17 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and move it out of the way118
18 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard118
19 Unplug the large 23 (35 for new controller) pin connector (3) from the controller by lifting up on the locking tab and pulling the connector housing away from the controller118
20 Disconnect the plug for the resistor, remove two screws that secure the sensor on top of the resistor118
Fig 3 Controller118
Fig 4 New Controller118
21 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through the splash shield CE vehicles will have a key switch in place of the toggle switch, unscrew the top ring to release the 119
Fig 5 Run / Tow Switch119
22 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield119
Fig 6 Reverse Warning Indicator119
23 Determine which solenoid is installed Two types of solenoid have been used for this vehicle, on early vehicles the solenoid was rectangular and hardwired into the wire harness, later vehicles have the round solenoid where all wires are connected119
24 HARDWIRED RECTANGULAR: Disconnect all wires from the terminal posts and remove two hex nuts (7) securing the solenoid to the controller heatsink If the vehicle has the hardwired rectangular solenoid a new round solenoid will need to be purchased119
Fig 7 Old Style Rectangular Solenoid119
25 ROUND: Remove two larger hex nuts (16) from the larger terminal posts and disconnect red wire from controller B+ terminal (Bus bar for new controller) and white wire (17) from the resistor, red wire (20) from BL+, battery terminal, and yellow wir119
Fig 8 Solenoid Connections119
Fig 9 New Solenoid Connections120
26 Two different main wire harness have been used on this vehicle Determine which main wire harness is installed on the vehicle On early vehicles the motor sensor connected directly to the main wire harness connector, later vehicles have the main 120
27 OLD WIRE HARNESS: Disconnect all the main harness connectors from the motor brake (31), motor temperature sensor (32) and motor sensor (33) as shown below120
Fig 10 Motor Connections (Early Vehicles)120
28 NEW WIRE HARNESS: Disconnect the connectors of motor brake (31), the temperature sensor (32) from the main harness connectors Two different electric motors have been used on the vehicle, the harness connections depend on which motor is installed120
a) OLD STYLE MOTOR: Disconnect male connector end of the adaptor harness from the female connector of the motor sensor harness, unplug the other end of the adaptor harness connector from the connector of the main harness as shown in detail below120
Fig 11 Old Style Motor Connections (later Vehicles)120
b) NEW STYLE MOTOR: Disconnect one end of the adaptor harness from the motor sensor harness, disconnect the other end of the adaptor harness from the main wire harness connector as shown in detail below120
Fig 12 New Style Motor Connections (later Vehicles)121
29 Remove main wiring harness from the vehicle121
30 Install new main wiring harness making sure that it follows the proper path121
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1, 2 & 3)121
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels121
Fig 13 Harness Routing & Pedal Connections121
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4)121
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6)121
e) Connect the wires to the brake pedal rotary position sensor (8) and the brake enable switch connector (9)121
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10)121
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel121
h) Feed the connectors for the key switch, the optional fuel gauge/state of charge meter and the diagnostic plug through the opening in the cup holder base (12) Place the diagnostic plug (13) into the cup holder base and route the connectors for the121
Fig 14 Cup Holder122
i) Route the wires (14) for the key switch and the optional fuel gauge/state of charge meter through the guide (15) on the front splash shield and the connectors for the key switch and the optional fuel gauge/state of charge meter through the opening122
l122
Fig 15 Front Splash Shield122
j) Connect the wire harness to the key switch122
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side122
l) Plug the connector (20) for the charger receptacle into the connector on the main wiring harness122
Fig 16 Charger Receptacle122
m) A new solenoid will ONLY be installed if the old one was connected directly to the wire harness (hard wired) Install solenoid (18) on the controller heat sink using two nuts (22)122
n) Reconnect the black wire (23) and red wire (24) to the solenoid (18) as shown and secure in place with small hex nuts (28)122
o) Connect the Red wire from the controller B+ and the white wire (17) from the resistor to the back terminal of the solenoid (18) and secure in place using a hex nut (16) Be sure to place larger terminal wires first on studs and smaller wires on la122
p) Connect the Red wire (20) from the positive (+), BL+, battery terminal and the yellow wire (21) from the wiring harness to the front terminal on the solenoid, secure in place with hex nut (16) as shown Be sure to place larger terminal wires first122
123
Fig 17 Controller Connections123
Fig 18 New Controller Connections123
q) Plug the 23 (35 for new controller) pin connector (3) from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched123
123
Fig 19 23 Pin Connector123
Fig 20 35 Pin Connector123
r) Plug the connectors for the motor brake (31), the motor temperature sensor (32) on the motor and motor brake123
s) OLD STYLE WIRE HARNESS: Plug the motor sensor (33) connector to the main wire harness connector as shown below123
124
Fig 21 Motor Connections (Early Vehicles)124
t) NEW STYLE WIRE HARNESS: Plug male connector end of the adaptor harness into the female connector on the motor sensor harness Plug the other end of the adaptor harness connector into the connector of main harness, push in firmly and make sure that124
Fig 22 Old Style Motor Connections (Later Vehicles)124
u) Connect one end of the adaptor harness to the motor sensor harness, connect the other end of the adaptor harness to the main wire harness connector as shown in detail below124
Fig 23 New Style Motor Connections (later Vehicles)124
31 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10)124
32 Press the fuse holder (12) into the hole on the controller splash shield124
Fig 24 Reverse Warning Indicator & Fuse124
33 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notch towards the RUN/ STORAGE direction Install the upper nut (5) finger tight and torque as specified in the torque table, 124
34 Replace the controller splash shield and secure it to the body with two Torx head screws125
35 Connect the negative battery wires using an insulated wrench125
36 Connect the positive battery wires using an insulated wrench125
37 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness125
REPLACING ELECTRICAL COMPONENTS125
Run / Tow Switch (Ref Fig 25 on page K-9)125
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench125
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the switch and wires125
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts125
4 Cut the wires from the existing run/tow switch close to the switch125
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness125
6 Remove the upper nut and seal (7) from the new switch (8)125
7 Install the switch (8) with the notch towards the RUN/ STORAGE direction125
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table125
Fig 25 Run / Tow Switch125
9 Install the splash shield using three plastic rivets to secure the shield to the body and the controller125
Reverse Warning Indicator (Ref Fig 26 on page K-10)125
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench126
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires126
3 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield126
4 Cut the wires close to the reverse warning indicator (11)126
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (11) to the wire harness126
6 Secure the new reverse warning indicator (11) to the splash shield with the torx head screws (10)126
7 Reinstall the splash shield126
Fig 26 Reverse Warning Indicator126
State of Charge / Fuel Gauge Replacement126
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel126
Fig 27 Trim Panel Hardware126
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20)126
3 Depress the tabs on the fuel gage/state of charge meter (20) and push the unit out of the trim panel (11)126
Fig 28 Fuel Gage/State of Charge Meter126
4 Insert the new fuel gage/state of charge meter (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place126
5 Connect the main harness (21) to the fuel gage/state of charge meter (20)126
6 Push the instrument panel trim (11) into place making sure that no wires are pinched126
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl126
Fig 29 Main Wiring Harness Diagram (after 23 January 2012)127
Fig 30 Main Wiring Harness Diagram (6 December 2009 through 23 January 2012)128
Fig 31 Main Wiring Diagram (before 5 December 2009)129
Fig 32 Accessory Wiring Harness Diagram130
Fig 33 Accessory Wiring Harness and Accessories131
ACCESSORY WIRING HARNESS131
Replacing the Accessory Wiring Harness131
1 Using an insulated wrench disconnect the accessory harness from the battery pack131
2 Unplug the red and purple wires from the brake light relay to the main harness131
3 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn, fuel gage (state of charge meter) and brake lights131
4 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder131
5 Remove the three fuse holders from the controller splash shield132
6 Disconnect the tail light wiring connectors132
7 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard132
8 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support132
9 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard132
10 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper132
11 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard132
12 Remove the accessory wiring harness from the vehicle132
13 Install new accessory wiring harness making sure that it follows the proper path132
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that the wires tagged ’Driver Side’ are routed to the driver’s side of the vehicle and the wires tagged ’Passenger Sid132
b) Route the wires for the headlight switch through the opening in the instrument panel for the headlight switch132
c) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle132
d) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn132
e) Connect the horn button connector to the accessory harness under the cup holder132
f) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmas tree rivet (2)132
132
Fig 34 Brake Light Relay132
g) Connect the red and purple wires from the accessory harness to the matching wires from the main wire harness132
h) Route the rest of the harness down through the cup holder and in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor132
i) Route the wires and connector for the driver side brake light between the rear body and the battery pack and around the driver’s side of the battery pack to the splash shield Secure the wires in the guides on the splash shield and connect to th132
j) Route the fuses and the passenger side brake light wires between the rear body and the battery pack132
k) Snap the fuse holders into the holes on the controller splash shield132
l) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light132
13 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness132
REPLACING ELECTRICAL ACCESSORIES133
Head Light Replacement133
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward133
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward133
3 Disconnect the accessory harness connector (5) from the headlight (3) and turn signal (4)133
133
Fig 35 Headlight Assembly133
4 To install the headlight assembly, connect the accessory harness connection (6) to the turn signal (4) and the accessory harness connection (5) to the headlight bulb (3)133
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position133
Head Light Bulb Replacement133
1 Turn the headlight bulb (3) clockwise and pull to remove133
2 Disconnect the accessory harness from the light bulb133
3 Connect the accessory harness to the light bulb133
4 Align the bulb with the opening in the back of the headlight assembly133
5 Turn the bulb (3) counter clockwise until it stops133
Turn signal Bulb Replacement133
1 Grip the turn signal bulb housing (7) and turn to align with slot then pull backward to remove housing from headlight assembly133
Fig 36 Turn Signal Bulb Replacement133
2 Remove bulb from housing and replace with a new one133
3 Align housing with slot and insert turn signal housing (7) into headlight assembly, turn to lock in place133
Head Light Switch Replacement133
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel133
Fig 37 Trim Panel Hardware134
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the head light switch (13)134
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11)134
Fig 38 Head Light Switch134
4 Insert the new head light switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place134
5 Connect the accessory harness (12) to the headlight switch (13)134
6 Push the instrument panel trim into place making sure that no wires are pinched134
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl134
Turn Signal Switch Replacement134
1 Remove the top part of the cup holder (ref Section B)134
2 Unplug the connector from the turn signal switch harness to the main electrical harness134
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder134
4 Remove the plastic cover from the steering column134
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw134
6 Remove the turn signal switch assembly including the clamp134
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column134
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape134
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column134
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove134
11 Route the wire harness under the floor mat to the cupholder134
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet134
13 Plug the turn signal wire harness connector into the accessory wire harness134
Turn signal Flasher Unit Replacement134
1 Remove the top part of the cup holder (ref Section B)134
2 Unplug the flasher unit from the turn signal wire harness134
3 Install the new flasher unit in the wire harness receptacle134
4 Replace the top part of the cup holder (ref Section B)134
Tail Light Assembly Replacement135
1 Remove the four Torx head screws (15) that secure the tail light assembly (16) to the rear body135
2 Pull the tail light (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17)135
Fig 39 Tail Light Assembly135
3 Plug the new tail light assembly (15) into the accessory wire harness connector (16) and push the tail light assembly (16) into the opening135
4 Install the four Torx head screws (15)135
Tail Light Lens Replacement135
1 Remove the two phillips head screws that secure the lens to the tail light assembly135
2 Install the new lens and secure in place with the two phillips head screws135
Tail Light Bulb Replacement135
1 Remove the two phillips head screws that secure the lens to the tail light assembly135
2 Remove the light bulb135
3 Install the new light bulb135
4 Install the lens and secure in place with the two phillips head screws135
Horn Button Replacement135
1 Remove the horn button cover using a flat blade to work the cover off of the switch135
2 Pull the upper corner of the floormat down to expose the switch retaining nut135
3 Remove the nut that secures the horn button135
4 Remove the horn button switch from the floor1board135
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch135
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder135
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame135
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness135
9 Replace the floormat and install the horn button cover135
Horn Replacement135
1 Disconnect the accessory wire harness from the horn135
2 Remove the hex head bolt that secures the horn to the mounting bracket135
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt135
4 Connect the accessory wire harness to the horn135
E-ELEC SPEED CONTROLLER- 22Mar12pdf 0
Fig 1 Electronic Speed Control 0
GENERAL 0
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, washers, etc) that are removed must always be installed in their original positions unless otherwise specified Non-specifie 0
Fig 2 Christmas Tree Rivet Removal 0
Fig 3 Pedal Cover 0
Accelerator Pedal Assembly 0
1 Remove four christmas tree rivets securing pedal cover to floorboard 0
2 Remove pedal cover 0
3 Remove three torx screws (2) securing accelerator pedal assembly (1) to the floorboard (Ref Fig 4) 0
4 Disconnect the wires from the rotary position sensor (5) and the throttle enable switch (12) 0
5 Remove the two Torx screws (4) from the rotary position sensor (5) and remove sensor 0
6 Remove the two Torx screws (8) from the throttle enable switch (7) and remove the switch 0
Installation 0
7 Align the slot in the rotary position sensor (5) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (4) Use Loctite® 242; according to product instructions; on the two Torx screws 0
8 Position the throttle enable switch (7) oriented as shown, secure in place with two Torx screws (6) Use Loctite 242; according to product instructions; on the two Torx screwsReconnect electrical harness to rotary position sensor (5) and to the t 0
9 Place pedal assembly in position on the floorboard and secure with three Torx screws (2) 0
Fig 4 Accelerator Pedal 0
10 Install the pedal cover, using new christmas tree rivets, replace the floormat and rocker panels 0
Solenoid Replacement 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Remove the controller splash shield; some vehicles will have two torx head screws and one christmas tree rivet, the remaining vehicles will have three christas tree rivets securing the splash shield in place After removing the fasteners place the 0
1 Disconnect the red wire from the upper terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire to the main wiring harness by removing the upper hex nut (5) 0
2 Disconnect the red wire from the lower terminal on the solenoid to B+ on the controller by removing the lower hex nut (6) 0
3 Remove two hex head nuts (7) securing the solenoid to the controller heat sink 0
4 Cut the two wires from the solenoid to the wire harness and strip approximately 1/2″ (13 mm) of insulation from the ends of the wires from the harness 0
5 Insert the stripped wires from the harness into ends of the ring terminals and crimp both ends 0
Fig 5 Old Style Rectangular Solenoid 0
Round Solenoid Removal 0
1 Disconnect the red wire (13) from the front terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire (14) to the main wiring harness by removing the front hex nut (6) 0
2 Disconnect the red wire (11) from the back terminal on the solenoid (4) to B+ on the controller and and white wire (12) from resistor by removing the back hex nut (5) 0
3 Disconnect the red wire (9) and black wire (8) from the terminals by removing smaller hex nuts (15) 0
4 Remove two hex head nuts (10) securing the solenoid (4) to the controller heat sink 0
Solenoid Installation 0
1 Secure the solenoid (4) to the controller heat sink with the two hex head nuts (10) 0
2 Reconnect the red wire (9) and black wire (8) from harness to solenoid (4) as shown and secure in place with two smaller hex nuts (15) 0
3 Reconnect the red wire (11) from the controller B+ to the back terminal of the solenoid (4) and the white wire (12) to the resistor, secure in place using a hex nut (5) Be sure to place larger terminal wires first on studs with smaller wires on last 0
4 Connect the red wire (13) from the positive (+), BL+, battery terminal and the yellow wire (14) from the wiring harness to the front terminal of the solenoid (4), secure in place with a hex nut (6) Be sure to place larger terminal wires first on 0
Fig 6 Round Solenoid 0
5 Reinstall the electronic controller shield as before 0
6 Reinstall three christmas tree rivets (1) to secure the shield to the body and the controller 0
7 Connect the negative (-) cable to the battery 0
Controller 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wait for the reverse warning indicator to become silent, turn the key switch to the off position and remove the key from the 0
3 Remove three christmas tree rivets (4) securing the controller splash shield to the rear body and to the controller heat sink; position splash shield off to one side to allow access to the controller 0
Fig 7 Controller Splash Shield Cover 0
4 Disconnect the Red positive (+) battery cable from the front terminal of the solenoid 0
5 Disconnect the Red wire from the controller B+ terminal to the back terminal of the solenoid 0
6 Remove two hex head nuts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 0
7 Disconnect the 2 pin connector (14) from the wire harness 0
8 Disconnect the 3 pin connector (12) from the resistor control (13) connector 0
9 Disconnect the 23 pin connector (9) from controller by lifting up on the locking tab and pulling the connector housing away from the controller 0
10 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 0
11 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 0
12 Remove the front two hex head bolts (10) securing the controller assembly to the floorboard and loosen the rear hex head bolt (10) Slide the controller towards the front of the car and lift it out 0
Fig 8 Solenoid Connections 0
Installation 0
13 To install the controller, position it on the floorboard; make sure that all wires are not pinched or under the controller feet; and slide it to the back aligning the slot under the head of the hex head bolt (10) Install the two hex head bolts ( 0
14 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 0
15 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 0
16 Install the solenoid on the controller heat sink using two hex head nuts (7) Reconnect the Red positive (+) battery cable to the front terminal of the solenoid Make sure that the red wire (17) and black wire (18) from the wire harness to the so 0
17 Install the Red wire to the B+ terminal of the controller (Do not over tighten the terminal screw (11) 0
18 Plug the 23 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
19 Check all wires to be sure they are connected to the proper terminal 0
20 Position the Splash Shield under the edge of the seat opening, install the three christmas tree rivets (4) 0
21 Reconnect wires to the battery pack Replace any worn or damaged hardware as required 0
For New Controller Post production 23rd Jan 2012 0
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 0
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wait for the reverse warning indicator to become silent, turn the key switch to the off position and remove the key from the 0
3 Remove three christmas tree rivets (4) securing the controller splash shield to the rear body and to the controller heat sink; position splash shield off to one side to allow access to the controller 0
4 Disconnect the Red positive (+) battery cable from the front terminal of the solenoid 0
5 Disconnect the Bus bar from the controller B+ terminal to the back terminal of the solenoid 0
6 Remove two hex head nuts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 0
7 Disconnect the 2 pin connector (14) from the wire harness 0
8 Disconnect the 35 pin connector (9) from controller and pull the connector housing away from the controller 0
9 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 0
10 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 0
11 Remove two button head torx bolts (10) that secure the controller assembly to floorboard Lift the controller and take it out 0
Fig 9 New Controller and Solenoid 0
Installation 0
12 To install the controller, position it on the floorboard; making sure that all wires are not pinched or under the controller feet; align the forward slot in each foot with the existing holes in the floorboard Install two button head torx bolts ( 0
13 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 0
14 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 0
15 Install the solenoid on the controller heat sink using two hex head bolts (7) Reconnect the Red positive (+) battery cable to the front terminal of the solenoid Make sure that the red wire (17) and black wire (18) from the wire harness to the s 0
16 Install the Bus bar(19) to the B+ terminal of the controller to the terminal of solenoid as shown (Do not over tighten the terminal screw (11) 0
17 Plug the 35 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 0
18 Connect the 2 pin connector (14) from the wire harness 0
19 Check all wires to be sure they are connected to the proper terminal 0
20 Position the Splash Shield under the edge of the seat opening, install the three christmas tree rivets (4) 0
21 Reconnect wires to the battery pack Replace any worn or damaged hardware as required 0
E-ELEC SPEED CONTROLLER_21NOV2012pdf 0
Fig 1 Electronic Speed Control 55
GENERAL 55
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, washers, etc) that are removed must always be installed in their original positions unless otherwise specified Non-specifie 55
Fig 2 Christmas Tree Rivet Removal 55
Fig 3 Pedal Cover 56
Accelerator Pedal Assembly 56
1 Remove four christmas tree rivets securing pedal cover to floorboard 56
2 Remove pedal cover 56
3 Remove three torx screws (2) securing accelerator pedal assembly (1) to the floorboard (Ref Fig 4) 56
4 Disconnect the wires from the rotary position sensor (5) and the throttle enable switch (12) 56
5 Remove the two Torx screws (4) from the rotary position sensor (5) and remove sensor 56
6 Remove the two Torx screws (8) from the throttle enable switch (7) and remove the switch 56
Installation 56
7 Align the slot in the rotary position sensor (5) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (4) Use Loctite® 242; according to product instructions; on the two Torx screws 56
8 Position the throttle enable switch (7) oriented as shown, secure in place with two Torx screws (6) Use Loctite 242; according to product instructions; on the two Torx screwsReconnect electrical harness to rotary position sensor (5) and to the t 56
9 Place pedal assembly in position on the floorboard and secure with three Torx screws (2) 56
Fig 4 Accelerator Pedal 57
10 Install the pedal cover, using new christmas tree rivets, replace the floormat and rocker panels 57
Solenoid Replacement 57
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 57
2 Remove the controller splash shield; some vehicles will have two torx head screws and one christmas tree rivet, the remaining vehicles will have three christas tree rivets securing the splash shield in place After removing the fasteners place the 57
1 Disconnect the red wire from the upper terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire to the main wiring harness by removing the upper hex nut (5) 57
2 Disconnect the red wire from the lower terminal on the solenoid to B+ on the controller by removing the lower hex nut (6) 57
3 Remove two hex head nuts (7) securing the solenoid to the controller heat sink 57
4 Cut the two wires from the solenoid to the wire harness and strip approximately 1/2″ (13 mm) of insulation from the ends of the wires from the harness 57
5 Insert the stripped wires from the harness into ends of the ring terminals and crimp both ends 57
Fig 5 Old Style Rectangular Solenoid 58
Round Solenoid Removal 58
1 Disconnect the red wire (13) from the front terminal on the solenoid to the positive (+), BL+, battery terminal and the yellow wire (14) to the main wiring harness by removing the front hex nut (6) 58
2 Disconnect the red wire (11) from the back terminal on the solenoid (4) to B+ on the controller and and white wire (12) from resistor by removing the back hex nut (5) 58
3 Disconnect the red wire (9) and black wire (8) from the terminals by removing smaller hex nuts (15) 58
4 Remove two hex head nuts (10) securing the solenoid (4) to the controller heat sink 58
Solenoid Installation 58
1 Secure the solenoid (4) to the controller heat sink with the two hex head nuts (10) 58
2 Reconnect the red wire (9) and black wire (8) from harness to solenoid (4) as shown and secure in place with two smaller hex nuts (15) 58
3 Reconnect the red wire (11) from the controller B+ to the back terminal of the solenoid (4) and the white wire (12) to the resistor, secure in place using a hex nut (5) Be sure to place larger terminal wires first on studs with smaller wires on last 58
4 Connect the red wire (13) from the positive (+), BL+, battery terminal and the yellow wire (14) from the wiring harness to the front terminal of the solenoid (4), secure in place with a hex nut (6) Be sure to place larger terminal wires first on 59
Fig 6 Round Solenoid 59
5 Reinstall the electronic controller shield as before 59
6 Reinstall three christmas tree rivets (1) to secure the shield to the body and the controller 59
7 Connect the negative (-) cable to the battery 59
Controller 59
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 59
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wait for the reverse warning indicator to become silent, turn the key switch to the off position and remove the key from the 59
3 Remove three christmas tree rivets (4) securing the controller splash shield to the rear body and to the controller heat sink; position splash shield off to one side to allow access to the controller 59
Fig 7 Controller Splash Shield Cover 59
4 Disconnect the Red positive (+) battery cable (13) from the front terminal of the solenoid (4) 59
5 Disconnect the Red wire (11) from the controller B+ terminal to the back terminal of the solenoid 59
6 Remove two hex head nuts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 59
7 Disconnect the 2 pin connector (14) from the wire harness 60
8 Disconnect the 3 pin connector (12) from the resistor control (13) connector 60
9 Disconnect the 23 pin connector (9) from controller by lifting up on the locking tab and pulling the connector housing away from the controller 60
10 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 60
11 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 60
12 Remove the front two hex head bolts (10) securing the controller assembly to the floorboard and loosen the rear hex head bolt (10) Slide the controller towards the front of the car and lift it out 60
Fig 8 Solenoid Connections 60
Installation 60
13 To install the controller, position it on the floorboard; make sure that all wires are not pinched or under the controller feet; and slide it to the back aligning the slot under the head of the hex head bolt (10) Install the two hex head bolts ( 60
14 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 60
15 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 60
16 Install the solenoid on the controller heat sink using two hex head nuts (7) Reconnect the Red positive (+) battery cable to the front terminal of the solenoid Make sure that the red wire (17) and black wire (18) from the wire harness to the so 60
17 Install the Red wire to the B+ terminal of the controller (Do not over tighten the terminal screw (11) 61
18 Plug the 23 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 61
19 Check all wires to be sure they are connected to the proper terminal 61
20 Position the Splash Shield under the edge of the seat opening, install the three christmas tree rivets (4) 61
21 Reconnect wires to the battery pack Replace any worn or damaged hardware as required 61
For New Controller Post production 23rd Jan 2012 61
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 61
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wait for the reverse warning indicator to become silent, turn the key switch to the off position and remove the key from the 61
3 Remove three christmas tree rivets (4) securing the controller splash shield to the rear body and to the controller heat sink; position splash shield off to one side to allow access to the controller 61
4 Disconnect the Red positive (+) battery cable from the front terminal of the solenoid 61
5 Disconnect the Bus bar from the controller B+ terminal to the back terminal of the solenoid 61
6 Remove two hex head nuts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 61
7 Disconnect the 2 pin connector (14) from the wire harness 61
8 Disconnect the 35 pin connector (9) from controller and pull the connector housing away from the controller 61
9 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) 61
10 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 61
11 Remove two button head torx bolts (10) that secure the controller assembly to floorboard Lift the controller and take it out 61
Fig 9 New Controller and Solenoid 62
Installation 62
12 To install the controller, position it on the floorboard; making sure that all wires are not pinched or under the controller feet; align the forward slot in each foot with the existing holes in the floorboard Install two button head torx bolts ( 62
13 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal screws finger tight, then torque as specified Do not over tighten the terminal screws (11) 62
14 Connect the black wire (3) from the B- terminal to the negative (-), BL-, battery terminal Do not over tighten the terminal screw (11) 62
15 Install the solenoid on the controller heat sink using two hex head bolts (7) Reconnect the Red positive (+) battery cable to the front terminal of the solenoid Make sure that the red wire (17) and black wire (18) from the wire harness to the s 62
16 Install the Bus bar(19) to the B+ terminal of the controller to the terminal of solenoid as shown (Do not over tighten the terminal screw (11) 62
17 Plug the 35 pin connector (9); with the locking tab located on top; from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 62
18 Connect the 2 pin connector (14) from the wire harness 62
19 Check all wires to be sure they are connected to the proper terminal 62
20 Position the Splash Shield under the edge of the seat opening, install the three christmas tree rivets (4) 63
21 Reconnect wires to the battery pack Replace any worn or damaged hardware as required 63
For Curtis Controller 63
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench 63
2 Drain the stored energy from the controller Place the Run/Tow switch in the Run position, turn the key switch to reverse, wait for the reverse warning indicator to become silent, turn the key switch to the off position and remove the key from the 63
3 Remove three christmas tree rivets (4) securing the controller splash shield to the rear body and to the controller heat sink; position splash shield off to one side to allow access to the controller 63
4 Disconnect the Red positive (+) battery cable (13) from the front terminal of the solenoid (4) 63
5 Disconnect the Bus bar from the controller B+ terminal to the back terminal of the solenoid 63
6 Remove two hex head nuts (7) securing the solenoid to the controller heat sink, place the solenoid off to one side out of the way The original solenoid is hard wired into the electrical harness 63
7 Disconnect the 2 pin connector (14) from the wire harness 63
8 Disconnect the 35 pin connector (9) from controller and pull the connector housing away from the controller 63
9 Disconnect the three wires (8) from the electric motor to terminals U, V and W by removing the three controller terminal screws (11) as shown in Fig 8 63
10 Disconnect the negative (-) battery wire (3) from the B- terminal by removing the terminal screw (11) 63
11 Remove two button head torx bolts (10) that secure the controller assembly to floorboard Lift the controller and take it out 63
Fig 10 Curtis Controller and Solenoid 64
Installation 64
12 Assemble the new curtis controller (1) to left bracket (2) and right bracket (3) 64
13 Position the heat shield (4) and match the holes on the two brackets and secure them by hand tightening the four hex head bolts (14) 64
14 Position resistor (5) along the slot in the heat shield and secure along with the controller assembly using hardware 64
15 Connect the two white wires (7) and (8) as shown in Fig 9 and tighten the hardware to a torque of 62 – 80 in lbs (7 – 9Nm) 65
16 Position the controller assembly on floorboard, make sure that no wires are pinched or under controller feet Position it on the floorboard and secure with two hex head bolts (H) Tighten the two hex head bolts (H) as per the specified torque 65
17 Secure the Bi-metal switch using two pan head phillips screws 65
18 Connect the three wires from the electric motor Blue to the W terminal, Yellow to the V terminal and Green to the U terminal Install the terminal bolts (12), finger tighten and then tighten to 80 – 97 in lbs (9 – 11 Nm) torque Do not over ti 65
19 Connect the black wire (9) from the B- terminal to the negative (-), BL-, battery terminal Tighten terminal bolt (12) to 80 – 97 in lbs (9 – 11 Nm) torque Do not over tighten the terminal bolt (12) 65
20 Install the solenoid on the controller heat shield using two hex head bolts (7) Reconnect the Red positive (+) battery cable to the front terminal of the solenoid 65
21 Connect the white wire (8) from the resistor along with red wire from B+ to rear terminal of the solenoid 65
22 Connect white wire (7) from resistor to RES terminal on controller Tighten terminal bolt (12) to 80 – 97 in lbs (9 – 11 Nm) torque Do not over tighten the terminal bolt (12) 65
23 Cut white brake switch wire (M) in the main harness and splice both ends of the cut wire together with the white wire from the adaptor harness (6) using splice 65
24 Cut orange wire (N) in main harness and fold piece of wire towards front of vehicle back on itself and tape in place, splice remaining end of orange wire (N) to orange wire from adaptor harness (6) with splice 65
25 Connect the red wire (R) to the B+ terminal of the controller Tighten terminal bolt (12) to 80 – 97 in lbs (9 – 11 Nm) torque Do not over tighten the terminal bolt (12) 65
26 Controller KIT comes with an adaptor (C) containing two 23 pin connector slots Plug the 23 pin connector from adaptor harness into one slot and the 23 pin connector from main harness into the second slot Ensure that the locking tab is latched f 66
27 Plug the 35 pin connector from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched 66
28 Attach Adaptor box (C) to floorboard using tapping screws (D) 66
29 Check all wires to be sure they are connected to the proper terminal 67
30 Position the Splash Shield under the edge of the seat opening, install the three christmas tree rivets (4) 67
31 Reconnect wires to the battery pack Replace any worn or damaged hardware as required 67

S.M 11/24