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Unread 10-27-2016, 08:30 PM   #1
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Default Club Car DS motor install Help

Going to swap my 48 volt DS series motor for a 36 volt series motor on saturday.

Any helpful tips I should know before tackling the job? I know to use two wrenched for the motor studs when removing the wires. Anything else?

My car has the older style rear body without an access panel. Should i try and jack up the cart high enough and do it from underneath or should I remove the whole rear body?

Thanks guys
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Unread 10-27-2016, 09:49 PM   #2
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Default Re: Club Car DS motor install Help

i jack up the cart about a foot and place stands under frame just in front of the wheel wells, remove the tires
then with a jack under the axle i take off the rear leaf springs and lower the axle till the wires are almost tight and remove them and lower the axle down to get at motor remember there are 4 bolts 3 from one side (towards motor) and 1 from the other way under motor



label wires and take a photo
if motor is stuck on try a rubber mallet or try TahoeDawg 's trick

Quote:
Originally Posted by TahoeDawgZ71 View Post
Take the rear end out of the car. Take the passenger side tire off of the rear end. Take brake drum off. Flip brake drum around backwards and tighten lug nuts to where they are snug enough to hold the drum to the axle. Don't torque them down. With the aid of an assistant, lift the rear end up 3 - 4 feet into the air and drop the rear end onto a concrete floor onto the inverted brake drum. The drum is inverted so you don't damage the wheel studs during this process. The motor will fall off as soon as it hits the ground. If it doesn't, try it again. I've never had to drop one more than three times. Don't laugh. Try it and thank me later.
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Unread 10-27-2016, 10:29 PM   #3
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Default Re: Club Car DS motor install Help

I jack up the rear of the cart, remove the 3 (4)bolts that hold the motor on, remove the white and blue wire, rotate the motor and remove the orange and green wires and pull the motor out and down in front of the differential.
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Unread 10-27-2016, 10:59 PM   #4
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Default Re: Club Car DS motor install Help

ok, does not seem to bad. I've been a little short on time lately so i called the local cart shop and they want $200 to do the swap. Not sure if that is expensive or not but doesn't seem to hard to tackle the job.
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Unread 10-27-2016, 11:09 PM   #5
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Default Re: Club Car DS motor install Help

it really is not hard to remove the motor when you drop the springs down
you can remove the motor from the rear and install the other too
$200 is not bad i would charge $100
i did a 36v swap in an hour ... then again the motor fell out with the last bolt
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Unread 10-28-2016, 05:12 AM   #6
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Default Re: Club Car DS motor install Help

If the motor is not stuck 200 is really really pricey.

Id do it for 68 bucks and be done in 20 minutes
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Unread 10-28-2016, 11:01 AM   #7
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Default Re: Club Car DS motor install Help

Any of you guys planning on coming down to south Florida

I should have been more clear $80 of it is just for the pick up and delivery.
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Unread 10-28-2016, 11:37 AM   #8
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Default Re: Club Car DS motor install Help

One time I had a CC motor corrosion welded to the drive spline. I had to remove the rear end to remove the motor. $160 would have been a bargain.

PS
If I could have gotten $80 pick up & delivery, I may still be in the service business

Either way enjoy the 36v motor in 48v system upgrade. Did you send that motor out for a clean up, a new bearing, and brushes first? Don't want to waste the install time and money.
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Unread 10-28-2016, 08:03 PM   #9
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Default Re: Club Car DS motor install Help

Quote:
Originally Posted by golf cart man View Post
Any of you guys planning on coming down to south Florida

I should have been more clear $80 of it is just for the pick up and delivery.

80 bucks just to pick up and delivery. That's really high too. Is it like a 40 mile trek to pick up your cart?
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Unread 10-28-2016, 08:07 PM   #10
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Default Re: Club Car DS motor install Help

Quote:
Originally Posted by scottyb View Post
One time I had a CC motor corrosion welded to the drive spline. I had to remove the rear end to remove the motor. $160 would have been a bargain.

PS
If I could have gotten $80 pick up & delivery, I may still be in the service business

Either way enjoy the 36v motor in 48v system upgrade. Did you send that motor out for a clean up, a new bearing, and brushes first? Don't want to waste the install time and money.

The money is not in the pick up and delivery, its in the quality of work and how you get your customers to trust your abilities. Ive got 5 other guys started in the golf cart repair business and all take home a 6 figure income in a variety of areas of the country.
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