Installing Motor with out a manual

[cheapjeep2]

So my manual is lost in the mail..

I am going to be installing my motor shortly and wondering what I need to know to do it right and safely with out the manual.

Cart is a 01 DS 48v
Here's what I figure I need to so do so tell me if what I missed.

1. Move the toggle under the seat to TOW mode to disable the electronics.
2. Disconnect the main battery wires so the entire pack is isolated.
3. Label each wire that is on A1, A2, S1 and S2 to ensure they are hooked up correctly for the install. Test for voltage and disconnect.
4. Unbolt motor and do the reverse to install.

So How much am I missing here?

Thanks again

[dereckbc]

Originally Posted by cheapjeep2

So my manual is lost in the mail..

I am going to be installing my motor shortly and wondering what I need to know to do it right and safely with out the manual.

Cart is a 01 DS 48v
Here's what I figure I need to so do so tell me if what I missed.

1. Move the toggle under the seat to TOW mode to disable the electronics.
2. Disconnect the main battery wires so the entire pack is isolated.
3. Label each wire that is on A1, A2, S1 and S2 to ensure they are hooked up correctly for the install. Test for voltage and disconnect.
4. Unbolt motor and do the reverse to install.

So How much am I missing here?

Thanks again

My advice is getting the batteries completely out of the cart. Or at least remove all cable connecting them including the inter-battery straps.

Batteries are very unforgiving and if you accidentally short even one of them out, you are going to have a very bad day. Like possibly the next few days in the hospital, and the next couple of moths living with friends while your house is being rebuilt from the fire you survived.

[BRS]

Better safe than sorry I suppose, but I (personally) wouldn't go to the work of removing all the batts? You may want to discharge the controller, once you disconnect the main pos. and neg. batt. cables (put the cart in reverse and hit gas until your buzzer is barely heard.) Then swap the motor, if your cart is lifted...you may not even need jackstands. 20 minute job if your motor comes right off. Otherwise...pb blaster, rubber mallet, and some little pry bars. Good luck.

[phasetim]

use two wrenches to make motor wires off, and put them on...

[ogre'sdad]

How-Dee, It has been my experience that all of the above are true and good ideas, I also like to either remove or lift the brushes and lock them away from the commutator with the brush springs. Murphys law definitely applies here and, as we all know, brushes are expensive and commutators are easily damaged. I've even been known to slip some thin cardboard between the brush box and comm. Best of luck. Randy

[shadowman]

take the 2 batts on pass. side out and your good to go.....if everything goes ok you,ll be done in less than 1/2 hour be careful motor is heavy so if you can get a little help there it dosn,t hurt..................................