ELECTRONIC SPEED CONTROL (48V)
Page F-35
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
CONTROLLER REPLACEMENT
Tool List Qty. Required
Socket, 10mm, 3/8" drive............................................ 1
Socket, 7/16", 3/8" drive.............................................. 1
Socket, 13mm, 3/8" drive............................................ 1
Ratchet, 3/8" drive....................................................... 1
Extension, 6", 3/8" drive.............................................. 1
Insulated wrench, 9/16"............................................... 1
Shop towel .................................................................. 1
Torque wrench, 3/8" drive, in. lbs................................ 1
Torque wrench, 3/8" drive, ft. lbs................................. 1
Remove the seat.
Before any electrical service is per-
formed on 48 volt model vehicles, the
Run-Tow/Maintenance switch must be placed in the ‘Tow/Mainte-
nance’ position.
If a power wire (battery, motor or controller) is disconnected for
any reason on the 48 volt model vehicle, the Run-Tow/Mainte-
nance switch must be left in the ‘Tow/Maintenance’ position for
at least 30 seconds after the circuit is restored.
To prevent electrical
shock, the BL- wire must
be removed before dis-
charging the controller by shorting the B+ and B- ter-
minals of the controller with a large screwdriver. Be
sure to hold screwdriver by the insulated portion.
Using an insulated wrench, remove the BL- wire from the
battery.
Note the location of the wiring on the controller
before removing wiring from controller. (Ref
Fig. 17 on page F-36)
Remove the controller mounting nuts and remove the
controller
.
Mount new controller to mount and reconnect wiring.
Tighten the controller mounting bolts to 108 - 132 in. lbs.
(12 - 15 Nm) torque and the M6 (F1 and F2) bolts to 80 -
90 in. lbs. (9 - 10 Nm) torque and M8 (B+, M-, B-) bolts to
120 - 130 in. lbs. (14 - 15 Nm) torque.
Replace controller mount assembly in vehicle. Replace
and tighten nuts to 6 - 8 ft. lbs. (8 - 11 Nm) torque.
Reconnect the BL- battery cable and replace the seat.
SOLENOID REPLACEMENT
Tool List Qty. Required
Socket, 3/8", 3/8" drive................................................ 1
Socket, 7/16", 3/8" drive.............................................. 1
Socket, 1/2", 3/8" drive................................................ 1
Ratchet, 3/8" drive....................................................... 1
Extension, 6", 3/8" drive .............................................. 1
Insulated wrench, 9/16"............................................... 1
Shop towel................................................................... 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
Remove the seat.
Before any electrical service is per-
formed on 48 volt model vehicles, the
Run-Tow/Maintenance switch must be placed in the ‘Tow/Mainte-
nance’ position.
If a power wire (battery, motor or controller) is disconnected for
any reason on the 48 volt model vehicle, the Run-Tow/Mainte-
nance switch must be left in the ‘Tow/Maintenance’ position for
at least 30 seconds after the circuit is restored.
To prevent electrical
shock, the BL- wire must
be removed before dis-
charging the controller by shorting the B+ and B- ter-
minals of the controller with a large screwdriver. Be
sure to hold screwdriver by the insulated portion.
Using an insulated wrench, remove the BL- wire from the
battery.
Note the location of the wiring on the solenoid
before removing wiring from solenoid (Ref Fig.
17 on page F-36)
Remove the solenoid mounting bolts and remove the
solenoid
.
Mount new solenoid and reconnect wiring. Tighten the
solenoid mounting nuts to 67 - 82 in. lbs. (8 - 9 Nm)
torque, the #10 terminal nuts to 13 - 17 in. lbs. (1 - 2 Nm)
and the 5/16" terminal nuts to 50 - 60 in. lbs (6 - 7 Nm)
torque.
Reconnect the BL- battery cable and replace the seat.
! !
! !
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