SERVICE MANUAL, HEADSET REPLACEMENT
Contents
1. SERVICE MANUAL Document Number SS ee 040 00067 Form Instructions Operation Description Sub Assembly Machine Occup Cycle Time Setup Time Batch Qty Standards Equipment Equipment Manufacturer List 1 Headset assembly T3 Motion 2 7 8 inch wrench Any 3 5 32 inch Allen driver Any 4 7 16 inch socket w ratchet amp extension Any Document Description Document Description Reference Docs Related Files Even Mam OOOO T3MOTION INC PROPRIETARY INFORMATION ALL TEXT AND GRAPHICS This document is the sole property of T3MOTION Inc The release of data COMPUTER GENERATED DO contained in this document and the reproduction of this document in whole SHEET 1 of 10 NOT REVISE MANUALLY or in part without the written permission of T3MOTION Inc is prohibited Form 040 00067 Rev 1 SERVICE MANUAL ent frame etn fy 024 00026 Headset assembly T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is D subject to the restriction on the cover or title page of this 040 00067 1 document SERVICE MANUAL Serious electrical shock can occur if precautions are not followed e ALWAYS TURN OFF POWER BREAKER IN GLOVE BOX AND REMOVE POWER MODULES BEFORE PERFORMING ANY ELECTRICAL WORK Power breaker in glove box Power modules e ALSO SET THE PARKING BRAKE PRIOR TO ANY WORK Parking brake T3MOTION PROPRIETARY INFORMATION2. Document No Revision Sheet Use or disclosure of data contained on this sheet is 3 subject to the restriction on the cover or title page of this 040 00067 1 document SERVICE MANUAL WORK INSTRUCTIONS 1 0 Recommended tools for replacing the headset assembly see equipment table above for the details ees s s d ve a 7 8 inch wrench 5 32 inch Allen driver 7 16 inch socket w ratchet amp extension 2 0 Anew headset assembly You may be replacing the entire assembly as shown or just some of the parts This instruction shows the entire replacement procedure for all the parts But you can use it to replace only the parts required for your application 3 0 Remove these two 5 32 Allen screws from the back of the headset a se F bea a 7 2 i a fa BAT i 4 I j L a W f 7 T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is A subject to the restriction on the cover or title page of this 040 00067 1 document SERVICE MANUAL 3 1 Remove these two 5 32 Allen screws from under the headlight on the front 3 2 Lift the headset top off W 3 3 Disconnect the plugs from the circuit board Take your time and do not pull by the wires pull from the connectors Also note the locking tabs that must be released on the connectors T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data conta
3. ined on this sheet is 5 subject to the restriction on the cover or title page of this 040 00067 1 document SERVICE MANUAL 3 4 Remove these four 5 32 Allen screws from the back of the headset 3 5 Slide the front of the headset off and using the 7 16 socket wrench remove the two bolts holding the headset rear onto the handlebars Note Bolt is behind wires 3 6 Remove rear of headset T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 6 subject to the restriction on the cover or title page of this 040 00067 1 document SERVICE MANUAL 4 0 Remove the two key switches mounted to the headset rear 4 1 Loosen the nut with a 7 8 wrench _ 4 2 Slide the lock out and install it in the new part Tighten the nut with the wrench but just snug do not over tighten Repeat the procedure with the other key switch Note that the lock washer goes on the inside the black gasket goes on the outside P T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 7 subject to the restriction on the cover or title page of this 040 00067 1 document SERVICE MANUAL 5 0 Install the rear of the new headset Line the two large notches on the front on the part up with the large grommets on the handlebars Install the two 7 16 bolts as shown here but do not tighten them yet adset front ove
4. ing works properly f ta For addition information contact T3 Motion at 714 619 3600 T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 10 subject to the restriction on the cover or title page of this 040 00067 1 document
5. r the brake line 5 1 Use care getting the he rE A z p ma d a T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 8 subject to the restriction on the cover or title page of this 040 00067 1 document SERVICE MANUAL 5 2 Install the four 5 32 Allen screws from the back of the headset Start all four but do not tighten until all are threaded Do not over tighten them Just make them tight enough to close the gaps between the front and rear Once they are tight go back and tighten the two 7 16 bolts from step 5 0 a ees 6 0 Install the headset top assembly Plug all the connectors into their respective receptacles The circuit board is labeled at each connection Trace the wires to their source if you are not sure where to plug them in r l i 7 Al T 6 1 Re install headset top Be sure to arrange wires so there is no binding or pinching T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 9 subject to the restriction on the cover or title page of this 040 00067 1 document SERVICE MANUAL 6 2 Re install headset top mounting screws Thread all four of them in part way before tightening any of them Do not over tighten them There are the two on the back shown here 6 3 And these are the two on the front under the head light 7 0 Turn power on and test to make sure everyth
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