service manual, throttle assembly replacement
Contents
1. SERVICE MANUAL Document Number SS 040 00073 Form Instructions Operation Description Sub Assembly Machine Occup Cycle Time Setup Time Batch Qty Standards Equipment Equipment Manufacturer List 1 Throttle Assembly T3 Motion 2 Phillips screw driver Any 3 5 32 inch Allen wrench Any 4 7 16 inch socket Any 5 Ratchet Any 6 Wire cutters 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 12 NOT REVISE MANUALLY or in part without the written permission of T3MOTION Inc is prohibited Form 040 00073 Rev 1 SERVICE MANUAL ent rane e fy 023 00014 Throttle 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 00073 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 IN2. 16 inch bolt on the right hand side of the vehicle that secures the headset to the handlebars 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 00073 1 document SERVICE MANUAL 4 1 Loosen but do not remove the 7 16 inch bolt on the left hand side m 4 2 Carefully pull apart the headset front and rear to allow the large handlebar grommet to slide out Do not force the plastic parts b o 4 3 Slide the grommet out a bit so you can slide the connector under it It takes two hands 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 00073 1 document SERVICE MANUAL 4 4 Loosen the top Phillips head screw to allow the throttle assembly to slide off the handlebar 5 0 Slide the new throttle assembly all the way onto the handlebar 5 1 Tighten both the top and bottom Phillips head screws to secure the throttle assembly to the handlebar Bottom screw being tightened in photo below FI Do not over tighten the two screws that secure the throttle to the handlebar or binding of the throttle may occur Check to make sure the throttle returns smoothly and rapidly when released If binding occurs back off the scr
3. FORMATION 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 00073 1 document SERVICE MANUAL WORK INSTRUCTIONS 1 0 Recommended tools for replacing the throttle assembly See equipment table above for the details 1 1 New throttle assembly 2 0 Cut nylon tie wrap s securing wire to handlebar with wire cutters 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 00073 1 document SERVICE MANUAL 3 0 Remove these four screws with the 5 32 Allen wrench OE 3 1 Remove these two screws with the 5 32 Allen wrench 3 2 Carefully lift off the headset cover Do not pull hard on the wires ER ike G j g h ie ca d i 3 Pa i a P F a 7 a A 8 i Pa t T Bo y MET a r F 7 gt i a eT f Pa aa a f Fj Fi ko y S ee 4 F 3 b i F My s L L L l 1 j ai T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 5 subject to the restriction on the cover or title page of this 040 00073 1 document SERVICE MANUAL 3 3 Locate the throttle connector on the circuit board 3 4 Disconnect the plug for the throttle Note the locking tab that must be released 4 0 Remove the 7
4. ed on this sheet is 10 subject to the restriction on the cover or title page of this 040 00073 1 document SERVICE MANUAL 6 0 Plug the throttle connector to the circuit board as shown Note position of locking tab 7 0 Re install headset top Be sure to arrange wires so there is no binding or pinching 7 1 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 T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 11 subject to the restriction on the cover or title page of this 040 00073 1 document SERVICE MANUAL 7 2 And these are the two on the front under the head light ao _ _ 7 l 8 0 Turn power on and test to make sure everything works properly 9 0 Secure wire to handlebar with a nylon tie wrap and cut excess from tie with wire cutters 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 12 subject to the restriction on the cover or title page of this 040 00073 1 document
5. ews a small amount until it works properly Also make sure the screws are sufficiently tight to hold the throttle on securely 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 00073 1 document SERVICE MANUAL 5 2 Feed the connector and wire through the grommet much the same way as you removed it earlier 5 3 Slide the grommet back to its correct position so it lines up with the headset parts 5 4 Gently work the grommet and the headset parts back into alignment 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 00073 1 document SERVICE MANUAL 5 5 Hand thread to start the 7 16 bolt that holds the headset to the handlebars Note routing of wires to avoid pinching or damaging them 5 7 Re install the forward upper right Allen head screw to fasten the headset around the grommet Do not over tighten or force Tighten just enough to close the gap here If the gap won t close inspect the area to find what is interfering Also see step 7 1 for re installing the headset screw on the back lower right at this time if you are having difficulty closing the gap T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contain
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