service manual, fork assembly replacement
Contents
1.2. 8 3 Tighten the castle nut with the 1 1 8 wrench using the crescent wrench again to leverage against the fork 8 4 Tighten the castle nut until it compresses the urethane bushing down to a maximum height of 0 15 inches or 3 8mm DO NOT UNDERTIGHTEN If the slots in the nut do not line up with the hole in the shaft once the bushing is compressed continue to tighten the nut until they do line up It is better to over tighten the nut to line up the hole for the cotter pin Do not loosen the nut to line up the hole Urethane bushing compressed to height of 0 15 inches Shaft hole and castle nut Slots lined up 8 5 Install cotter pin and bend ends out flat as shown Adjustable pliers are recommended 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 00064 1 document SERVICE MANUAL 9 0 Connect the wires to the motor Use the 1 2 inch wrench IMPORTANT Black goes to the Positive Terminal j 9 1 Plug the soeedometer connectors together Wire Guide Connectors 9 2 Mount the speedometer connectors to the wire guide with a nylon wire tie as shown T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 13 subject to the restriction on the cover or title page of this 040 00064 1 document SERVICE MANUAL 1
3. 0 0 Slide the wire conduit strap over the conduit Note position of fastening hole TEN T 10 1 Start the 7 16 bolt into the threaded hole to fasten the strap to the fork It might be easier for you to start it by hand This step may take some patience T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 14 subject to the restriction on the cover or title page of this 040 00064 1 document SERVICE MANUAL 11 0 Test for full range of motion Slowly turn the fork assembly from lock to lock and make sure the range of motion is smooth with no binding If any binding or lack of smoothness is felt visually check for any obstruction DO NOT FORCE The most common cause of binding is due to the routing of the main power wires You may have to loosen the wire conduit strap and reposition the wires to alleviate any friction 12 0 Reinstall front fender Use the same fasteners you removed to take it off Just reverse the procedure Do not fully tighten any of the fasteners until all of the fasteners are in place Do not over tighten the fasteners Once installed check the range of motion of the steering again 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 15 subject to the restriction on the cover or title page of this 040 00064 1 document
4. 3MOTION 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 00064 1 document SERVICE MANUAL 7 0 Feed the wire bundle through the 4 X 2 1 4 inch rectangular opening in the top of the fork assembly Note angle of fork assembly in relation to T3 unit Fork must be turned as shown to avoid damage to Note parts are within T3 unit s bodywork easy reach prior to installing fork on vehicle 7 1 Slide the fork onto the steering shaft Be sure the steering shaft is turned to the vehicles left so the fork will align to the shaft easily 7 2 Make sure the fork is fully seated to the shaft as shown here Continue to support fork while installing hardware even if it feels like it will stay on its own 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 00064 1 document SERVICE MANUAL 7 0 Install the fork mounting hardware The urethane bushing goes on to the shaft first 8 1 Slide the washer on the steering shaft 8 2 Thread the castle nut on 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 00064 1 document SERVICE MANUAL
5. ARY INFORMATION 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 00064 1 document SERVICE MANUAL WORK INSTRUCTIONS 1 0 Recommended tools for replacing the fork assembly see equipment table above for the details 1089763 2 5 4 11 Place the T3 unit on a raised surface sturdy enough to hold the weight of the vehicle 300 pounds Removing the batteries will lighten the vehicle by 40 pounds The front wheel should be at least six inches from the ground but ideally the unit should be two to three feet off the ground for ease of handling the removal and replacement of the fork assembly A work table like the one shown below is very helpful 2 0 T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet 4 Use or disclosure of data contained on this sheet is subject to the restriction on the cover or title page of this 040 00064 1 document SERVICE MANUAL 2 1 A stand like this can be placed under the front of the unit can to elevate the front wheel if a work platform as described above is not available 2 2 Be sure to set the parking brake For maximum stability do not place the stand too far back under the unit Place it as shown below 3 0 Take off the front fender by removing the Allen head fastener with the 5 32 Allen wrench Remove the left and right axle mounting ones first T3MOTION PROPRIETARY INFO
6. RMATION 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 00064 1 document SERVICE MANUAL 3 1 Next remove the left and right rear side fasteners with the same Allen wrench If your T3 unit only has these four fasteners attaching fender remove the fender now 3 2 If your T3 unit has two fasteners on the top of the front fender remove them now and the fender can be removed 3 3 An exposed fork with fender removed 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 00064 1 document SERVICE MANUAL 4 0 Cut just the nylon wire tie holding the speedometer wire with the wire cutters to release it from the guide Unplug the connectors ci Nacsa 4 1 Note Your motor may have a black coating on the terminal end Photo shows an un coated motor for clarity 4 2 Remove the 7 16 bolt holding the wire conduit strap using a socket with an extension swivel and ratchet The strap may have to be bent forward to access the head of the bolt This can be done by hand from the front or with a screwdriver from the side if needed 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 p
7. SERVICE MANUAL Document Number SS 040 00064 Form Instructions Equipment Equipment Manufacturer List 1 Fork Assembly T3 Motion 2 1 1 8 inch wrench Any 3 Adjustable Crescent wrench Any 4 Diagonal cutter Any 5 Adjustable Pliers Any 6 inch wrench Any 7 Ratchet Any 8 7 16 socket Any 9 Extension Any 10 Swivel Any 11 5 32 inch Allen wrench 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 15 NOT REVISE MANUALLY or in part without the written permission of T3MOTION Inc is prohibited Form 040 00064 Rev 1 SERVICE MANUAL ent rane ews fy 024 00036 Front Fork 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 00064 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 PROPRIET
8. age of this 040 00064 1 document SERVICE MANUAL 5 0 Remove this cotter pin with pliers and or diagonal cutters and discard Urethane Bushing Washer Castle Nut 5 1 Loosen but do not remove 1 1 8 inch castle nut with wrench Use crescent wrench on fork for leverage as shown 5 2 Support fork assembly while removing castle nut washer and urethane bushing A little force applied to the front of the tire will wedge the assembly onto the shaft so you wont have to support the full weight of the fork while installing the bushing washer and nut 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 00064 1 document SERVICE MANUAL 5 3 VERY IMPORTANT Turn the fork as shown BEFORE removal When facing the front of the vehicle the motor should be on your left and the tire pointing to your right Failure to do so will damage the bodywork of the T3 vehicle The fork assembly weighs 50 LBS Use appropriate caution to avoid injury to self and or vehicle Sometimes the fork will slip off the steering shaft easily sometimes it must be worked off with a side to side rocking motion Once free of the shaft lower the fork assembly to the ground making sure the wiring does not snag on anything 6 0 Installation of the new fork assembly is similar to the steps of removal in reverse T
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