service manual, front pulleys & belts & bearings
Contents
1. aca Tor 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 00119 1 document SERVICE MANUAL 10 2 Slide axle with a nut a locking tab an adjustment block and a spacer into the wheel from the right side 10 4 Install a spacer on the left side _ 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 00119 1 document SERVICE MANUAL 10 5 Guide the secondary belt around the pulley and position the wheel assembly between the forks 11 0 Note the orientation of the adjustment block in this picture This is the right side and for now install the adjustment block upside down to the way it came off T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 16 subject to the restriction on the cover or title page of this 040 00119 1 document SERVICE MANUAL 11 2 Then push the axle all the way through hy 11 3 Install the left side adjustment block the same way it came off You will probably need to tap it into place with the mallet 11 4 Install the locking tab and nut but leave a space between the nut and adjustment block as shown T3MOTION PROPRIETARY INFORMATION Document No Rev2. 1 document
3. side plate with the shoulder bolt and secondary pulley assembly as one unit The secondary belt is on the floor in this picture 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 00119 1 document SERVICE MANUAL 7 4 If you are changing the primary belt remove and replace it at this time 8 0 Note there is a shim between the small pulley and the inner mounting plate It is possible to have different sized shims and one or more on each side of the pulley bearing assembly Note location of shoulder bolt in side plate and the shims on the shoulder bolt Be sure to replace them the same way they were installed originally 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 00119 1 document SERVICE MANUAL 8 1 This is an assembled secondary pulley and bearing set with a crush tube between the bearings If the removed assembly did not have a crush tube when it was disassembled install one at this time when you are installing new bearings Bearings should be a very tight fit into the pulleys as should the fit of the smaller pulley into the larger pulley Be sure to seat the bearings completely into the pulleys 9 0 Slide the secondary pulley bearing assemb
4. If your T3 unit does not have locking tabs continue with the procedure they can be added during reassembly D PE ea mu a 5 2 Loosen the 1 1 8 nut on the axle E 5 3 Elevate the front of the T3 unit T3MOTION PROPRIETARY INFORMATION Use or disclosure of data contained on this sheet is subject to the restriction on the cover or title page of this 040 00119 1 document Document No Revision Sheet SERVICE MANUAL 5 4 Remove the nut you loosened on the left side of ae 6 0 Slide the axle through towards the right side You will probably need the mallet and screwdriver 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 00119 1 document SERVICE MANUAL 6 1 Note the amount and location of the shims when the axle comes out There are two shims for the left side of the axle 6 2 7 0 Remove the 9 16 inch nylock nut on the on the shoulder bolt 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 00119 1 document SERVICE MANUAL 7 1 Remove the three 9 16 bolts that hold the side plate onto the fork frame 7 2 Remove the shoulder bolt with a 1 4 inch Allen wrench Socket type shown 7 3 Remove the
5. SERVICE MANUAL Document Number SS 040 00119 Form Instructions Equipment Equipment Manufacturer List 1 Channel lock type pliers Any 2 2 Soft face mallet Any 1 3 5 32 inch Allen driver Any 1 4 Standard screwdriver Any 1 5 9 16 inch wrench Any 1 6 1 4 inch Allen wrench Any 1 7 1 1 8 inch open end wrench Any 1 8 Secondary Pulley Small T3 Motion 1 9 Secondary Pulley Large T3 Motion 1 10 Bearings T3 Motion 2 11 Crush Tube T3 Motion 1 12 Primary Belt T3 Motion 1 13 Secondary Belt T3 Motion 1 Document Description Document Description Reference Docs Related Files even Mes OOOO O 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 0040 00119 Rev 1 SERVICE MANUAL Item Part Description Qty 8 200 00118 18G Secondary Pulley Small 10 1 shown 1 9 200 00111 49G Secondary Pulley Large 10 1 shown 1 10 100 50043 Bearings 1 1 200 00148 Crush Tube 2 12 100 50028 Primary Belt 1 13 100 50027 Secondary Belt 1 T3MOTION PROPRIETARY INFORMATION C DocumenttNo _ Revision Shet Use or disclosure of data contained on this sheet is D subject to the restriction on the cover or titl
6. e page of this 040 00119 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 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 00119 1 document SERVICE MANUAL WORK INSTRUCTIONS 1 0 Recommended tools for replacing the secondary pulley set bearings and belts See equipment table above for the details NOTE This instruction shows the parts of a 10 1 ratio pulley and belt system Other ratios are available but require different parts The process is the same for all ratios Be sure to verify the ratio of the vehicle work is being performed on prior to commencing work i 2 Channel lock type pliers 3 Soft face mallet 4 5 32 inch Allen driver 5 Standard screwdriver 6 9 16 inch wrench 7 Y inch Allen wrench 8 1 1 8 inch open end wrench 1 1 A Support or stand is required to elevate the front of the vehicle A stand like this works well 2 0 Secondary pulleys bearings and crush tube T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is A subj
7. ect to the restriction on the cover or title page of this 040 00119 1 document SERVICE MANUAL 2 1 Primary small and Secondary large belts 3 0 Remove the two 5 32 Allen bolts at the axle one on each side Note that some vehicles have mounting points on the bottoms of the fender instead of the sides as shown below 3 1 Remove the two 5 82 Allen bolts at the top rear sides of the fender one on each side If your T3 unit has only these four fasteners remove fender and proceed to step 4 0 If your T3 unit has two more fasteners on the top proceed to step 3 2 3 2 Remove the two 5 82 Allen bolts at the top of the fender and remove the fender 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 00119 1 document SERVICE MANUAL 4 0 Front tire and final drive pulley assembly left hand side 4 1 Check the tension of the belt now so you will know what the proper tension feels like and can check it after you reassemble it _ 5 0 With the screwdriver and the mallet pry down the locking tab on the left side 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 00119 1 document SERVICE MANUAL 5 1 This shows how far to bend the locking tab
8. ision Sheet Use or disclosure of data contained on this sheet is 17 subject to the restriction on the cover or title page of this 040 00119 1 document SERVICE MANUAL 11 6 Rotate the right side adjustment block 180 degrees back to the position it was before disassembly 11 7 Tap the axle back through towards the left side a eS T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 18 subject to the restriction on the cover or title page of this 040 00119 1 document SERVICE MANUAL not over tighten 11 8 Tighten nut on left side Make it firmly snug but do 12 0 Check the tension of the belt 12 1 With the pliers bend the locking tab up against the nut T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 19 subject to the restriction on the cover or title page of this 040 00119 1 document SERVICE MANUAL 13 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 For addition information contact T3 Motion at 714 619 3605 T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 20 subject to the restriction on the cover or title page of this 040 00119
9. ly onto the shoulder bolt that is installed in the side plate with the shims that were removed earlier Place the primary belt on the larger pulley as shown a 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 00119 1 document SERVICE MANUAL 9 1 Place the secondary belt on the smaller pulley and thread the shoulder bolt into the fork Allen wrench socket is shown in shoulder bolt Do Not tighten the shoulder bolt at this time 9 2 Install the three 9 16 bolts that attach the side plate to the fork Fully tighten them at this time 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 00119 1 document SERVICE MANUAL 9 3 Tighten the shoulder bolt using the 1 4 inch Allen wrench Be sure not to pinch any shims between the edge of the shoulder bolt and the fork Torque to 20 it lbs Install the nylock nut onto the shoulder bolt and tighten 10 0 Sometimes the bearings shift inside the hub during transit or being moved without an axle installed They can be realigned easily with the axle just by sliding it in at an angle to catch the bearings See photo in step 10 2 10 1 Note the order of the nut locking tab adjustment block and spacer on the axle i y
Download Pdf Manuals
Related Search