Invacare SX-3P, LX-3, SX-3, MX-4, LX-4 User Manual

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Service Manual

LYNX /PANTHER

SERIES SCOOTERS

LYNX SX-3P

LYNX SX-3 LYNX LX-3

Plus

LYNX LX-3

PANTHER LX-4

PANTHER MX-4

DEALER: KEEP THIS MANUAL. THE PROCEDURES IN THIS MANUAL MUST BE PERFORMED BY AN AUTHORIZED DEALER ONLY.

WARNING/SPECIAL NOTES

WARNING

THE PROCEDURES IN THIS MANUAL SHOULD ONLY BE PERFORMED

A R N

N G

S P E C

A L

N O T E S

BY A QUALIFIED SERVICE TECHNICIAN.

DO NOT SERVICE OR OPERATE THIS EQUIPMENT WITHOUT FIRST

READING AND UNDERSTANDING THIS MANUAL AND THE OWNERS

MANUAL SUPPLIED WITH THE SCOOTERS. IF YOU ARE UNABLE TO

UNDERST AND THE WARNINGS, CAUTIONS, AND INSTRUCTIONS,

CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATTEMPTING

TO SERVICE OR OPERATE THIS EQUIPMENT - OTHERWISE,

INJURY OR DAMAGE MAY RESULT.

SPECIAL NOTES

W ARNING/CAUTION notices as used in this manual apply to hazards or unsafe practices which could result in personal injury or property damage.

NOTICE

THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE.

WARNING

As a manufacturer of powered scooters, Invacare endeavors to supply a wide variety of powered scooters to meet the many needs of the user. However, final selection of the type of powered scooter to be used by an individual rests solely with the user and his/her healthcare professional capable of making such a selection.

TIE-DOWN RESTRAINTS AND SEAT POSITIONING STRAPS Invacare recommends that powered scooter users NOT be transported in vehicles of any kind while in a powered scooter. As of this date, the Department of Transportation has not approved any tie-down systems for transportation of a user while in a powered scooter, in a moving vehicle of any type.

It is the position of Invacare that users of powered scooter should be transferred into appropriate seating in vehicles for transportation and use be made of the restraints made available by the auto industry. Invacare cannot and does not recommend any powered scooter transportation systems.

AS REGARDS RESTRAINTS - SEAT POSITIONING STRAP - IT IS THE OBLIGATION OF THE DME DEALER, THERAPISTS AND OTHER HEALTHCARE PROFESSIONALS TO DETERMINE IF A SEAT POSITIONONG STAP IS REQUIRED TO ENSURE THE SAFE OPERATION OF THIS EQUIPMENT BY THE USER. SERIOUS INJURY CAN OCCUR IN THE EVENT OF A FALL FROM A POWERED SCOOTER.

SAVE THESE INSTRUCTIONS

TABLE OF CONTENTS

NOTE: The procedures in this manual pertain to all five (5) scooter models EXCEPT where specified.

WARNING/SPECIAL NOTES .................. 2

SPECIFICA TIONS................................... 4

PROCEDURE 1 - GENERAL GUIDELINES5

OPERATING INFORMATION ................ 5

WARNING/CAUTION LABEL

LOCATION ....................................... 7

PROCEDURE 2 - SAFETY INSPECTION

MAINTENANCE/TROUBLESHOOTING. 8

SAFETY INSPECTION CHECKLIST ...... 8

MAINTENANCE .................................. 9

LUBRICATION POINTS .....................10

PROCEDURE 3 - SEAT ......................... 11

REPLACING SEAT POST ................... 11

PROCEDURE 4 - TILLER.......................12

REPLACING HAND GRIPS .................12

REPLACING LED CANOPY ................12

REPLACING THROTTLE LEVER ........12

REMOVING/INSTALLING TILLER

ASSEMBLY .....................................13

REMOVING/INSTALLING BOOT ........19

PROCEDURE 5 - SHROUD/FORK/

WHEELS/TIE RODS ............................20

REPLACING TIRE AND TUBE ............. 20

REMOVING/INSTALLING FRONT

SHROUD ASSEMBLY .....................20

REMOVING/INSTALLING FORK

WITH BEARING ASSEMBLY ...........22

REMOVING/INSTALLING FRONT

AXLE ASSEMBLY ...........................23

REPLACING TIE ROD ASSEMBLY ......25

REMOVING/INSTALLING SMALL

TIE RODS .......................................28

REMOVING/INSTALLING LARGE

TIE RODS .......................................30

PROCEDURE 6 - TRANSAXLE/MOTOR/

BRAKE ...............................................32

REMOVING/INSTALLING

TRANSAXLE ASSEMBLY ................32

REPLACING MOTOR/BRAKE

ASSEMBLY .....................................35

REPLACING BRAKE RELEASE

LEVER ASSEMBLY ......................... 36

PROCEDURE 7 - CONTROLLER...........37

REMOVING/INSTALLING

CONTROLLER................................37

REMOVING/INSTALLING

CONTROLLER HARNESSES ..........39

REPLACING CIRCUIT BREAKER ......43

PROCEDURE 8 - REPLACEMENT

P ARTS - LYNX SX - 3P .........................44

REPLACING TILLER CHARGER

PORT COVER ................................44

PROCEDURE 9 - REPLACEMENT

P ARTS - LYNX - LX 3 ...........................45

REMOVING/INSTALLING HEAD

LIGHT ASSEMBLY ..........................45

PROCEDURE 10 - REPLACEMENT

P ARTS - PANTHER LX - 4 ....................46

REMOVING/INSTALLING HEAD

LIGHT ASSEMBLY ............................46

REPLACING TILLER CHARGER PORT

COVER...........................................47

REPLACING CUSHION/FRONT

BUMPER ASSEMBLY ......................47

PROCEDURE 11 - REPLACEMENT

P ARTS - PANTHER MX - 4 ...................48

REMOVING/INSTALLING HEAD

LIGHT ASSEMBLY ............................48

REPLACING TAIL LIGHT ASSEMBLY ....50

REPLACING TAIL LIGHT CABLES .....50

REPLACING DISC BRAKE

ASSEMBLY .....................................51

REPLACING DISC BRAKE SHOES ....51

REPLACING HAND BRAKE

ASSEMBLY .....................................52

REMOVING/INSTALLING FRONT

SHOCK ABSORBERS .....................53

REMOVING/INSTALLING REAR

SHOCK ABSORBERS .....................54

PROCEDURE 12 - OPTIONS .................56

PREPARING THE SCOOTER FOR

LEFT HAND OPERATION ................48

NOTES..................................................58

W ARRANTY ..........................................59

A B L E

O F

C O N

T E N

T S

S P E C

C A

O N S

SPECIFICATIONS

LYNX (3-Wheel Models) P ANTHER (4-Wheel Models)

SX-3P SX-3 LX-3 LX-3

Overall Length: 43.5-inches (104 cm) 43.5-inches (104 cm) 47-inches (119 cm) 47-inches (119 cm) 47.5-inches (125 cm) 54-inches (137 cm) Overall Width: 23-inches (58 cm) 23-inches (58 cm) 25-inches (64 cm) 25-inches (64 cm) 25-inches (64 cm) 26-inches (66 cm)

Ground Clearance: 3.5-inches (8.89 cm)3.5-inches (8.89 cm) 3-inches (7.62 cm) 3-inches (7.62 cm) 3.25-inches (8.26 cm) 6-inches (15.24 cm)

Seat Height From Floor Pan: Contour Seat: 14-1/2-inches (37 cm) 14-1/2-inches (37 cm) 14-1/2-inches (37 cm) 14-1/2-inches (37 cm) N/A N/A

Deluxe Seat: N/A N/A 15-inches (38 cm) 15-inches (38 cm) 16-1/2-inches (42 cm) 17-inches (43 cm)

Armpad to Floor:

Fixed: 21-1/2-inches (55 cm) 21-1/2-inches (55 cm) 21-1/2-inches (55 cm) 21-1/2-inches (55 cm) 23-inches (58 cm) N/A

Adjustable: N/A N/A 21-inches (53 cm) 21-inches (53 cm) 22-1/2-inches (57 cm) 21-inches (53 cm)

Weights: Front Frame

Section: 31-lbs (14 kg) 39 -lbs (17 Kg) 47 -lbs (21 kg) 47 -lbs (21 kg) 48 -lbs (22 kg) 75 -lbs (34 kg)

Rear Frame

Section: 35 -lbs (16 kg) 35 -lbs (16 kg) 38 -lbs (17 kg) 38 -lbs (17 kg) 39 -lbs (18 kg) 58 -lbs (26 kg)

Contour Seat

w/arms 22 -lbs (10 kg) 22 -lbs (10 kg) 22 -lbs (10 kg) 22 -lbs (10 kg) N/A N/A

Deluxe Seat

w/Arms N/A N/A 31-lbs (14 kg) 31-lbs (14 kg) 35 -lbs (16 kg) 43 -lbs (19 kg) Rear Shroud 2-lbs (1 kg) 2-lbs (1 kg) 3 -lbs ( 1 kg) 3 -lbs ( 1 kg) 2 -lbs (1 kg) 4 -lbs (2 kg) Batteries:(each) 14 -lbs (6 kg) 14 -lbs (6 kg) 23 -lbs (10 kg) 23 -lbs (10 kg) 23-lbs (10 kg) 31-lbs (14 kg)

Total Weight of Scooter

w/o Batteries: 90-lbs (41 kg) 98-lbs (44 kg) *110-lbs (50 kg) *110-lbs (50 kg) 124-lbs (56 kg) 180-lbs (82 kg) w/ Batteries: 118-lbs (53 kg) 126-lbs (57 kg) *156-lbs (70 kg) *156-lbs (70 kg) 170-lbs (77 kg) 242-lbs (110 kg)

LWheel Size

Front: 2 x 8-inches 2 x 8-inches 2-1/2 x 9-inches 2-1/2 x 9-inches 3 x 10-inches 4 x 13-inches

(5.08 x 20.32 cm) (5.08 x 20.32) cm (6.35 x 22.86 cm) (6.35 x 22.86 cm) (7.62 x 25.40 cm) (10.16 x 33.02 cm)

Rear: 2-1/2 x 9-inches 2-1/2 x 9-inches 3 x 10-inches 3 x 10-inches 3 x 10-inches 4 x 13-inches

(6.35x22.86 cm) (6.35x22.86 cm) (7.62 x 25.40 cm) (7.62 x 25.40 cm) (7.62 x 25.40 cm) (10.16 x 33.02 cm)

Max. Weight

Limitation: 250 lbs (114 kg ) 250lbs (114 kg ) 300lbs (136 kg ) 300lbs (136 kg ) 300 lbs (136 kg ) 400 lbs (181 kg)

Maximum Speed: 4-1/2 M.P.H. 4-1/2 M.P.H. 5 M.P.H. 5 M.P .H. 5-1/2 M.P.H. 5¼ M.P.H. 7¼ M.P.H.

7-1/4 K.P.H. 7-1/4 K.P.H 8 K.P .H 8 K.P .H 9 K.P .H 8½ K.P.H 11¾ K.P.H

Max. Incline and Stability: 8o incline 8o incline 8o incline 8o incline 8o incline 8o incline

15-1/2-inches (39 cm) 15-1/2-inches (39 cm) 15-1/2-inches (39 cm) 15-1/2-inches (39 cm) 16-1/2-inches (42 cm) 16-1/2-inches (42 cm) 16-1/2-inches (42 cm) 16-1/2-inches (42 cm)

17-1/2-inches (44 cm) 17-1/2-inches (44 cm)

16-inches (41 cm) 16-inches (41 cm) 17-1/2-inches ( 44 cm) 18-inches (46 cm) 17-inches (43 cm) 17-inches (43 cm) 18-1/2-inches (47 cm) 19-inches (48 cm) 18-inches (46 cm) 18-inches (46 cm) 19-1/2-inches (49 cm)

K22-1/2-inches (57 cm) K22-1/2-inches (57 cm)

22-inches (56 cm) 22-inches (56 cm) 23-1/2-inches (60 cm) 22-inches (56 cm) 23-inches (58 cm) 23-inches (58 cm) 24-1/2-inches (62 cm) 23-inches (58 cm) 24-inches (61 cm) 24-inches (61 cm) 25-1/2-inches (65 cm) 24-inches (61 cm)

Plus

LX-4 MX- 4

LOW HIGH

NOTE: with Optional Deluxe Seat.

NOTE: Flat free inserts are standard on all wheels.

*NOTE: Total weight of scooter includes Contour Seat Only. Add an additional 9-lbs for Deluxe Seat.

GENERAL GUIDELINES

PROCEDURE 1

This Procedure Includes the Following: Operating Information Warning/Caution Label Location

OPERATING INFORMATION

GENERAL WARNINGS

Performance adjustments should ONLY be made by professionals of the healthcare field or persons fully conversant with this process and the driver's capabilities. Incorrect settings could cause injury to the driver, bystanders, damage to the powered scooter and surrounding property.

DO NOT use parts, accessories, or adapters other than those authorized by Invacare. ELECTRICAL

Check to ensure that all electrical connections are secure at all times. Grounding Instructions:

DO NOT, under any circumstances, cut or remove the round grounding prong from any plug. Some devices are equipped with three-prong (grounding) plugs for protection against possible shock hazards. Where a two-prong wall receptacle is encountered, it is the personal responsibility and obligation of the customer to contact a qualified electrician and have the two-prong receptacle replaced with a properly grounded three-prong wall receptacle in accordance with the National Electrical Code. If you must use an extension cord, use ONLY a three-wire extension cord having the same or higher electrical rating as the device being connected.

G E N E R A L

G U

I D E L

I N E S

BATTERIES Only deep cycle, sealed case construction batteries should be used in this device. Carefully read battery/battery charger information prior to installing, servicing or op-

erating your powered scooter. In addition, Invacare has placed WARNING TAGS on batteries and IDENTIFICATIONS TAGS on battery cables. DO NOT remove these tags.

EMI WARNINGS

CAUTION: IT IS VERY IMPORTANT THAT YOU READ THIS INFORMATION REGARDING THE POSSIBLE EFFECTS OF ELECTROMAGNETIC INTERFERENCE ON YOUR POWERED SCOOTER.

Electromagnetic Interference EMI From Radio Wave sources. Powered scooters may be susceptible to electromagnetic interference (EMI), which

is interfering electromagnetic energy (EM) emitted from sources such as radio stations, TV stations, amateur radio (HAM) transmitters, two way radios, and cellular phones. The interference (from radio wave sources) can cause the powered scooter to release its brakes, move by itself, or move in unintended directions. It can also permanently damage the powered scooter's control system. The intensity of the interfering EM energy can be measured in volts per meter (V/m). Each powered scooter can resist EMI up to a certain intensity. This is called its "immunity level." The higher the immunity level, the greater the protection. At this time, current technology is capable of achieving at least a 20 V/m immunity level, which would provide useful protection from the more common sources of radiated EMI.

There are a number of sources of relatively intense electromagnetic fields in the everyday environment. Some of these sources are obvious and easy to avoid. Others are not apparent and exposure is unavoidable. However, we believe that by following the warnings listed, your risk to EMI will be minimized.

GENERAL GUIDELINESPROCEDURE 1

A L

G U

E L

E S

The sources of radiated EMI can be broadly classified into three types:

1) Hand-held Portable transceivers (transmitters-receivers with the antenna mounted directly on the transmitting unit. Examples include: citizens band (CB) radios, "walkie talkie," security, fire, and police transceivers, cellular telephones, and other personal communication devices. **NOTE: Some cellular telephones and similar devices transmit signals while they are ON, even when not being used;

2) Medium-range mobile transceivers, such as those used in police cars, fire trucks, ambulances, and taxis. These usually have the antenna mounted on the outside of the vehicle; and

3) Long-range transmitters and transceivers, such as commercial broadcast transmitters (radio and TV broadcast antenna towers) and amateur (HAM) radios.

NOTE: Other types of hand-held devices, such as cordless phones, laptop computers, AM/FM radios, TV sets, CD players, cassette players, and small appliances, such as

EMI WARNINGS (CONTINUED)

electric shavers and hair dryers, so far as we know, are not likely to cause EMI problems to your powered scooter.

Powered Scooter Electromagnetic Interference (EMI) Because EM energy rapidly becomes more intense as one moves closer to the

transmitting antenna (source), the EM fields from hand-held radio wave sources (transceivers) are of special concern. It is possible to unintentionally bring high levels of EM energy very close to the powered scooter's control system while using these devices. This can affect powered scooter movement and braking. Therefore, the warnings listed are recommended to prevent possible interference with the control system of the powered scooter.

Electromagnetic interference (EMI) from sources such as radio and TV stations, amateur radio (HAM) transmitters, two-way radios, and cellular phones can affect powered scooters. Following the warnings listed should reduce the chance of unintended brake release or powered scooter movement which could result in serious injury.

1) Do not operate hand-held transceivers (transmitters receivers), such as citizens band (CB radios, or turn ON personal communication devices, such as cellular phones, while the powered scooter is turned ON;

2) Be aware of nearby transmitters, such as radio or TV stations, and try to avoid coming close to them;

3) If unintended movement or brake release occurs, turn the powered scooter OFF as soon as it is safe;

4) Be aware that adding accessories or components, or modifying the powered scooter, may make it more susceptible to EMI (Note: There is no easy way to evaluate their effect on the overall immunity of the powered scooter); and

5) Report all incidents of unintended movement or brake release to the powered scooter manufacturer, and note whether there is a source of EMI nearby.

Important Information

1) 20 volts per meter (V/m) is a generally achievable and useful immunity level against EMI (as of May 1994) (the higher the level, the greater the protection);

2) The immunity level of this product is unknown.

PROCEDURE 1GENERAL GUIDELINES

WARNING/CAUTION LABEL LOCATION

DELTA TILLER

! W ARNING

Remove key from the ignition while scooter is not in use. Otherwise, injury and/or damage to the scooter or surrounding property may occur.

1090105

! WARNING

DO NOT operate without the antitip tubes installed.

60106X144

G E N E R A

G U

I D E

I N E S

! CAUTION

DO NOT lift scooter up by the front or rear shroud. Otherwise, damage to the scooter may occur.

1089265

! WARNING

DO NOT operate the scooter unless the tiller is in the locked position.

DO NOT lean against or pull forward on the tiller while mounting or dismounting the scooter. Otherwise, injury may occur.

The manufacturer disclaims all responsibility for any personal injury or property damage which may occur as a result of improper or unsafe use of its products.

1090104

PROCEDURE 2 SAFETY INSPECTION/MAINTENANCE/TROUBLESHOOTING

S A F E T Y

S P E

O N

A N C

This Procedure Includes the Following:

Safety Inspection Checklist Maintenance

NOTE: Every six (6) months take the scooter to a qualified dealer for a thorough inspection and servicing. Regular cleaning will reveal loose or worn parts and enhance the smooth operation of the scooter. To operate

properly and safely, the scooter must be cared for just like any other vehicle. Routine maintenance will extend the life and efficiency of the scooter.

Initial adjustments should be made to suit your personal body structure and preference. Thereafter follow these maintenance procedures:

ITEM INITIALL Y INSPECT/ADJUST

WEEKL Y MONTHL Y PERIODICALLY

GENERAL Scooter drives straight (no excessive drag/pull to one side). X X

BRAKE*

Does not bind or interfere with travel. XX Brake easy to disengage/engage. XX

UPHOLSTERY (PROCEDURES 5 AND 6 OF THE OWNER’S MANUAL**) Inspect for rips, tears. XX

REAR WHEELS (PROCEDURE 9 OF THE OWNER’S MANUAL**) No excessive side movement or binding when raised and turned. XX

FRONT WHEELS (PROCEDURE 9 OF THE OWNER’S MANUAL**)

Inspect wheel/fork assembly for proper tension by spinning wheel, wheel should come to a gradual stop. XX Loosen/tighten locknut if wheel wobbles noticeably or binds to a stop. XX Wheel bearings are clean and free of moisture. XX

CAUTION: As with any vehicle, the wheels and tires should be checked periodically for cracks and wear and should be replaced.

TILLER (PROCEDURE 8 OF THE OWNER’S MANUAL**)

Ensure that tiller adjustment handle engages and disengages properly and securely (PROCEDURE 3 OF THE OWNER’S MANUAL**). XX Scooter stops completely when throttle is released

(Does not continue to roll as if throttle is activated). X X SEAT (PROCEDURE 5 OF THE OWNER’S MANUAL**)

Inspect seat swivel for release and engagement. XX Seat locks into the determined swivel positions. XX

TIRES (PROCEDURE 9 OF THE OWNER’S MANUAL**) Inspect for flat spots and wear. XX CAUTION: As with any vehicle, the wheels and tires should be checked periodically for cracks and wear and should be replaced.

CLEANING

Clean upholstery and armrests. X Clean molded frame. X

FRONT AND REAR SHOCKS - P ANTHER MX-4 ONL Y Bolts are tight. XX

HEADLIGHTS (where applicable)

Inspect headlight bulbs for proper operation.

*NOTE: This includes the manually engaged brake on ALL scooters AND the hand brake on the PANTHER MX-4 (Before 10/00)ONLY.

**NOTE: Refer to the Owner’s Manual, part number 1090132.

SAFETY INSPECTION/MAINTENANCE/TROUBLESHOOTING

PROCEDURE 2

MAINTENANCE

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely

- otherwise, injury or damage may occur.

CAUTION

DO NOT over-tighten hardware attaching to the frame. This could cause damage to the frame.

Initial Maintenance Procedures (FIGURE 1)

1. Before using the powered scooter, make sure all nuts and bolts are tight. Check any parts for damage or wear and replace. Check all parts for proper adjustment.

2. Ensure that batteries are properly maintained and charged as required (PROCEDURE 4 of Owner’s Manual, part number 1090132).

3. Inspect brake for proper operation (PROCEDURE 3 of Owner’s Manual, part number 1090132).

Transaxle Assembly

CAUTION

Ensure that the cover is removed from the grease nipple BEFORE operation of the PANTHER MX-4 scooter. Otherwise, damage to the scooter may occur.

4. For the PANTHER MX-4 ONLY, remove the

cover from the grease nipple located on TOP of the transaxle assembly (FIGURE 1).

Periodic Maintenance Procedures

1. The wheels and tires should be checked periodically for cracks and wear, and should be replaced by a qualified technician.

2. Regularly check for loose nuts and/or bolts in the front and rear wheels. If loose, have them adjusted by a qualified technician (PROCEDURE 9 of Owner’s Manual, part number 1090132).

3. Clean dirt, dust and grease from exposed components.

Cover

Grease

Nipple

S A F E T Y

S P E

I O N

I N

T E

A N C

FIGURE 1 - INITIAL MAINTENANCE PROCEDURES

PROCEDURE 2 SAFETY INSPECTION/MAINTENANCE/TROUBLESHOOTING

S A F E T Y

S P E

O N

A N C

Lubrication Points (FIGURE 2)

1. Every six (6) months the following components should be lubricated. Use a Teflon® lubricant. (FIGURE 2).

A. Seat Lever, Connecting Pin, and Release Pin. B. Axle of Scooter.

C. Top of Seat Adaptor.

STEPS 1A AND 1C

Seat

Plate

See

DETAIL

"A"

Top

Seat

Adaptor

DET AIL "A"

Connecting

D. For Models LYNX SX-3P, LYNX SX-3,

L YNX LX-3, and L YNX LX-3 wheel Bearings of Front Wheel.

2. For all Models EXCEPT the P ANTHER MX - 4:

A. Remove the four (4) bolts securing the

gearbox cover to the transaxle and remove the gearbox cover.

B. Lubricate the gears inside the transaxle with

Black Pearl Grease

STEP 1D

OR equivalent.

STEP 1B

Axle of

Scooter

Wheel

Bearings

STEP 2

Transaxle

Release

Seat Lever

FIGURE 2 - LUBRICA TION POINTS

Teflon - Registered trademark of E.I. Du Pont Nemours and Company .

Bolts

(Only Two

(2) Shown)

Gearbox Cover

Black Pearl Grease - Registered trademark of Chevron Corporation.

1010

SEAT PROCEDURE 3

This Procedure Includes the Following:

Replacing Seat Post

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely

- otherwise injury or damage may occur.

REPLACING SEAT POST (FIGURE 1)

WARNING

Ensure that seat is locked into the forward position BEFORE and DURING operation of the scooter. Otherwise, injury to the user and/or damage to the scooter may result.

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

NOTE: The swivel release lever is located just beneath the seat on the right side.

2. Pull the swivel release lever up.

4. While holding the swivel release lever in the upward position, insert the NEW seat post into the seat frame.

NOTE: The seat post locks at 90° intervals. In order to ensure that the NEW seat post is locked into position, it may be necessary to rotate the seat post until an audible “click” is heard.

5. Release the swivel release lever, allowing the NEW seat post to lock into place.

6. Reinstall the seat. Refer to THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

REMOVING/INSTALLING

Seat Frame

Swivel

Release

Lever

Seat Post

S E

3. While holding the swivel release lever in the upward position, pull the seat post out of the seat frame.

FIGURE 1 - REPLACING SEAT POST

1111

PROCEDURE 4 TILLER

This Procedure Includes the Following:

Replacing Hand Grips Replacing LED Canopy Replacing Throttle Lever

I L L E

Removing/Installing Tiller Assembly Removing/Installing Boot

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that ALL attaching hardware is tightened securely

- otherwise, injury or damage may occur. Turn Power OFF and remove key from

ignition. Disconnect battery harness from motor lead.

REPLACING HAND GRIPS (FIGURE 1)

1. Grasp the hand grip and twist it off of the handle bar.

2. Slide the NEW hand grip over the handle bar.

3. If necessary, repeat STEPS 1-2 for the other hand grip.

Hand Grip

Handle Bar

3. Repeat this procedure for the other pointed locking tab of the LED canopy.

4. Remove the EXISTING LED canopy and the EXISTING rubber gasket.

5. Discard the EXISTING LED canopy and the EXISTING rubber gasket.

NOTE: Before installing the NEW LED canopy, be sure the NEW rubber gasket is between the NEW LED canopy and the front cover.

6. Align the NEW LED canopy with the mounting holes in the front cover and snap it into place.

7. Align the pointed locking tabs of the NEW LED canopy with the mounting holes in the electronics board, and snap the electronics board into place.

LED Canopy

Pointed Locking

Tab

Rubber

Gasket

Electronics

Front

Cover

Pointed Locking

Tab

Board

Hand Grip

FIGURE 1 - REPLACING HAND GRIPS

REPLACING LED CANOPY (FIGURE 2)

NOTE: This procedure applies to all models EXCEPT the Panther MX - 4.

1. Grasp one (1) of the pointed locking tabs of the LED canopy under the front cover and squeeze the ends of it together.

2. While squeezing the ends, slowly pull the pointed locking tab through the front cover and through the electronics board.

FIGURE 2 - REPLACING LED CANOPY

REPLACING THROTTLE LEVER (FIGURE 3)

1. Remove the four (4) self-tapping screws and housings securing the cable cover to the tiller assembly.

NOTE: Save the four (4) self tapping screws and housings for reuse when installing the NEW throttle lever.

2. Slowly remove the cable cover from the tiller assembly and allow it to hang by the connecting wires.

3. Remove the two (2) socket screws securing the throttle lever to the potentiometer assembly.

4. Remove the throttle lever from the potentiometer assembly.

1212

TILLER PROCEDURE 4

NOTE: To ensure the NEW throttle lever performs correctly, make certain the tab on the back of the NEW throttle lever is positioned between the two (2) ends of the spring on the potentiometer assembly.

5. Position the NEW throttle lever on the potentiometer assembly.

6. Secure the NEW throttle lever to the potentiometer assembly using the two (2) NEW socket screws. Securely tighten.

7. Align the four (4) mounting holes in the cable cover with the four (4) mounting holes in the tiller assembly.

8. Secure the cable cover to the tiller assembly using the four (4) EXISTING self-tapping screws and housings. Securely tighten.

(DETAIL “A”)

Front Cover

Housings

See

DETAIL "A"

Self

Tapping

Screws

Spring

Handle Bar

Potentiometer

Assembly

Cable

Self

Tapping

Screws

Cover

Socket

Screw

Housings

REMOVING/INSTALLING TILLER ASSEMBLY

WARNING

Ensure that tiller is properly adjusted before driving the scooter. Refer to TILLER ADJUSTMENT in PROCEDURE 8 of the Owner’s Manual, part number 1090132.

After making ANY tiller angle adjustments and BEFORE use, the tiller MUST be securely locked into position with adjustment pin protruding through the adjustment plate.

Tiller

Adjustment

A fall from the scooter could occur causing bodily injury and/or damage to the scooter. Gently, push/pull against tiller to ensure that the tiller is securely engaged into the adjustment plate.

NOTE: When removing the tiller assembly, perform the following steps:

STEP 1: Determine the scooter model to be serviced.

Tiller

Adjustment

Plate

I L L E R

Tab

Socket Screw

Throttle

Lever

DET AIL "A"

Spring

Ends

Tab

Spring

Throttle

Potentiometer

Lever

Assembly

FIGURE 3 - REPLACING THROTTLE LEVER

STEP 2: Carefully review the following chart to determine the necessary sections and the specific order in which these sections need to be performed.

NOTE: The sections outlined below are to remove the tiller assembly. To install the tiller assembly, reverse the order of the outlined sections.

SECTIONS TO BE

PERFORMED AND THE

PROPER ORDER

LYNX SX - 3 A D E F LYNX SX - 3P A D E F LYNX LX - 3 A D C E F

MODEL

P ANTHER LX - 4 A C D E F P ANTHER MX - 4 A B C D E F

STEP 3: Perform the appropriate steps as specified for the model.

1313

PROCEDURE 4 TILLER

Section A - Disassembling/Assembling Scooter (FIGURE 4)

DISASSEMBLING.

1. If necessary, remove the floor basket. Refer to REMOVING/INSTALLING THE FLOOR BAS-

I L L

E R

KET in PROCEDURE 11 of the Owner’s Manual, part number 1090132.

2. Remove the batteries. Refer to STALLING THE BATTERIES WITH CABLES in PROCEDURE 4 of the Owners Manual, part number 1090132.

3. If necessary, remove the on - board battery charger. Refer to BATTERY CHARGER in PROCEDURE 11 of the Owner’s Manual, part number 1090132.

REPLACING ON - BOARD

REMOVING/IN-

(LYNX SX - 3 AND LYNX SX - 3P)

Tiller

4. Separate the front frame assembly from the rear frame assembly. Refer to TRANSPORTING THE SCOOTER in PROCEDURE 10 of the Owner’s Manual, part number 1090132.

5. Position the front frame assembly on its side.

NOTE: Note the position of the tie wraps before removing.

6. Cut the cable ties securing the tiller wiring harness to the underside of the front frame assembly.

7. For PANTHER MX - 4 - cut the cable ties securing the brake cable to the underside of the front frame assembly.

8. Remove the tiller wiring harness from the retaining tabs on the underside of the front frame assembly.

(LYNX LX - 3)

Retaining Tab

Wiring

Harness

Cable Tie

Retaining Tab

Cable Ties

Retaining

Tabs

(P ANTHER LX - 4)

Tiller

Wiring

Harness

Cable Ties

Retaining

Tab

Cable Tie

Retaining Tabs

Retaining

Tabs

Cable

Ties

Tiller

Wiring

Harness

(P ANTHER MX - 4)

Tiller Wiring Harness

Brake Cable

Retaining Tabs

Cable

Tie

Retaining

Tabs

Retaining

Tabs

Cable

Ties

FIGURE 4 - DISASSEMBLING/ASSEMBLING SCOOTER

1414

Retaining Tabs

TILLER PROCEDURE 4

9. For PANTHER MX - 4, remove the brake cable from the retaining tabs on the underside of the front frame assembly.

10. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

ASSEMBLING.

1. Secure the tiller wiring harness in the retaining tabs on the underside of the front frame assembly.

2. For PANTHER MX - 4, secure the brake cable in the retaining tabs on the underside of the front frame assembly.

NOTE: Before installing the cable ties, be sure they are in the proper positions.

3. Secure the tiller wiring harness to the underside of the front frame assembly using NEW cable ties.

4. For PANTHER MX - 4, secure the brake cable to the underside of the front frame assembly using NEW cable ties.

5. Return the front frame assembly to the upright position.

6. Reassemble the front frame assembly and the rear frame assembly. Refer to ING THE SCOOTER in PROCEDURE 10 of the Owner’s Manual, part number 1090132.

7. If necessary, reinstall the on - board battery charger. Refer to CHARGER in PROCEDURE 11 of the Owner’s Manual, part number 1090132.

REPLACING ON - BOARD BATTERY

TRANSPORT-

1. Remove the adjusting nut from the hand brake cable assembly.

2. Slide the hand brake cable assembly out of the brake arm joint, the spring and the tab on the rear frame assembly.

3. Remove the spring.

4. Remove the brake arm joint from the disc brake assembly.

NOTE: Save the hand brake cable assembly and all components for reassembly.

5. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

CONNECTING.

1. Position the brake arm joint in the mounting hole in the disc brake assembly.

2. Position the spring between the tab on the rear frame and the brake arm joint.

3. Slide the hand brake cable assembly through the tab on the rear frame, the spring and the brake arm joint.

4. Thread the adjusting nut onto the hand brake cable assembly until there is approximately 1/2 inch of thread showing.

5. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

I L L

E R

8. Reinstall the batteries. Refer to STALLING THE BATTERIES WITH CABLES in PROCEDURE 4 of the Owners Manual, part number 1090132.

9. Reinstall the floor basket. Refer to INSTALLING THE FLOOR BASKET in PROCEDURE 11 of the Owner’s Manual, part number 1090132.

REMOVING/IN-

REMOVING/

Section B - Disconnecting/Connecting Hand Brake Cable Assembly (FIGURE 5)

NOTE: This procedure applies to the PANTHER MX

- 4 ONLY.

DISCONNECTING.

NOTE: Note the distance that the adjusting nut is threaded on the hand brake cable assembly before removing for proper reinstallation.

Hand

Brake

Rear Frame

Assembly

Cable

Assembly

Spring

Tab On

Mounting Hole

Rear Frame

Brake Arm Joint

FIGURE 5 - DISCONNECTING/

CONNECTING HAND BRAKE ASSEMBLY

1515

Disc Brake

Assembly

Adjusting

Nut

PROCEDURE 4 TILLER

Section C - Disconnecting/Connecting Head light Assembly (FIGURE 6)

DISCONNECTING.

1. For LYNX LX - 3 ONLY - slowly pull the head light assembly away from the base handle bar joint.

L E R

2. Pull back the plastic guards on the RED and

BLACK cables connecting the tiller wiring har-

ness to the head light assembly.

(LYNX SX - 3P)

3. Disconnect the RED and BLACK cable metal

connectors of the head light assembly from the RED and BLACK cable metal connectors of the tiller wiring harness.

4. Separate the head light assembly from the tiller wiring harness.

5. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

(P ANTHER LX - 4)

Tiller

Wiring

Harness

Head

light

Assembly

Red/

Black

Cables

Head light

Assembly

Plastic

Guards

Metal

Connectors

Red/Black

Cables

(P ANTHER MX - 4)

Metal

Connectors

Red/Black

Cables

To Head

Light

Assembly

Red/Black

Cables

Metal

Connectors

Plastic

Guards

To Tiller

Wiring

Harness

Plastic

Guards

Tiller

Wiring

Harness

Red/Black

Cables

FIGURE 6 - DISCONNECTING/CONNECTING HEAD LIGHT ASSEMBLY

1616

PROCEDURE 4TILLER

CONNECTING (FIGURE 6).

1. Connect the RED cable metal connector of the head light assembly to the RED cable metal connector of the tiller wiring harness.

2. Connect the BLACK cable metal connector of the head light assembly to the BLACK cable metal connector of the tiller wiring harness.

3. Reposition the plastic guards on the RED and BLACK cables connecting the tiller wiring harness to the head light assembly.

4. For LYNX LX - 3 ONLY, slowly thread the wires of the head light assembly through the hole in the shroud, until most of the wires of the head light assembly are on the underside of the front frame assembly.

Section D - Disconnecting/Connecting Tiller Assembly And Handle Bar Joint (FIGURE 7)

DISCONNECTING.

1. Return the front frame assembly to the upright position.

2. Remove the bolt, small washer, two (2) large washers and self-locking nut securing the base handle bar joint to the tiller assembly.

3. Slowly pull the tiller assembly away from the front frame assembly until there is no slack left in the tiller wiring harness (DETAIL “A”).

4. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

3. Push any remaining slack in the tiller wiring harness through the hole in the shroud, until the wiring harness is on the underside of the front frame assembly (DETAIL “A”).

4. Flip the front frame assembly onto its side.

5. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

DET AIL “A”

Hole In Shroud

Tiller Wiring

Harness

Front Frame

Assembly

Large

Washers

Tiller Assembly

Base Handle

Bar Joint

Self-

locking

nut

Small

Bolt

Washer

Tiller Wiring

Harness

Boot

I L L E R

CONNECTING.

NOTE: To simplify this procedure, lay the tiller assembly on the shroud and then align the necessary components.

1. Align the mounting hole in the tiller assembly with the holes in the two (2) large washers and with the mounting holes in the base handle bar joint.

CAUTION

DO NOT overtighten the bolt securing tiller assembly to the base handle bar joint. The tiller will bind and not work properly.

2. Secure the tiller assembly to the base handle bar joint using the provided bolt, small washer, and self-locking nut, making sure the bolt passes through the two (2) large washers. Torque the locking nut between 3 - 6 in./lbs.

FIGURE 7 - DISCONNECTING/CONNECTING

TILLER ASSEMBLY AND HANDLE BAR JOINT

1717

PROCEDURE 4 TILLER

Section E - Disconnecting/Connecting Base Handle Bar Joint From/To Front Frame Assembly (FIGURE 7)

DISCONNECTING.

L L E

1. Remove the two (2) bolts and self-locking nuts

securing the base handle bar joint (and for the LYNX LX - 3 ONLY, the head light assembly) to the front frame assembly.

2. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

CONNECTING.

1. Align the two (2) mounting holes in the base handle bar joint with the two (2) mounting holes in the front frame assembly.

2. For the LYNX LX - 3, align the two (2) mounting holes in the head light assembly with the two (2) mounting holes in the front frame assembly and the two (2) mounting holes in the base handle bar joint.

3. Secure the base handle bar joint (and for the LYNX LX - 3, the head light assembly) to the front frame assembly using the two (2) bolts and self-locking nuts. Securely tighten.

4. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

Tiller Assembly

Section F - Removing/Installing Tiller From/To Front Frame Assembly (FIGURE 8)

REMOVING.

1. Slowly pull the tiller wiring harness through the hole in the shroud assembly, until the tiller assembly is free from the front frame assembly (DETAIL “A”).

2. Pull the base handle bar joint from the front frame assembly (DETAIL “B”).

3. Remove the boot. Refer to ING BOOT in this procedure of this manual.

4. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

INSTALLING.

1. Reinstall the boot. Refer to ING BOOT in this procedure of this manual.

2. Position the base handle bar joint in the front frame assembly, making sure the mounting holes in the base handle bar joint line up with the mounting holes in the front frame assembly (DETAIL “A”).

3. Slowly thread the tiller wiring harness through the hole in the shroud, until most of the tiller wiring harness is on the underside of the front frame assembly.

4. Refer to the chart on page 11 of this manual to determine which section(s) need to be performed next to successfully complete the removal/installation of the tiller assembly.

REMOVING/INSTALL-

Base Handle

Bar Joint

locking

Front

Frame

Assembly

Head

Light

Assembly

(LYNX LX - 3

Bolts

Boot

ONLY)

FIGURE 7 - DISCONNECTING/

CONNECTING BASE HANDLE BAR JOINT

FROM/TO FRONT FRAME ASSEMBLY

Self-

nuts

1818

PROCEDURE 4TILLER

Boot

Hole

DET AIL “A”

DET AIL “B”

Tiller Wiring

Harness

Shroud

Assembly

Base Handle

Bar Joint

Front Frame

Assembly

REMOVING/INSTALLING BOOT (FIGURE 9)

Removing

1. Remove the tiller assembly. Refer to REMOVING/INSTALLING TILLER ASSEMBLY in this procedure of this manual.

2. Remove the EXISTING boot by sliding it over the front fork with bearing assembly.

Installing

1. Install the NEW boot by sliding it over the front fork with bearing assembly.

2. Install the tiller assembly. Refer to INSTALLING TILLER ASSEMBLY in this procedure of this manual.

Boot

Fork With Bearing

REMOVING/

Assembly

I L L E

FIGURE 8 - REMOVING/INST ALLING TILLER

FROM/TO FRONT FRAME ASSEMBLY

FIGURE 9 - REMOVING/INST ALLING BOOT

1919

PROCEDURE 5 SHROUD/FORK/WHEELS/TIE RODS

S H R O U D

/ F O R K

D S

H E E L S

This Procedure Includes the Following:

Replacing Tire And Tube Removing/Installing Front Shroud Assembly

Removing/Installing Fork With Bearing

Assembly

Removing/Installing Front Axle Assembly Replacing Tie Rod Assembly

Removing/Installing Small Tie Rods Removing/Installing Large Tie Rods

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may occur.

T urn Power OFF and remove key from ignition. Disconnect battery harness from motor lead.

B. PANTHER LX - 4:

1. Remove the front head light assembly. Refer to

REMOVING/INSTALLING FRONT HEAD LIGHT ASSEMBLY in PROCEDURE 10 of this manual.

C. PANTHER MX - 4:

1. Remove the front head light assembly. Refer to

REMOVING/INSTALLING FRONT HEAD LIGHT ASSEMBLY in PROCEDURE 11 of this manual.

6. Remove the front shroud assembly from the front frame assembly.

7. Note the position of the U-type plate nuts before removing for proper reinstallation.

8. Remove the U-type plate nuts from the front frame assembly.

NOTE: The LYNX SX - 3, LYNX SX - 3P and LYNX LX - 3 have four (4) U-type plate nuts, the PANTHER LX - 4 and PANTHER MX - 4 have two (2) U-type

REPLACING TIRE AND TUBE

plate nuts.

WARNING

This procedure MUST be performed by an authorized Invacare dealer or qualified technician.

REMOVING/INSTALLING FRONT SHROUD ASSEMBLY (FIGURE 1)

Removing

1. Pull up on the rug to remove it from the front shroud assembly.

2. Remove the tiller assembly. Refer to ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

3. Remove the boot. Refer to

REMOVING/INSTALL-

ING BOOT in PROCEDURE 4 of this manual.

4. Remove the two (2) mounting screws, spring washers and flat washers securing the front shroud assembly to the front frame assembly.

NOTE: Four (4) mounting screws, spring washers and flat washers are required on the PANTHER LX - 4.

5. Perform one (1) of the following: A. LYNX SX - 3, LYNX SX - 3P and LYNX LX - 3:

1. Proceed to STEP 6.

REMOV-

Installing

1. Place U-type plate nuts in position noted from STEP 7 of REMOVING.

2. Perform one (1) of the following: A. LYNX SX - 3, LYNX SX - 3P and LYNX LX - 3 :

1. Position the four (4) U-type plate nuts on the front frame, making certain the mounting holes in the U-type plate nuts align with the mounting holes in the front frame assembly.

B. PANTHER MX - 4 and PANTHER LX - 4:

1. Position the two (2) U-type plate nuts on the front frame, making certain the mounting holes in the U-type plate nuts align with the mounting holes in the front frame assembly.

3. Place the front shroud assembly over the front frame, making certain the mounting holes in the front shroud assembly align with the mounting holes in the U-type plate nuts and/or the mounting holes in the front frame assembly.

4. Secure the front shroud assembly to the front frame using the two (2) mounting screws, spring washers and flat washers. Securely Tighten.

NOTE: Four (4) mounting screws, spring washers and flat washers are required on the PANTHER LX - 4.

2020

SHROUD/FORK/WHEELS/TIE RODS PROCEDURE 5

5. Perform one (1) of the following:

A. LYNX SX - 3, LYNX SX - 3P, LYNX LX - 3

and PANTHER LX - 4 :

1. Proceed to STEP 5.

C. PANTHER MX - 4:

1. Reinstall the front head light assembly. Refer to

REMOVING/INSTALLING THE FRONT HEAD LIGHT ASSEMBLY in PROCEDURE 11 of this manual.

B. PANTHER LX - 4:

1. Reinstall the front head light assembly. Refer to

REMOVING/INSTALLING THE FRONT HEAD LIGHT ASSEMBLY in PROCEDURE 10 of this manual.

6. Reinstall the boot. Refer to ING BOOT in PROCEDURE 4 of this manual.

7. Reinstall the tiller assembly. Refer to ING/INSTALLING TILLER ASSEMBLY in PRO-

REMOVING/INSTALL-

REMOV-

CEDURE 4 of this manual.

8. Position the rug on the shroud assembly.

L YNX SX - 3/LYNX SX - 3P

NOTE: Only the LYNX SX - 3/LYNX SX - 3P is shown for clarity. The front shroud for the LYNX LX - 3 removes/installs in the same manner.

Mounting Screw

Front

Spring Washer

Flat Washer

Shroud

Assembly

S H R O U

O R

D S

H E E L S

U Type Plate

Nut

Type

Plate

Nut

P ANTHER LX - 4

NOTE: Only the PANTHER LX - 4 is shown for clarity. The front shroud for the PANTHER MX - 4 removes/ installs in the same manner.

Mounting Screw

(Required for

PANTHER LX - 4 AND

PANTHER MX - 4)

Spring Washer

Flat Washer

(Required for PANTHER

LX - 4 ONLY)

Spring Washer

Washer

Front Shroud Assembly

Type

Plate

Nut

FIGURE 1 - REMOVING/INST ALLING FRONT SHROUD ASSEMBLY

2121

PROCEDURE 5 SHROUD/FORK/WHEELS/TIE RODS

S H R O U D

F O R K

W H

REMOVING/INSTALLING FORK WITH BEARING ASSEMBLY

4. Secure the TOP bearing bushing by threading it into the TOP bearing housing. Torque the TOP bearing bushing between 26 - 39 in./lbs.

(FIGURE 2)

NOTE: This procedure applies to the LYNX SX - 3,

LYNX SX - 3P and the LYNX LX - 3 ONLY.

Removing

1. Remove the tiller assembly. Refer to REMOV-

R O

D S

ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

2. Remove the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

3. Remove the front wheel. Refer to

REMOVING/ INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

4. Remove the bearing gap nut from the front fork.

5. Remove the TOP bearing bushing from the TOP

bearing housing.

6. Remove the TOP bearing from the TOP bearing

DO NOT overtighten the bearing gap nut. Otherwise, damage to the front fork assembly may occur.

5. Secure the bearing gap nut by threading it into the front fork. Torque the bearing gap nut between 217 - 243 in./lbs.

NOTE: When reinstalling the front wheel, replace the EXISTING hardware with the NEW hardware supplied.

6. Reinstall the front wheel. Refer to REMOVING/INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

7. Reinstall the shroud assembly. Refer to ING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

8. Reinstall the tiller assembly. Refer to ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

housing.

7. Slide the front fork, BOTTOM bearing and BOT- TOM bearing bushing away from the front frame assembly.

8. Remove the TOP and BOTTOM bearing housings from the front frame assembly.

Installing

Top

Bearing

Bushing

Top

Bearing

Top Bearing

Housing

1. Secure the TOP and BOTTOM bearing housing onto the front frame assembly.

NOTE: Before installing the front fork, be sure it is

Front

Frame

Assembly

facing the proper direction.

2. Slide the front fork with the BOTTOM bearing and the BOTTOM bearing bushing through the

Bottom

Bearing

Housing

mounting hole in the front frame assembly.

3. Slide the TOP bearing over the top of the front fork and into the TOP bearing housing.

CAUTION

DO NOT overtighten the TOP bearing bushing . Otherwise, damage to the f ront fork assembly may occu r.

Bottom

Bearing

Bottom

Bearing

Bushing

FIGURE 2 - REMOVING/INST ALLING FORK

WITH BEARING ASSEMBLY

CAUTION

Front Frame Assembly

Bearing

Gap Nut

Back of

Scooter

REMOV-

Front Fork

Facing Proper

Direction

Front of

Scooter

2222

PROCEDURE 5SHROUD/FORK/WHEELS/TIE RODS

REMOVING/INSTALLING FRONT AXLE ASSEMBLY

NOTE: This procedure applies to the PANTHER LX

- 4 and the PANTHER MX - 4 ONLY.

Panther LX - 4 (FIGURE 3)

REMOVING.

1. Remove the tiller assembly. Refer to REMOVING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

2. Remove the shroud assembly. Refer to ING/INSTALLING SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

3. Remove the front wheels. Refer to INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

4. Position the front frame assembly onto its side.

5. Remove the self-locking nut and spacer securing the front axle assembly to the right front wheel axle assembly.

NOTE: Save the self-locking nut, spacer and washer for reuse when installing the NEW front axle assembly.

6. Slide the right front wheel axle assembly and the washer away from the front axle assembly.

7. Repeat STEPS 4 - 5 for the left side of the front axle assembly.

8. Remove the self-locking nut and three (3) washers securing the front axle assembly to the front frame assembly.

9. Slide the front axle assembly and washer away from the front frame assembly.

REMOV-

REMOVING/

2. Secure the front axle assembly to the front frame using the washer and self-locking nut. Torque the locking nut between 108 - 135 in./lbs.

3. Position the EXISTING washer and the right front wheel axle assembly on the front axle assembly.

CAUTION

DO NOT overtighten the self-locking nut securing the front axle assembly to the right front wheel axle assembly. Otherwise, damage to the front axle assembly may occur.

4. Secure the right front wheel axle assembly to the front axle assembly using the EXISTING spacer and self-locking nut. Torque the self-locking nut between 17 - 30 in./lbs.

5. Repeat STEPS 3 - 4 for the left side of the front axle assembly.

6. Return the front frame assembly to the upright position

7. Reinstall the front wheels. Refer to INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

8. Reinstall the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

9. Reinstall the tiller assembly. Refer to ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

Self-locking nut

Spacer

Right Front Wheel

Axle Assembly

REMOVING/

REMOV-

S H R O U

O R

D S

H E E L S

INSTALLING.

NOTE: Position the two (2) washers between the front frame assembly and the front axle assembly.

1. Position the two (2) washers and front axle assembly onto the front frame assembly.

CAUTION

DO NOT overtighten the self-locking nut securing the front axle assembly to the front frame assembly. Otherwise, damage to the front axle assembly may occur.

Washer

Washers

Washer

Self-locking nut

Front Frame

Assembly

Front Axle

Assembly

FIGURE 3 - REMOVING/INST ALLING FRONT

AXLE ASSEMBL Y - P ANTHER LX - 4

2323

PROCEDURE 5 SHROUD/FORK/WHEELS/TIE RODS

S H R O U D

F O R K

H E E

L S

Panther MX - 4 (FIGURE 4)

REMOVING.

1. Remove the tiller assembly. Refer to REMOV-

D S

ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

2. Remove the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

3. Remove the front wheels. Refer to

REMOVING/ INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

4. Position the front frame assembly onto its side.

5. Remove the front shock absorbers. Refer to MOVING/INSTALLING FRONT SHOCK ABSORBERS in PROCEDURE 11 of this manual.

NOTE: Save the self-locking nut, washer and spacer for reuse when installing the NEW front axle assembly.

6. Remove the self-locking nut and washer securing the right front axle to the tie rod assembly.

7. Slide the tie rod assembly and the spacer away from the right front axle.

8. Remove the bolt, spring washer and washer secur-

DO NOT overtighten the self-locking nut securing the tie rod assembly to the right front axle. Otherwise, damage to the tie rod assembly may occur.

4. Secure the tie rod assembly onto the right front axle

using the EXISTING washer and self-locking nut. Torque the self-locking nut between 17 - 30 in./lbs.

5. Repeat STEPS 1 - 4 to install the left front axle.

6. Reinstall the front shock absorbers. Refer to MOVING/INSTALLING FRONT SHOCK ABSORBERS in PROCEDURE 11 of this manual.

7. Return the front frame assembly to the upright

RE-

position

8. Reinstall the front wheels. Refer to INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

9. Reinstall the shroud assembly. Refer to ING/INSTALLING SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

10. Reinstall the tiller assembly. Refer to ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

CAUTION

RE-

REMOVING/

REMOV-

ing the right front axle to the front frame assembly.

9. Remove the right front axle assembly.

10. Repeat STEPS 5 - 9 to remove the left front axle.

INSTALLING.

1. Align the mounting hole in the right front axle with the mounting hole in the front frame assembly.

CAUTION

DO NOT overtighten the bolt securing the right front axle to the front frame assembly. Otherwise, damage to the right front axle may occur.

2. Secure the right front axle to the front frame assembly using the washer, spring washer and bolt. Torque the bolt between 191 - 226 in./lbs.

NOTE: Position the spacer between the top of the right front axle and the tie rod assembly.

3. Slide the EXISTING spacer and the tie rod assembly onto the mounting pin of the right front axle.

Front Frame

Assembly

Right Front Axle

Spacer

Tie Rod Assembly

Washer

Self-locking nut

Washer

Spring

Washer

Mounting Pin

Bolt

FIGURE 4 - REMOVING/INST ALLING FRONT

AXLE ASSEMBL Y - P ANTHER MX - 4

2424

PROCEDURE 5SHROUD/FORK/WHEELS/TIE RODS

REPLACING TIE ROD ASSEMBLY

NOTE: This procedure applies to the PANTHER LX

- 4 and the PANTHER MX - 4 ONLY.

Panther LX - 4 (FIGURE 5)

1. Remove the tiller assembly. Refer to REMOVING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

2. Remove the shroud assembly. Refer to ING/INSTALLING SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

3. Remove the front wheels. Refer to INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

4. Position the front frame assembly onto its side.

5. Remove the front axle assembly. Refer to ING/INSTALLING FRONT AXLE ASSEMBLY, PANTHER LX - 4 in this procedure of this manual.

6. Remove the two (2) hex cap screws and self-locking nuts securing the steering shaft to the U - plate on the tie rod assembly.

7. Remove the U - plate and the tie rod assembly from the steering shaft.

REMOV-

REMOVING/

REMOV-

15. Slide the NEW steering shaft with the NEW BOTTOM bearing and the NEW BOTTOM bearing bushing into the front frame assembly.

16. Slide the NEW TOP bearing over the top of the NEW steering shaft and into the NEW TOP bear- ing housing.

CAUTION

DO NOT overtighten the TOP bearing bushing. Otherwise, damage to the tie rod assembly may occur.

17. Secure the NEW TOP bearing bushing by threading it into the NEW TOP bearing housing. Torque the NEW TOP bearing bushing between 26 - 39 in./lbs.

CAUTION

DO NOT overtighten the bearing gap nut. Otherwise, damage to the tie rod assembly m a y occur.

18. Secure the NEW bearing gap nut by threading it into the NEW steering shaft. Torque the NEW bearing gap nut between 216 - 243 in./lbs.

19. Align the two (2) mounting holes in the NEW U- plate on the tie rod assembly with the two (2) mounting holes in the NEW steering shaft.

S H R O U

O R

D S

H E E

8. Remove the bearing gap nut from the steering shaft.

9. Remove the TOP bearing bushing from the TOP bearing housing.

10. Remove the TOP bearing from the TOP bearing housing.

11. Remove the steering shaft, BOTTOM bearing and the BOTTOM bearing bushing from the BOTTOM bearing housing.

12. Remove the TOP and BOTTOM bearing housings from the front frame assembly.

13. Secure the NEW TOP and BOTTOM bearing housing onto the front frame assembly.

14. Slide the NEW BOTTOM bearing and the NEW BOTTOM bearing bushing onto the steering shaft.

NOTE: Before installing the NEW steering shaft, be sure it is in the proper direction (FIGURE 5).

20. Secure the NEW U-plate and the tie rod assembly to the NEW steering shaft using the two (2) NEW hex cap screws and self-locking nuts. Torque the NEW self-locking nuts between 112 138 in./lbs.

21. Reinstall the front axle assembly. Refer to

REMOVING/INSTALLING FRONT AXLE ASSEMBLY, PANTHER LX - 4 in this procedure of this manual.

22. Return the front frame assembly to the upright position.

23. Reinstall the front wheels. Refer to

REMOVING/ INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

24. Reinstall the front shroud assembly. Refer to

REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 4 of this manual.

25. Reinstall the tiller assembly. Refer to

REMOVING/INSTALLING TILLER ASSEMBLY in PROCEDURE 3 of this manual.

2525

O U D

O R K

H E E

PROCEDURE 5 SHROUD/FORK/WHEELS/TIE RODS

Bearing Gap Nut

S H R

R O

D S

(STEPS 8 and 18)

Top Bearing Bushing

(STEPS 9 and 17)

Top Bearing

(STEPS 10 and 16)

Top Bearing Housing

(STEPS 12 and 13)

Front Frame Assembly

Bottom Bearing Housing

(STEPS 12 and 13)

Bottom Bearing

(STEPS 11 and 14)

Bottom Bearing Bushing

(STEPS 11 and 14)

Steering Shaft

(STEPS 11 and 15)

Hex Cap Screws

(STEPS 6 and 20)

U - Plate

(STEPS 7 and 19)

Self-locking nuts

(STEPS 6 and 20)

Tie Rod Assembly (STEPS 7 and 20)

Front Axle Assembly (Removed For Clarity)

FIGURE 5 - REPLACING TIE ROD ASSEMBL Y - PANTHER LX - 4

Panther MX - 4 (FIGURE 6)

1. Remove the tiller assembly. Refer to REMOVING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

2. Remove the front shroud assembly. Refer to MOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

3. Remove the front wheels. Refer to

REMOVING/INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

4. Position the front frame assembly onto its side.

5. Remove the front shock absorbers. Refer to MOVING/INSTALLING FRONT SHOCK ABSORBERS in PROCEDURE 11 of this manual.

6. Remove the small tie rod. Refer to

REMOVING/ INSTALLING SMALL TIE RODS in this procedure of this manual.

7. Remove the large tie rod. Refer to

REMOVING/INSTALLING LARGE TIE RODS in this procedure of this manual.

8. Remove the bearing gap nut from the steering shaft.

9. Remove the TOP bearing bushing from the TOP

bearing housing.

10. Remove the TOP bearing from the TOP bearing

housing.

RE-

11. Remove the steering shaft, BOTTOM bearing and the BOTTOM bearing bushing from the front frame assembly.

12. Remove the TOP and BOTTOM bearing housings from the front frame assembly.

13. Remove the self-locking nut and washer securing the right front wheel axle to the right front axle.

14. Slide the right front wheel axle and the spacer away from the right front axle.

15. Repeat STEPS 11-12 to remove the tie rod assembly from the left front axle.

16. Remove the tie rod assembly.

NOTE: Before installing the NEW tie rod assembly, be sure it is in the proper direction (FIGURE 6).

17. Position the NEW spacer between the top of the right front axle and the right front wheel axle.

18. Slide the NEW right front wheel axle and the NEW spacer onto the right front axle.

CAUTION

DO NOT overtighten the self-locking nut securing the tie rod assembly to the right front axle. Otherwise, damage to the tie rod assembly may occur.

2626

PROCEDURE 5SHROUD/FORK/WHEELS/TIE RODS

19. Secure the NEW tie rod assembly onto the right front axle using the NEW washer and self-locking nut. Torque the NEW self-locking nut between 139 - 165 in./lbs.

20. Repeat STEPS 17-18 to attach the NEW tie rod assembly to the left front axle.

21. Secure the NEW TOP and BOTTOM bearing housing onto the front frame assembly.

22. Slide the NEW BOTTOM bearing and the NEW BOTTOM bushing onto the steering shaft.

NOTE: Before installing the NEW steering shaft, be sure it is facing toward the tie rods (FIGURE 6).

23. Slide the NEW steering shaft with the NEW BOT- TOM bearing and the NEW BOTTOM bushing through the mounting hole in the front frame assembly.

24. Slide the NEW TOP bearing over the top of the NEW steering shaft and into the NEW TOP bear- ing housing.

CAUTION

DO NOT overtighten the TOP bearing bushing. Otherwise, damage to the tie rod assembly may occur.

25. Secure the NEW TOP bearing bushing by screwing it into the NEW TOP bearing housing. Torque the NEW TOP bearing bushing between 26 - 39 in./lbs.

CAUTION

DO NOT overtighten the bearing gap nut. Otherwise, damage to the tie rod assembly m a y occur.

26. Secure the NEW bearing gap nut by screwing it into the steering shaft. Torque the NEW bearing gap nut between 217 - 243 in./lbs.

27. Reinstall the small tie rod. Refer to STALLING SMALL TIE RODS in this procedure of this manual.

28. Reinstall the large tie rod. Refer to INSTALLING LARGE TIE RODS in this procedure of this manual.

29. Reinstall the front shock absorbers. Refer to MOVING/INSTALLING FRONT SHOCK ABSORBERS in PROCEDURE 11 of this manual.

30. Return the front frame assembly to the upright position.

31. Reinstall the front wheels. Refer to STALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

32. Reinstall the front shroud assembly. Refer to MOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

33. Reinstall the tiller assembly. Refer to ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 5 of this manual.

REMOVING/IN-

REMOVING/

RE-

REMOVING/IN-

RE-

REMOV-

S H R O U

O R

D S

H E E L S

Right Front Axle

Spacer

(STEPS 14

and 18)

Right Front Wheel Axle (STEPS 14

and 18)

Washer

(STEPS 13

and 19)

Self-locking nut

(Steps 13 and 19)

Steering Shaft

(Steps 11 and 23)

Small Tie Rod

(Removed)

Large Tie Rod

(Removed)

Bearing Gap Nut

(STEPS 8 and 26)

Top Bearing Bushing

(STEPS 9 and 25)

Top Bearing

(STEPS 10 and 24)

Top Bearing Housing

(STEPS 12 and 21)

Front Frame Assembly

Bottom Bearing Housing

(STEPS 12 and 21)

Bottom Bearing

(STEPS 11 and 22)

Bottom Bearing Bushing

(STEPS 11and 22)

FIGURE 6 - REPLACING TIE ROD ASSEMBL Y - PANTHER MX - 4

2727

PROCEDURE 5 SHROUD/FORK/WHEELS/TIE RODS

H R O U D

O R K

REMOVING/INSTALLING SMALL TIE RODS

DO NOT overtighten the self-locking nuts secur-

CAUTION

ing the small tie rod to the right front wheel axle.

NOTE: This procedure applies to the PANTHER LX

- 4 and the PANTHER MX - 4 ONLY.

Panther LX - 4 (FIGURE 7)

REMOVING.

1. Remove the tiller assembly. Refer to REMOV-

R O

D S

ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

2. Remove the front shroud assembly. Refer to

RE-

MOVING/INSTALLING FRONT SHROUD AS-

E E L S

SEMBLY in PROCEDURE 5 of this manual.

3. Remove the front wheels. Refer to

REMOVING/ INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

4. Position the front frame assembly onto its side.

NOTE: Before removing the two (2) self-locking nuts and spring washers, note the mounting holes in the U plate and the right front wheel axle for proper reinstallation.

NOTE: Save the self-locking nut and spring washer for reuse when installing the NEW small tie rod.

Otherwise, damage to the tie rod may occur.

4. Secure the small tie rod to the right front wheel axle using the spring washer and self-locking nut. Securely tighten. Torque the self-locking nut between 112 - 139 in./lbs.

5. Return the front frame assembly to the upright position.

6. Reinstall the front wheels. Refer to

REMOVING/INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

7. Reinstall the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

8. Reinstall the tiller assembly. Refer to

REMOVING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

Self-locking nut

(STEP 5)

Spring Washer

(STEP 5)

U - Plate

5. Remove the self-locking nut and spring washer securing the small tie rod to the U - plate.

NOTE: Save the self-locking nut and spring washer for reuse when installing the NEW small tie rod.

6. Remove the self-locking nut and spring washer securing the small tie rod to the right front wheel axle.

Mounting

Bolt

Right Front

Wheel

Axle

Small Tie Rod

Mounting Bolt

Large Tie Rod

7. Remove the small tie rod.

INSTALLING.

1. Position the mounting bolt of the NEW small tie rod in the U -plate mounting hole as noted in the REMOVING section of this procedure.

CAUTION

DO NOT overtighten the self-locking nuts securing the small tie rod to the U-plate. Otherwise, damage to the tie rod may occur.

2. Secure the small tie rod to the U-plate using the spring washer and self-locking nut. Securely tighten. Torque the self-locking nut between 112

- 139 in./lbs.

3. Position the mounting bolt of the NEW small tie rod in the right front wheel axle mounting hole as noted in the cedure.

REMOVING section of this pro-

Spring Washer

(STEP 6)

Self-locking nut

(STEP 6)

FIGURE 7 - REMOVING/INST ALLING SMALL

TIE RODS - PANTHER LX - 4

2828

PROCEDURE 5SHROUD/FORK/WHEELS/TIE RODS

Panther MX - 4 (FIGURE 8)

REMOVING.

1. Remove the tiller assembly. Refer to REMOVING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

2. Remove the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

3. Remove the front wheels. Refer to INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

4. Flip the front frame assembly onto its side.

5. Remove the front shock absorbers. Refer to MOVING/INSTALLING FRONT SHOCK ABSORBERS in PROCEDURE 10 of this manual.

NOTE: Save the hex cap screw, small spacer and self-locking nut for reuse when installing the NEW small tie rod.

6. Remove the hex cap screw, small spacer and self-locking nut securing the small tie rod to the steering shaft.

NOTE: Before removing the hex cap screw, large spacer and self-locking nut, note the mounting holes in the right front wheel axle for proper reinstallation.

NOTE: Save the hex cap screw, large spacer and self-locking nut for reuse when installing the NEW small tie rod.

7. Remove the hex cap screw, large spacer and self-locking nut securing the small tie rod to the right front wheel axle.

8. Remove the small tie rod.

REMOVING/

RE-

4. Align the mounting hole in the small tie rod with the mounting hole in the steering shaft.

5. Position the small spacer between the small tie rod and the steering shaft.

CAUTION

DO NOT overtighten the self-locking nuts securing the small tie rod to the the steering shaft. Otherwise, damage to the tie rod may occur.

6. Secure the small tie rod to the steering shaft using the hex cap screw, small spacer and selflocking nut. Torque the self-locking nut between 139 - 165 in./lbs.

7. Reinstall the front shock absorbers. Refer to MOVING/INSTALLING FRONT SHOCK ABSORBERS in PROCEDURE 11 of this manual.

8. Return the front frame assembly to the upright position.

9. Reinstall the front wheels. Refer to

REMOVING/ INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

10. Reinstall the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

11. Reinstall the tiller assembly. Refer to ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

Self-

locking

nut

Large

Spacer

Small

Tie

Rod

Self-

locking

nut

RE-

REMOV-

S H R O U

O R

D S

H E E

INSTALLING.

1. Align the mounting hole in the small tie rod with the center mounting hole in the right front wheel axle.

2. Position the large spacer between the small tie rod and the front wheel axle.

CAUTION

DO NOT overtighten the self-locking nuts securing the small tie rod to the right front wheel axle. Otherwise, damage to the tie rod may occur.

3. Secure the small tie rod to the right front wheel axle using the hex cap screw, large spacer and self-locking nut. Torque the self-locking nut between 139 - 165 in./lbs.

Right Front

Wheel

Axle

Large Tie Rod

Small

Spacer

Hex Cap Screws

Steering Shaft

FIGURE 8 - REMOVING/INST ALLING SMALL

TIE RODS - PANTHER MX - 4

2929

PROCEDURE 5 SHROUD/FORK/WHEELS/TIE RODS

S H R

REMOVING/INSTALLING LARGE TIE RODS

NOTE: This procedure applies to the PANTHER LX

U D

- 4 and the PANTHER MX - 4 ONLY.

Panther LX - 4 (FIGURE 9)

REMOVING.

1. Remove the tiller assembly. Refer to REMOV-

H E E L S

ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

2. Remove the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

3. Remove the front wheels. Refer to

REMOVING/ INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

4. Flip the front frame assembly onto its side.

NOTE: Save the self-locking nut and spring washer for reuse when installing the NEW large tie rod.

5. Remove the self-locking nut and spring washer securing the large tie rod to the left front wheel axle.

3. Position the mounting bolt on the large tie rod in the mounting hole in the right front wheel axle.

CAUTION

DO NOT overtighten the self-locking nuts securing the large tie rod to the right front wheel axle. Otherwise, damage to the tie rod may occur.

4. Secure the large tie rod to the right front wheel axle using the EXISTING spring washer and selflocking nut. Torque the self-locking nuts between 112 - 139 in./lbs.

5. Return the front frame assembly to the upright position.

6. Reinstall the front wheels. Refer to INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

7. Reinstall the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

8. Reinstall the tiller assembly. Refer to ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

REMOVING/

REMOV-

NOTE: Before removing the self-locking nut and spring washer, take note of the mounting holes in the front right wheel axle for proper reinstallation.

NOTE: Save the self-locking nut and spring washer for reuse when installing the NEW large tie rod.

6. Remove the self-locking nut and spring washer securing the large tie rod to the right front wheel axle.

7. Remove the large tie rod.

Right Front

Wheel

Axle

Spring Washer

(STEP 6)

Self-locking nut

(STEP 6)

Small Tie Rod

Large Tie Rod

INSTALLING.

1. Position the mounting bolt on the large tie rod in the mounting hole in the left front wheel axle.

CAUTION

DO NOT overtighten the self-locking nuts securing the large tie rod to the left front wheel axle. Otherwise, damage to the tie rod may occur.

2. Secure the large tie rod to the left front wheel

Spring Washer (STEP 5)

Self-locking nut (STEP 5)

FIGURE 9 - REMOVING/INST ALLING LARGE

TIE RODS - PANTHER LX - 4

Left

Front

Wheel

Axle

axle using the EXISTING spring washer and selflocking nut. Securely tighten. Torque the self-locking nuts between 112 - 139 in./lbs.

NOTE: Before installing the hardware, be sure the large tie rod is in the proper mounting hole in the right front wheel axle.

3030

PROCEDURE 5SHROUD/FORK/WHEELS/TIE RODS

Panther MX - 4 (FIGURE 10)

REMOVING.

1. Remove the tiller assembly. Refer to REMOVING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

2. Remove the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

3. Remove the front wheels. Refer to INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

4. Flip the front frame assembly onto its side.

5. Remove the front shock absorbers. Refer to REPLACEMENT PARTS - PANTHER MX - 4 in PROCEDURE 11 of this manual.

NOTE: Save the hex cap screw, spacer and self-locking nut for reuse when installing the NEW large tie rod.

6. Remove the hex cap screw, spacer and self-locking nut securing the large tie rod to the left front wheel axle.

NOTE: Before removing the hex cap screw, spacer and self-locking nut, be sure to take note of the proper mounting holes in the right front wheel axle.

NOTE: Save the hex cap screw, spacer and selflocking nut for reuse when installing the NEW large tie rod.

7. Remove the hex cap screw, spacer and self-locking nut securing the large tie rod to the right front wheel axle.

8. Remove the large tie rod.

REMOVING/

4. Position the EXISTING spacer between the tie

rod and the left front wheel axle.

5. Align the mounting hole in the large tie rod with the mounting hole in the left front wheel axle.

CAUTION

DO NOT overtighten the self-locking nuts securing the large tie rod to the left front wheel axle. Otherwise, damage to the tie rod may occur.

6. Secure the large tie rod to the left front wheel axle using the EXISTING hex cap screw and selflocking nut. Torque the self-locking nuts between 139 - 165 in./lbs.

7. Reinstall the front shock absorbers. Refer to MOVING/INSTALLING FRONT SHOCK ABSORBERS in PROCEDURE 11 of this manual.

8. Return the front frame assembly to the upright position.

9. Reinstall the front wheels. Refer to

REMOVING/ INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

10. Reinstall the front shroud assembly. Refer to REMOVING/INSTALLING FRONT SHROUD ASSEMBLY in PROCEDURE 5 of this manual.

11. Reinstall the tiller assembly. Refer to ING/INSTALLING TILLER ASSEMBLY in PROCEDURE 4 of this manual.

Right Front Wheel Axle

Self-locking nut

RE-

REMOV-

S H R O U

O R

H E E L S

INSTALLING.

1. Position the EXISTING spacer between the tie

rod and the right front wheel axle.

2. Align the mounting hole in the large tie rod with the mounting hole noted in the

REMOVING sec-

tion.

CAUTION

DO NOT overtighten the self-locking nuts securing the large tie rod to the right front wheel axle. Otherwise, damage to the tie rod may occur.

3. Secure the large tie rod to the right front wheel axle using the EXISTING hex cap screw and selflocking nut. Torque the self-locking nuts between 139 - 165 in./lbs.

Spacer

Large Tie

Rod

Spacer

Hex Cap Screw

Left Front

Wheel Axle

FIGURE 10 - REMOVING/INST ALLING LARGE

TIE RODS - PANTHER MX - 4

3131

PROCEDURE 6 TRANSAXLE/MOTOR/BRAKE

T R A N S A X L E

/ M O

B R A K

This Procedure Includes the Following: Removing/InstallingTransaxle Assembly Replacing Motor/Brake Assembly Replacing Brake Release Lever Assembly

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may result.

T urn Power OFF and remove key from ignition. Disconnect battery harness from motor lead.

REMOVING/INSTALLING TRANSAXLE ASSEMBLY

Lynx SX - 3P, Lynx SX - 3, Lynx LX - 3, Panther LX - 4 (FIGURE 1)

REMOVING.

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

2. Remove the rear shroud. Refer to STALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

3. Remove the batteries. Refer to STALLING THE BATTERIES WITH CABLES in PROCEDURE 4 of the Owners Manual, part number 1090132.

4. Remove the rear wheels. Refer to STALLING THE REAR WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

NOTE: For proper reinstallation, note the position of the cable ties securing the transaxle assembly wires before cutting.

5. Cut the cable ties securing the transaxle assembly wires to the rear frame assembly.

REMOVING/IN-

9. Remove the two (2) bolts, washers, spring washers and self-locking nuts securing the bracket and rubber spacer located near the transaxle housing to the rear frame assembly.

10. Remove the bracket and rubber spacer located near the transaxle housing.

11. Slide the transaxle assembly out of the rear frame assembly.

INSTALLING.

1. Slide the transaxle assembly into the rear frame assembly.

NOTE: Before installing the brackets, be sure they are in the proper mounting positions.

2. Align the mounting holes in the bracket closet to the transaxle with the mounting holes in the rear frame assembly and the mounting holes in the rubber spacer.

CAUTION

DO NOT overtighten the two (2) bolts securing the bracket and rubber spacer to the rear frame assembly. Otherwise, damage to the bracket and rubber spacer may occur.

3. Install the two (2) bolts, washers, spring washers and self-locking nuts. Torque the two (2) self locking nuts between 130 - 156 in./lbs.

4. Align the mounting holes in the notched bracket closet to the motor with the mounting holes in the rear frame assembly and the mounting holes in the rubber spacer.

CAUTION

DO NOT overtighten the two (2) bolts securing the bracket and rubber spacer to the rear frame assembly. Otherwise, damage to the bracket and rubber spacer may occur.

5. Install the two (2) bolts, washers, spring washers and self-locking nuts. For the Lynx SX - 3P and the Lynx SX - 3, torque the two (2) self locking

6. Disconnect the WHITE connector of the transaxle assembly wiring harness from the WHITE connector of the controller wiring harness.

NOTE: Before removing the brackets, take note of the mounting position for proper reinstallation.

7. Remove the two (2) bolts, washers, spring washers and self-locking nuts securing the bracket and rubber spacer located near the motor to the rear

nuts between 17 - 26 in./lbs. For the Lynx LX - 3 and the Panther LX - 4, torque the two (2) self locking nuts between 130 - 156 in./lbs.

6. Connect the WHITE connector of the transaxle assembly wiring harness to the WHITE connector of the controller wiring harness.

NOTE: Be sure the cable ties are positioned as noted in STEP 5.

frame assembly.

7. Secure the wires of the transaxle assembly wir-

8. Remove the bracket and rubber located near the motor.

ing harness to the rear frame assembly using NEW cable ties.

3232

TRANSAXLE/MOTOR/BRAKE

PROCEDURE 6

8. Reinstall the rear wheels. Refer to

REMOVING/INSTALLING THE REAR WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

9. Reinstall the batteries. Refer to

REMOVING/INSTALLING THE BATTERIES WITH CABLES in PROCEDURE 4 of the Owners Manual, part number 1090132.

L YNX SX - 3P, LYNX SX - 3

Removing STEP 9, Installing STEP 3

Bolt

Washer

Spring Washer

Self-Locking Nut

Transaxle Housing

10. Reinstall the rear shroud. Refer to REMOVING/IN-

11. Reinstall the seat. Refer to

Bracket

Rubber Spacer

STALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

Removing STEP

Installing STEP 5

Motor

Bolts

T R A N S A X L E

/ M O

B R A K

White Connector (Disconnected)

Transaxle Assembly Wires

Rear Frame Assembly

Removing STEP 9, Installing STEP 3

Bolt

Washer

Spring Washer

Self-locking nut

Transaxle Housing

White Connector (Disconnected)

Transaxle Assembly Wires

Cable Tie

Bracket

Rubber Spacer

L YNX LX - 3, PANTHER LX - 4

Bracket

Rubber Spacer

Cable Tie

Washer

Spring Washer

Self-Locking

Nut

Removing STEP 7, Installing STEP 5

Motor

Bracket

Bolts

Washer

Spring

Washer

Self-locking nut

Rear Frame Assembly Rubber Spacer

FIGURE 1 - REMOVING/INST ALLING TRANSAXLE ASSEMBL Y - LYNX SX - 3P, LYNX SX - 3, L YNX

LX - 3 AND PANTHER LX - 4

3333

TRANSAXLE/MOTOR/BRAKEPROCEDURE 6

S A X L E

M O

T O R

B R

A K

Panther MX - 4 (FIGURE 2)

REMOVING.

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

2. Remove the rear shroud. Refer to

INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

3. Remove the batteries. Refer to

REMOVING/INSTALLING THE BATTERIES WITH CABLE ASSEMBLY in PROCEDURE 4 of the Owners Manual, part number 1090132

4. Remove the rear wheels. Refer to

REMOVING/INSTALLING THE REAR WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

5. Remove the disc brake assembly. Refer to PLACING DISC BRAKE ASSEMBLY in PROCEDURE 11 of this Manual.

6. Remove the TOP bolts on the two (2) rear shock absorbers (DETAIL “A”).

7. Rotate the top of the two (2) rear shock absorbers away from the frame (DETAIL “A”).

8. Disconnect the WHITE connectors of the transaxle assembly from the WHITE connectors of the control assembly.

9. Remove the two (2) bolts, spring washers, selflocking nuts, and four (4) washers securing the U-brace and rubber spacer to the rear frame assembly.

REMOVING/

RE-

DO NOT overtighten the two (2) screws securing the bracket and rubber spacer to the rear frame assembly. Otherwise, damage to the bracket and rubber spacer may occur.

3. Secure the bracket and the rubber spacer to the rear frame assembly using the two (2) screws and self-locking nuts. Torque the two (2) self locking nuts between 16 - 20 in./lbs.

4. Align the mounting holes of the U - brace with the mounting holes in the rear frame assembly.

5. Position the rubber spacer between the U - brace and the rear frame assembly.

DO NOT overtighten the two (2) bolts securing the U - brace and rubber spacer to the rear frame assembly. Otherwise, damage to the U - brace and rubber spacer may occur.

6. Secure the U - brace and the rubber spacer to the rear frame assembly using the two (2) bolts, spring washers, self-locking nuts, and four (4) washers. Torque the two (2) self locking nuts between 16 - 20 in./lbs.

7. Rotate the top of the two (2) rear shock assemblies toward the frame.

8. Align the two (2) rear shock assemblies with the two (2) mounting holes on the rear frame assembly (DETAIL “A”).

9. Secure the two (2) rear shock assemblies to the rear frame assembly using the existing screws (DETAIL “A”). Securely tighten.

CAUTION

10. Remove the U-brace and rubber spacer from the rear frame assembly.

11. Remove the two (2) screws and self-locking nuts securing the bracket and rubber spacer to the rear frame assembly.

12. Remove the bracket and rubber spacer from the rear frame assembly.

13. Slide the transaxle assembly out of the rear frame assembly.

INSTALLING.

1. Slide the transaxle assembly into the rear frame assembly.

2. Align the mounting holes in the bracket and the rubber spacer with the mounting holes in the rear frame assembly.

10. Connect the WHITE connector of the transaxle assembly to the WHITE connector of the control assembly.

11. Reinstall the disc brake assembly. Refer to PLACING DISC BRAKE ASSEMBLY in PROCEDURE 11 of this manual.

12. Reinstall the rear wheels. Refer to

REMOVING/INSTALLING THE REAR WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

13. Reinstall the batteries. Refer to

REMOVING/INSTALLING THE BATTERIES WITH CABLES in PROCEDURE 4 of the Owners Manual, part number 1090132.

14. Reinstall the rear shroud. Refer to

REMOVING/ INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

3434

RE-

PROCEDURE 6TRANSAXLE/MOTOR/BRAKE

15. Reinstall the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

Top Bolt

Rear Shock

Absorbers

DETAIL “A”

Bolts

Washer

U - Brace

Rubber Spacer

Transaxle Assembly

REPLACING MOTOR/BRAKE ASSEMBLY (FIGURE 3)

1 Remove the transaxle assembly. Refer to RE-

MOVING/INSTALLING TRANSAXLE ASSEMBLY in PROCEDURE 6 of this manual.

2. Remove the four EXISTING (4) nylock socket

bolts that secure the motor/brake assembly to the transaxle assembly.

3. Remove the EXISTING motor/brake assembly

from the transaxle assembly.

4. Remove the EXISTING plate and bushing from

the transaxle assembly.

5. Position the NEW plate in the transaxle.

6. Position the NEW bushing over the plate.

7. Position the NEW motor/brake assembly so that the mounting holes in the NEW motor/brake assembly line up with the mounting holes in the transaxle assembly.

8. Install the four (4) NEW nylock socket bolts that secure the motor/brake assembly to the transaxle. Torque the four (4) NEW nylock socket bolts between 156 - 191 in./lbs.

S A X L E

/ M O

T O R

/ B R

Assembly

Washer

Spring

Washer

Self-locking

nut

Rear

Frame

White Connector

(Disconnected)

Screw

Rear

Frame

Assembly

Rubber

Spacer

Bracket

Self-locking

nut

9. Reinstall the transaxle assembly. Refer to MOVING/INSTALLING TRANSAXLE ASSEMBLY in PROCEDURE 6 of this manual.

Motor/Brake

Assembly

Nylock Bolts

Plate

Bushing

Transaxle

FIGURE 3 - REPLACING MOTOR/BRAKE

ASSEMBL Y

RE-

FIGURE 2 - REMOVING/INST ALLING

TRANSAXLE ASSEMBL Y - P ANTHER MX - 4

3535

PROCEDURE 6

TRANSAXLE/MOTOR/BRAKE

T R A N S A X

L E

T O R

B R A K

REPLACING BRAKE RELEASE LEVER ASSEMBLY (FIGURE 4)

For All Models EXCEPT Panther MX - 4

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

2. Remove the rear shroud. Refer to INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

NOTE: Save the two (2) mounting screws and spring washers for reuse when reinstalling the brake cover.

3. Remove the two (2) mounting screws and spring washers securing the brake cover to the motor/

REMOVING/

brake assembly.

4. Remove the brake cover from the motor/brake assembly.

3. Remove the socket screw and the bolt socket securing the brake release lever to motor/brake assembly.

4. Remove the brake release lever.

5. Align the mounting holes in the NEW brake release lever with the mounting holes in motor/brake assembly.

6. Secure the NEW brake release lever to the motor/brake assembly using the NEW socket screw and bolt socket. Securely tighten.

7. Reinstall the rear shroud. Refer to

REMOVING/ INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

8. Reinstall the seat. Refer to

REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

ALL MODELS EXCEPT PANTHER MX - 4

5. Remove the mounting screw and self-locking nut securing the brake release lever to the motor/brake assembly.

6. Remove the brake release lever.

7. Align the mounting hole in the NEW brake re-

Motor/Brake

Assembly

Self-locking

nut

Brake

Release

Lever

lease lever with the mounting hole in the motor brake assembly.

8. Secure the NEW brake release lever to the motor/brake assembly using the NEW mounting screw and self-locking nut. Securely tighten.

9. Align the two (2) mounting holes in the EXIST- ING brake cover with the two (2) mounting holes in the motor/brake assembly.

10. Secure the EXISTING brake cover to the motor/ brake assembly using the two (2) EXISTING mounting screws and spring washers. Securely tighten.

11. Reinstall the rear shroud. Refer to

REMOVING/INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

12. Reinstall the seat. Refer to

REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

Panther MX - 4

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

2. Remove the rear shroud. Refer to STALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

REMOVING/IN-

Brake Cover

Spring Washers

Mounting Screws

P ANTHER MX - 4

Bolt

Socket

Screw

Brake Release Lever

Mounting Holes

Motor/Brake

FIGURE 4 - REPLACING BRAKE RELEASE

LEVER ASSEMBLY

Mounting

Screw

Assembly

3636

CONTROLLER

PROCEDURE 7

This Procedure Includes the Following:

Removing/Installing Controller Removing/Installing Controller Harnesses Replacing Circuit Breaker

W ARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may occur.

Turn Power OFF and remove key from ignition. Disconnect battery harness from the motor lead.

REMOVING/INSTALLING CONTROLLER

Disconnecting/Connecting Controller Wires (FIGURE 1)

DISCONNECTING.

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

CONNECTING.

1. Connect the following (FIGURE 1):

A. The RED and WHITE connectors to the slot

marked “B+” on the controller.

B. The BLACK and GREEN connectors to the

slot marked “B-” on the controller.

C. The BLACK connector to the slot marked

“M+” on the controller.

D. The RED connector to the slot marked “M-”

on the controller.

E. The housing of the main control wiring har-

ness to the slot marked “P2” on the controller.

ALL MODELS EXCEPT PANTHER MX - 4

Main Control

Housing

Black

Connector

“P2” Slot

Connector

C O N T R O L L E R

Red

Black And

Green

Connectors

2. Remove the rear shroud. Refer to

REMOVING/ INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

3. Remove the transaxle assembly. Refer to

REMOVING/INSTALLING TRANSAXLE ASSEMBLY in PROCEDURE 6 of this manual.

4. Disconnect the following from the controller (FIGURE 1):

A. The RED and WHITE connectors from the

slot marked “B+” on the controller.

B. The BLACK and GREEN connectors from

the slot marked “B-” on the controller.

C. The BLACK connector from the slot marked

“M+” on the controller.

D. The RED connector from the slot marked

“M-” on the controller.

E. The housing of the main control wiring har-

ness from the slot marked “P2” on the con- troller.

Controller

Red And White

Connectors

Black

And

Green

Connectors

“B-” Slot

“M-” Slot

“M+” Slot

P ANTHER MX - 4

“P2”

Slot

Red

Connector

“B+” Slot

“B-” Slot

“M-” Slot

“M+” Slot

“B+” Slot

Main

Control

Housing

Black

Connector

Red And White

Connectors

3737

FIGURE 1 - DISCONNECTING/

CONNECTING CONTROLLER WIRES

PROCEDURE 7 CONTROLLER

2. Reinstall the transaxle assembly. Refer to REMOVING/INSTALLING TRANSAXLE ASSEMBLY in the PROCEDURE 6 of this manual.

C O N T R O

L E R

3. Reinstall the rear shroud. Refer to STALLING THE REAR SHROUD in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

4. Reinstall the seat. Refer to STALLING THE SEAT in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

Removing/Installing Controller From/ To Controller Plate (FIGURE 2)

REMOVING/IN-

REMOVING.

1. Disconnect the controller wires. Refer to DISCONNECTING/CONNECTING CONTROLLER WIRES in this procedure of the manual.

2. Perform one (1) of the following: A. LYNX SX - 3 and LYNX SX - 3P (FIGURE 2):

1. Cut the cable ties securing the wires to the two (2) retaining tabs.

2. Remove the wires from the two (2) retaining tabs.

3. Remove the two (2) short screws, washers and self-locking nuts from the controller assembly.

4. Gently slide the controller and the controller plate from the rear frame.

5. Separate the controller from the controller plate.

B. LYNX LX - 3 and PANTHER LX - 4 (FIG-

URE 2):

1. Remove the short screw, washer and selflocking nut from the controller assembly.

2. Remove the long screw, washer and selflocking nuts from the controller assembly and the retaining tab.

INSTALLING.

1. Perform one of the following:

A. LYNX SX - 3 and LYNX SX - 3P (FIGURE 2):

1. Gently slide the controller and the controller plate onto the rear frame, making sure the support on the rear frame is positioned in the slot on the controller plate.

2. Align the mounting holes in the controller plate with the mounting holes in the controller.

3. Insert the two (2) short screws through the controller and the controller plate, and secure them with the washer and self-locking nut. Securely tighten.

4. Position the wires in the two (2) retaining tabs.

5. Secure the wires to the two (2) retaining tabs using NEW cable ties.

B. LYNX LX - 3 and PANTHER LX - 4 (FIG-

URE 2):

1. Gently slide the controller and the controller plate onto the rear frame, making sure the support on the rear frame is positioned in the slot on the controller plate.

2. Align the mounting hole in the retaining tab with the mounting holes in the controller plate and the mounting holes in the controller.

3. Insert the long screw through the controller, the controller plate and the retaining tab, and secure it with the washer and self-locking nut. Securely tighten.

4. Insert the provided short screw through the controller and the controller plate, and secure it with the washer and self-locking nut. Securely tighten.

C. PANTHER MX - 4 (FIGURE 2):

3. Remove the retaining tab from the controller.

4. Gently slide the controller and the controller plate from the rear frame.

5. Separate the controller from the controller plate.

C. PANTHER MX - 4 (FIGURE 2):

1. Remove the two (2) screws, washers, and self-locking nuts from the rear frame.

2. Remove the controller from the rear frame/controller plate.

1. Position the controller on the rear frame so that the mounting holes in the controller align with the mounting holes in the rear frame/controller plate.

2. Insert the two (2) screws through the controller and the rear frame, and secure them with the washers and self-locking nuts. Securely tighten.

2. Connect the controller wires. Refer to NECTING/CONNECTING CONTROLLER WIRES in this procedure of the manual.

3838

DISCON-

CONTROLLER PROCEDURE 7

L YNX SX - 3P AND LYNX SX - 3

Short

Washer

Controller

Retaining

Tab

Controller

Plate

Self-locking

nuts

Screws

L YNX LX - 3 AND PANTHER LX - 4

Short

Screw

Washer

Controller

Retaining

Tab

Controller

Plate

Self-locking nuts

P ANTHER MX - 4

Washer

Rear

Frame

Support

Slot

Retaining

Tab

Long

Screw

Washer

Rear

Frame

Support

Slot

Retaining

Tab

REMOVING/INSTALLING CONTROLLER HARNESSES

Lynx SX - 3P And Lynx SX - 3 (FIGURE 3)

REMOVING.

1. Disconnect the controller wires. Refer to DISCONNECTING/CONNECTING CONTROLLER WIRES in this procedure of the manual.

2. Disconnect the RED and BLACK connectors of the power wiring harnesses from the RED and BLACK connectors of the controller wiring harnesses.

3. Disconnect the WHITE connector of the transaxle assembly wiring harness from the WHITE con- nector of the controller wiring harness.

NOTE: Note the positions of the metal connectors before removing for proper reinstallation.

4. Disconnect the metal connectors of the controller wiring harnesses from the metal connectors of the circuit breaker.

5. Disconnect the BLUE connector of the tiller wiring harness from the BLUE connector of the controller wiring harness.

6. Disconnect the YELLOW connector of the tiller wiring harness from the YELLOW connector of the controller wiring harness.

7. Cut the cable ties securing the transaxle wiring harness to the rear frame.

8. Cut the cable tie securing the power wiring harnesses and the tiller wiring harnesses to the rear frame.

9. Cut the cable tie securing the tiller wiring harnesses to the retaining tabs of the controller.

C O N T R O L L E R

Self-locking

nuts

Controller

Washer

Screws

Rear Frame/

Controller Plate

FIGURE 2 - REMOVING/INST ALLING

CONTROLLER FROM/TO CONTROLLER PLATE

10. Remove the tiller wiring harnesses from the retaining tabs.

11. Remove the wiring harnesses from the scooter.

INSTALLING.

1. Position the tiller wiring harnesses in the retaining tabs.

2. Secure the tiller wiring harnesses to the retaining tabs using NEW cable ties.

3. Secure the power wiring harnesses and the tiller wiring harnesses to the rear frame using NEW cable ties.

4. Secure the transaxle wiring harnesses to the rear frame using NEW cable ties.

3939

PROCEDURE 7 CONTROLLER

5. Connect the RED and BLACK connectors of the power wiring harnesses to the RED and BLACK connectors of the controller wiring harnesses.

C O N T R O

L E R

6. Connect the WHITE connector of the transaxle assembly wiring harness to the WHITE connec- tor of the controller wiring harness.

NOTE: Be sure the metal connectors are in the positions noted in STEP 4 of REMOVAL.

7. Connect the metal connectors of the power wiring harnesses to the metal connectors of the circuit breaker.

8. Connect the BLUE connector of the tiller wiring harness to the BLUE connector of the controller wiring harness.

9. Connect the YELLOW connector of the tiller wiring harness to the YELLOW connector of the controller wiring harness.

10. Reinstall the rear shroud. Refer to

REMOVING/ INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

11. Reinstall the seat. Refer to

REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

Blue Connectors - Tiller

Wiring Harness

Yellow Connectors - Tiller

Wiring Harness

Yellow Connectors - Controller

Wiring Harness

Black Connectors -

Controller Wiring Harness

Black Connectors - Power

Wiring Harness

Blue Connectors - Controller

Wiring Harness

Metal Connectors -

Circuit Breaker

Metal Connectors -

Controller Wiring Harness

White Connector -

Controller Wiring Harness

White Connector -

Transaxle Assembly

Transaxle Wiring Harness

Rear Frame

Cable Ties

Tiller Wiring Harness

Power Wiring Harness

Cable Tie

Red Connector - Controller

Wiring Harness

Red Connector - Power

Wiring Harness

Retaining Tabs

FIGURE 3 - REMOVING/INST ALLING CONTROLLER HARNESSES - LYNX SX - 3P AND LYNX SX 3

Lynx LX - 3 and Panther LX - 4 (FIGURE 4)

REMOVING.

1. Disconnect the controller wires. Refer to DISCONNECTING/CONNECTING CONTROLLER WIRES in this procedure of the manual.

2. Disconnect the RED and BLACK connectors of the power wiring harnesses from the RED and BLACK connectors of the controller wiring harnesses.

3. Disconnect the WHITE connector of the transaxle assembly wiring harness from the WHITE con- nector of the controller wiring harness.

NOTE: Note of the positions of the metal connectors before removing for proper reinstallation.

4. Disconnect the metal connectors of the controller wiring harnesses from the metal connectors of the circuit breaker.

5. Disconnect the BLUE connector of the tiller wiring harness from the BLUE connector of the controller wiring harness.

6. Disconnect the YELLOW connector of the tiller wiring harness from the YELLOW connector of the controller wiring harness.

4040

CONTROLLER PROCEDURE 7

7. Cut the cable tie securing the transaxle wiring harness to the rear frame.

8. Cut the cable tie securing the power wiring harnesses to the rear frame.

9. Remove the tiller wiring harness from the retaining tab.

10. Remove the wiring harnesses from the scooter.

INSTALLING.

1. Position the tiller wiring harnesses in the retaining tabs.

2. Secure the power wiring harnesses to the rear frame using NEW cable ties.

3. Secure the transaxle wiring harness to the rear frame using a NEW cable tie.

4. Connect the RED and BLACK connectors of the power wiring harnesses to the RED and BLACK connectors of the controller wiring harnesses.

5. Connect the WHITE connector of the transaxle assembly wiring harness to the WHITE connec- tor of the controller wiring harness.

NOTE: Be sure the metal connectors are in the positions noted in STEP 2 of REMOVAL.

6. Connect the metal connectors of the power wiring harnesses to the metal connectors of the circuit breaker.

7. Connect the BLUE connector of the tiller wiring harness to the BLUE connector of the controller wiring harness.

8. Connect the YELLOW connector of the tiller wiring harness to the YELLOW connector of the controller wiring harness.

9. Reinstall the rear shroud. Refer to

REMOVING/INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

10. Reinstall the seat. Refer to

REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

C O N T R O

L E R

Black Connectors - Power

Wiring Harness

Metal Connectors -

Circuit Breaker

Metal Connectors -

Controller Wiring Harness

Cable Tie

Transaxle Wiring Harness

White Connector -

Transaxle Assembly

White Connector -

Controller Wiring Harness

Blue Connectors - Controller

Wiring Harness

Yellow Connectors - Controller

Wiring Harness

Rear Frame

Black Connectors -

Controller Wiring Harness

Power Wiring Harness

Cable Tie

Red Connector - Controller

Wiring Harness

Red Connector - Power

Wiring Harness

Tiller Wiring Harness

Retaining Tabs

Blue Connectors - Tiller

Wiring Harness

Yellow Connectors - Tiller

Wiring Harness

FIGURE 4 - REMOVING/INST ALLING CONTROLLER HARNESSES - LYNX LX - 3 AND

PANTHER LX - 4

4141

PROCEDURE 7

CONTROLLER

Panther MX - 4 (FIGURE 5)

REMOVING.

1. Disconnect the controller wires. Refer to DIS-

C O N T R O

L E R

CONNECTING/CONNECTING CONTROLLER WIRES in this procedure of the manual.

2. Disconnect he RED and BLACK connectors of the power wiring harnesses from the RED and BLACK connectors of the controller wiring harnesses.

3. Disconnect the WHITE connector of the transaxle assembly wiring harness from the WHITE con- nector of the controller wiring harness.

NOTE: Note of the positions of the metal connectors before removing for proper reinstallation.

4. Disconnect the metal connectors of the controller wiring harnesses from the metal connectors of the circuit breaker.

5. Disconnect the WHITE connector of the tiller wiring harness from the WHITE connector of the controller wiring harness

6. Cut the cable tie securing power wiring harnesses and the metal connector wiring harness to the rear frame.

7. Cut the cable tie securing the metal connector wiring harnesses to the retaining tab.

8. Remove the metal connector wiring harnesses from the retaining tab.

9. Cut the cable tie securing the tiller wiring harness to the rear frame.

10. Cut the cable tie securing the main control housing wiring harnesses to the retaining tab.

11. Remove the wiring harnesses from the scooter.

INSTALLING.

1. Position the metal connector wiring harnesses in the retaining tab.

2. Secure the metal connector wiring harness into the retaining tab using NEW cable ties.

3. Secure the power wiring harnesses and the metal connector wiring harness to the rear frame using NEW cable ties.

4. Secure the tiller wiring harness to the rear frame using NEW cable ties.

5. Secure the main control housing wiring harnesses to the retaining tab using a NEW cable tie.

6. Connect the RED and BLACK connectors of the power wiring harnesses to the RED and BLACK connectors of the controller wiring harnesses.

7. Connect the WHITE connector of the transaxle assembly wiring harness to the WHITE connec- tor of the controller wiring harness.

NOTE: Be sure the metal connectors are in the positions noted in STEP 2 of REMOVAL.

White Connector -

Transaxle Assembly

White Connector -

Controller Wiring Harness

Retaining Tabs

Cable Tie

Main Control

Wiring Harness

White Connector -

Controller Wiring Harness

White Connector -

Transaxle Assembly

Tiller Wiring

Harness

Metal Connectors -

Circuit Breaker

Cable Ties

Retaining Tab

Metal Connectors -

Controller Wiring Harness

Red Connector - Power

Wiring Harness

Red Connector - Controller

Wiring Harness

Black Connectors - Power

Wiring Harness

Black Connectors -

Controller Wiring Harness

Metal Connector Wiring

Harness

Power Wiring Harness

FIGURE 5 - REMOVING/INST ALLING CONTROLLER HARNESSES - PANTHER MX - 4

4242

PROCEDURE 7CONTROLLER

8. Connect the metal connectors of the power wiring harnesses to the metal connectors of the circuit breaker.

9. Connect the WHITE connector of the tiller wiring harness to the WHITE connector of the controller wiring harness

REPLACING CIRCUIT BREAKER (FIGURE 6)

Note: Note the proper positions of the metal connectors before removing for proper reinstallation.

1. Remove the RED and BLACK metal connectors of the power cables from the metal connectors of the circuit breaker.

2. Remove the nut and washer that secures the circuit breaker to the rear frame assembly.

3. Remove the washer from the circuit breaker.

4. Remove the circuit breaker.

5. Position the NEW circuit breaker so that it passes through the mounting hole in the rear frame assembly.

10. Reinstall the rear shroud. Refer to REMOVING/INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

11. Reinstall the seat. Refer to

REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

Nut

Washer

Rear

Frame

Assembly

Circuit

Breaker

Metal

Connectors

Red/Black Metal

Connectors

C O N T R O L L E R

6. Position the NEW washer on the circuit breaker.

7. Position the NEW nut on the end of the circuit

breaker and securely tighten.

NOTE: Be sure the metal connectors are positioned as noted above.

8. Connect the RED and BLACK connectors of the power cables to the metal connectors on the NEW circuit breaker as noted from STEP 1.

Power

Cables

FIGURE 6 - REPLACING CIRCUIT BREAKER

4343

REPLACEMENT PARTS - LYNX SX - 3PPROCEDURE 8

R E P L A C E

This Procedure Includes the Following:

Replacing Tiller Charge Port Cover

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may occur.

Tiller

Charger

Port Cover

Mounting

Holes

Self-locking

nuts

Turn Power OFF and remove key from igni-

P A

T S

tion. Disconnect battery harness from the motor lead.

RE PLACING TILLER CHARGER PORT COVER (FIGURE 1)

Mounting

Screws

Tiller

Assembly

FIGURE 1 - REPLACING TILLER CHARGER

PORT COVER

NOTE: Save the two (2) mounting screws and selflocking nuts for reuse when installing the NEW tiller charger port cover.

1. Remove the two (2) mounting screws and selflocking nuts securing the tiller charger port cover to the tiller assembly.

2. Remove the tiller charger port cover from the tiller

L Y N X

S X

assembly.

3. Align the mounting holes in the NEW tiller charger port cover with the mounting holes in the tiller assembly.

4. Secure the NEW tiller charger port cover to the tiller assembly using the two (2) EXISTING mount- ing screws and self-locking nuts. Securely tighten.

4444

PROCEDURE 9REPLACEMENT PARTS - LYNX LX - 3

This Procedure Includes the Following:

Removing/Installing Head light Assembly

W ARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may occur.

Turn Power OFF and remove key from ignition. Disconnect battery harness from the motor lead.

REMOVING/INSTALLING HEAD LIGHT ASSEMBLY (FIGURE 1)

Removing

NOTE: Partial disassembly of the tiller assembly is required to remove the head light assembly.

1. Perform SECTIONS “A” and “D” in REMOVING/ INSTALLING TILLER ASSEMBLY in PROCEDURE 3 of this manual.

Tiller

Wiring

Harness

Head

light

Assembly

Plastic

Red/

Guards

Black

Cables

Red/Black

Cables

Metal

Connectors

FIGURE 1 - REMOVING/INST ALLING HEAD

LIGHT ASSEMBL Y

R E P L A C E

E N T

P A R T S

2. Pull back the plastic guards on the RED and BLACK cables connecting the tiller wiring har-

ness to the head light assembly.

3. Disconnect the RED and BLACK cable metal connectors of the head light assembly from the RED and BLACK cable metal connectors of the tiller wiring harness.

4. Separate the head light assembly from the tiller wiring harness.

Installing

1. Connect the RED cable metal connector of the head light assembly to the RED cable metal connector of the tiller wiring harness.

2. Connect the BLACK cable metal connector of the head light assembly to the BLACK cable metal connector of the tiller wiring harness.

3. Reposition the plastic guards on the RED and BLACK cables connecting the tiller wiring harness to the head light assembly.

L Y N X

L X 3

4. Perform SECTIONS “D” and “A” in DURE 3 - REMOVING/INSTALLING TILLER ASSEMBLY in the TILLER section of this manual.

PROCE-

4545

PROCEDURE 10 REPLACEMENT PARTS - P ANTHER LX - 4

R E P

L A C E

E N

This Procedure Includes the Following:

Removing/Installing Head Light Assembly Replacing Tiller Charge Port Cover Replacing Cushion/Front Bumper Assembly

W ARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or

5. Reposition the plastic guards over the metal con-

nectors on the RED and BLACK cables connecting the tiller wiring harness to the head light assembly (DETAIL “A”).

6. Return the front frame assembly to the upright position.

damage may occur.

P A R

Turn Power OFF and remove key from ignition. Disconnect battery harness from the motor lead.

REMOVING/INSTALLING HEAD LIGHT ASSEMBLY (FIGURE 1)

Removing

1. Flip the scooter onto its side.

2. Pull back the plastic guards on the RED and

BLACK cables connecting the tiller wiring har-

P A

ness to the head light assembly (DETAIL “A”).

3. Disconnect the RED and BLACK cable metal

connectors of the head light assembly from the RED and BLACK cable metal connectors of the tiller wiring harness (DETAIL “A”).

4. Remove the bolt, self-locking nut, spring washer, and washer securing the head light assembly to

L X 4

the front frame assembly.

5. Separate the head light assembly from the front frame assembly.

Installing

1. Align the bolt in the head light assembly with the mounting holes in the front frame assembly.

To Head

Light

Assembly

Red/Black

Cables

Metal

Connectors

DETAIL “A”

Bolt

To Tiller

Wiring

Harness

Plastic

Guards

Head light Assembly

2. Secure the head light assembly to the front frame assembly using the washer, spring washer and self-locking nut. Securely tighten.

3. Connect the RED cable metal connector of the head light assembly to the RED cable metal connector of the tiller wiring harness (DETAIL “A”).

4. Connect the BLACK cable metal connector of the head light assembly to the BLACK cable metal connector of the tiller wiring harness (DETAIL “A”).

Front Frame

Assembly

Washer

Spring Washer

Self-locking nut

FIGURE 1 - REMOVING/INST ALLING HEAD

LIGHT ASSEMBL Y

4646

REPLACEMENT PARTS - PANTHER LX - 4 PROCEDURE 10

REPLACING TILLER CHARGER PORT COVER (FIGURE 2)

NOTE: Save the two (2) mounting screws and selflocking nuts for reuse when installing the NEW tiller charger port cover.

1. Remove the two (2) mounting screws and selflocking nuts securing the tiller charger port cover to the tiller assembly.

2. Remove the tiller charger port from the tiller assembly.

3. Align the mounting holes in the NEW tiller charger port cover with the mounting holes in the tiller assembly.

4. Secure the NEW tiller charger port cover to the tiller assembly using the two (2) EXISTING mount- ing screws and self-locking nuts. Securely tighten.

Mounting

Holes

Tiller

Charger

Port Cover

5. Secure the NEW cushion to the front frame assembly using the two (2) NEW mounting screws, spring washers and washers. Securely tighten.

6. Return the scooter to the upright position.

FRONT BUMPER (DETAIL “B”).

1. Grasp the front bumper firmly and pull it away from the front shroud assembly.

2. Position the mounting tape on the bottom of the front shroud assembly.

3. Position the NEW bumper on the mounting tape on the front shroud assembly.

Spring Washers

Washers

Front

Frame

Assembly

Mounting

Screws

R E P L A C E M E N T

P A R T S

Mounting

Screws

Tiller

Assembly

FIGURE 2 - REPLACING TILLER CHARGE

PORT COVER

REPLACING CUSHION/FRONT BUMPER ASSEMBLY (FIGURE 3)

Removing The Front Bumper Assembly

CUSHION (DETAIL “A”).

1. Position the scooter on its side.

2. Remove the two (2) mounting screws, spring washers and washers securing the cushion to the front frame assembly.

3. Remove the cushion from the front frame assembly

Cushion

DETAIL “A”

Front Shroud

Assembly

Mounting Tape

Front Bumper

DETAIL “B”

FIGURE 3 - REPLACING CUSHION/FRONT

BUMPER ASSEMBLY

P A N T H E R

L X

4. Align the two (2) mounting holes in the NEW cush- ion with the mounting holes in the front frame assembly.

4747

PROCEDURE 11 REPLACEMENT PARTS - PANTHER MX - 4

R E P L A C E

Removing/Installing Head Light Assembly Replacing Tail Light Assembly Replacing Tail Light Cable Replacing Disc Brake Assembly Replacing Disc Brake Shoes

This Procedure Includes the Following:

Replacing Hand Brake Assembly Rmoving/Installing Front Shock Absorbers Removing/Installing Rear Shock Absorbers

P A

8. Remove the two (2) self-locking nuts, three (3) washers, spring washer, spring and the long screw securing the bottom of the head light assembly to the bracket on the front frame assembly.

9. Remove the head light assembly from the front shroud assembly.

Installing

1. Position the head light assembly through the front shroud assembly so the mounting holes on the top and bottom of the head light assembly align with the mounting holes on the top and bottom of the front shroud assembly.

WARNING

T S

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may occur.

Turn Power OFF and remove key from ignition. Disconnect battery harness from the motor lead.

2. Position the long screw through the bottom hole in the front shroud assembly, making sure there is a washer on either side of the front shroud assembly.

3. Position one (1) nut on the long screw, so that it is flush against the washer on the inside of the front shroud assembly.

4. Position the long screw through the bottom hole on the head light assembly.

P A N T H E R

REMOVING/INSTALLING HEAD LIGHT ASSEMBLY (FIGURE 1)

Removing

1. Separate the front frame assembly from the rear frame assembly. Refer to TRANSPORTING THE SCOOTER in PROCEDURE 10 of the Owner’s Manual, part number 1090132.

2. Flip the front frame assembly onto its side.

3. Pull back the plastic guards on the RED and BLACK cables connecting the tiller wiring har-

ness to the head light assembly.

4. Disconnect the RED and BLACK cable metal connectors of the head light assembly from the RED and BLACK cable metal connectors of the tiller wiring harness.

5. Remove the two (2) screws, spring washers and washers securing the front bumper and rubber spacer onto the front shroud assembly.

6. Remove the front bumper and rubber spacer from the front shroud assembly.

7. Remove the screw, spring washer and washer from the plate securing the top of the head light assembly to the front shroud assembly.

NOTE: Before removing the mounting hardware from

5. Position the spring and one (1) washer on the

long screw so that the spring is between the head light assembly and the bracket on the front frame assembly.

6. Position the long screw so that it passes through the bracket on the front frame assembly.

7. Secure the long screw to the bracket assembly using one (1) spring washer and self-locking nut. Securely tighten.

8. Position the plate on the TOP of the head light assembly making sure the mounting holes in the plate lines up with the TOP mounting hole in the front shroud assembly.

9. Secure the plate to the front shroud assembly using one (1) screw, spring washer and washer. Securely tighten.

10. Connect the RED cable metal connector of the head light assembly in the RED cable metal connector of the tiller wiring harness.

11. Connect the BLACK cable metal connector of the head light assembly in the BLACK cable metal connector of the tiller wiring harness.

12. Reposition the plastic guards on the RED and BLACK cables connecting the tiller wiring harness to the head light assembly.

the long screw, be sure to take note of the proper position for each components.

4848

PROCEDURE 11REPLACEMENT PARTS - PANTHER MX - 4

13. Position the rubber spacer and the front bumper so that the mounting holes in the rubber spacer and the front bumper align with the mounting holes in the front shroud assembly.

14. Secure the rubber spacer and the front bumper to the front shroud assembly using the two (2) screws, spring washers and washers. Securely tighten.

Front Shroud Assembly

Washer

Screw

Rubber

Spacer

Front

Bumper

Washer

Long Screw

Spring

Washer

Washers

15. Return the front frame assembly to the upright position.

16. Reassemble the front frame assembly and the rear frame assembly. Refer to

TRANSPORTING THE SCOOTER in PROCEDURE 10 of the Owner’s Manual, part number 1090132.

Red/Black

Cables

Plastic

Guards

Spring

Washer

Bracket

Washer

Plate

Spring

Washer

Head light

Assembly

Self-locking

nut

Screws

Metal

Connectors

Red/Black

Cables

Spring

REMOVING, STEPS 7-8/

INST ALLING, STEPS 2-7

Tiller

Wiring

Harness

Self-

locking

nut

R E P L A C E M E N T

P A R T S

P A N T H E R

X 4

FIGURE 1 - REMOVING/INST ALLING HEAD LIGHT ASSEMBLY

4949

PROCEDURE 11 REPLACEMENT PARTS - PANTHER MX - 4

R E P

A C E

E N T

P A R T S

REPLACING TAIL LIGHT

Locking Tabs

(Squeeze Together)

ASSEMBLY (FIGURE 2)

INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

2. Disconnect the tail light assembly from the tail light

1. Remove the rear shroud. Refer to REMOVING/

cable by performing STEPS 2-3 in TAIL LIGHT CABLE in this procedure of this manual.

REPLACING

Steel Plate

3. From outside of the rear shroud, grasp the locking tabs on the back of the tail light assembly, and squeeze them together.

4. From outside of the rear shroud, slowly pull the tail light assembly and the rubber spacer through steel plate and the holes in the rear shroud.

5. Remove the steel plate from the inside of the rear

FIGURE 2 - REPLACING T AIL LIGHT

shroud.

6. Align the NEW tail light assembly with the hole in the rear shroud.

REPLACING TAIL LIGHT CABLES

Cables

ASSEMBL Y

Tail Light

Assembly

Rubber

Spacer

Rear Shroud

(FIGURE 3)

NOTE: To ensure the tail light assembly is installed securely, be sure to position the rubber spacer be-

P A N

T H E R

tween the OUTSIDE of the rear shroud and the tail light assembly.

7. Push the locking tabs of the NEW tail light as-

sembly through the rubber spacer and through the hole in the rear shroud until the they “snap” into place.

8. Thread the cables of the NEW tail light assembly

through the NEW steel plate, and position the NEW steel plate over the locking tabs on the NEW

tail light assembly

9. Connect the tail light assembly to the tail light cable by performing STEPS 6-8 in

REPLACING TAIL LIGHT CABLE in this procedure of this manual.

10. Reinstall the rear shroud. Refer to

REMOVING/INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

1. Remove the rear shroud. Refer to REMOVING/ INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

2. Pull back the plastic guards on the RED and BLACK cables connecting the tail light cable to the tail light assembly.

3. Remove the RED and BLACK cable metal con- nectors of the tail light assembly from the RED and BLACK cable metal connectors of the tail light cable.

4. Remove the tail light cable.

5. Position the RED cable connector of the NEW tail light assembly in the RED cable metal connector of the of the tail light cable.

6. Position the BLACK cable connector of the NEW tail light assembly in the BLACK cable metal connector of the of the tail light cable.

7. Reposition the plastic guards on the RED and BLACK cables connecting the NEW tail light cable to the tail light assembly.

8. Reinstall the rear shroud. Refer to

REMOVING/ INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

5050

PROCEDURE 11REPLACEMENT PARTS - PANTHER MX - 4

Plastic

Guards

Assembly

Red And Black

Cables

Tail Light

Cable

Metal

Connectors

Tail Light

Rear Shroud

FIGURE 3 - REPLACING T AIL LIGHT CABLES

REPLACING DISC BRAKE ASSEMBLY (FIGURE 4)

Removing The Disc Brake Assembly

8. Secure the NEW disc brake assembly to the transaxle assembly using the four (4) NEW hex cap screws and spring washers. Torque the hex cap screws between 43 - 61 in./lbs.

9. Reconnect the hand brake cable assembly. Re-

REMOVING/INSTALLING TILLER AS-

fer to SEMBLY, SECTION “B” - DISCONNECTING/ CONNECTING HAND BRAKE CABLE ASSEMBLY in PROCEDURE 4 of this manual.

10. Reinstall the rear wheels. Refer to

REMOVING/INSTALLING THE REAR WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

11. Reinstall the rear shroud. Refer to

REMOVING/INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

12. Reinstall the seat. Refer to

REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

R E P L A C E

E N T

P A R T S

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

2. Remove the rear shroud. Refer to

REMOVING/INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

3. Remove the rear wheels. Refer to

REMOVING/INSTALLING THE REAR WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

4. Disconnect the hand brake cable assembly. Refer to

REMOVING/INSTALLING TILLER ASSEMBLY, SECTION “B” - DISCONNECTING/ CONNECTING HAND BRAKE CABLE ASSEMBLY in PROCEDURE 4 of this manual.

5. Remove the four (4) hex - cap screws and spring

washers securing the disc brake assembly to the transaxle assembly.

6. Remove the disc brake assembly.

7. Align the NEW disc brake assembly with the

mounting holes in the transaxle assembly.

Spring

Washers

Hex

Cap

Screws

Transaxle Assembly

Spring

Washers

Disc Brake

Assembly

FIGURE 4 - REPLACING DISC BRAKE

ASSEMBL Y

REPLACING DISC BRAKE SHOES (FIGURE 5)

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

P A N T H E R

CAUTION

DO NOT overtighten the four (4) hex cap screws securing the disc brake assembly to the transaxle assembly. Otherwise, damage to the disc brake assembly may occur.

2. Remove the rear shroud. Refer to INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

3. Remove the rear wheels. Refer to INSTALLING THE REAR WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

5151

REMOVING/

PROCEDURE 11 REPLACEMENT PARTS - PANTHER MX - 4

P A N

H E R

4. Disconnect the hand brake cable assembly. ReREMOVING/INSTALLING TILLER AS-

fer to

E P L A

SEMBLY, SECTION “B” - DISCONNECTING/ CONNECTING HAND BRAKE CABLE ASSEMBLY in PROCEDURE 4 of this manual.

5. Remove the self-locking nut and washer secur-

ing the brake arm to the cam.

NOTE: Save the spring for reuse when installing the NEW disc brake shoes.

6. Remove the spring securing the two (2) disc brake

shoes to the brake disc.

P A

7. Remove the two (2) disc brake shoes.

8. Position the two (2) NEW disc brake shoes on

T S

the disc brake and around the cam.

9. Secure the NEW disc brake shoes to the disc

brake using the EXISTING spring.

10. Position the brake arm so the two (2) mounting

holes in the brake arm align with the cam.

CAUTION

DO NOT overtighten the self locking nut securing the brake arm to the cam. Otherwise, damage to the brake arm may occur.

11. Secure the brake arm to the cam using the EX-

ISTING self-locking nut and washer. Torque the

self-locking nut between 86 - 122 in./lbs.

12. Reconnect the hand brake cable assembly. ReREMOVING/INSTALLING TILLER AS-

fer to SEMBLY, SECTION “B” - DISCONNECTING/ CONNECTING HAND BRAKE CABLE ASSEMBLY in PROCEDURE 4 of this manual.

13. Reinstall the rear wheels. Refer to

REMOVING/INSTALLING THE REAR WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

14. Reinstall the rear shroud. Refer to

REMOVING/INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

15. Reinstall the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

REPLACING HAND BRAKE ASSEMBLY (FIGURE 6)

1. Remove the bolt securing hand brake assembly to the handle bar. Refer to DETAIL “A”.

2. Unscrew the adjusting nut from the cable lock and hand brake assembly. Refer to DETAIL “B”.

3. Align the slit in the cable lock with the brake cable, and remove the cable lock. Refer to DETAIL “C”.

4. Align the slit in the adjusting nut with the brake cable, and remove the adjusting nut. Refer to DETAIL “C”.

NOTE: Note the position of the the hand brake assembly before removing for proper reinstallation.

5. Slide the hand brake assembly toward the tiller until there is slack in the brake cable.

6. Maneuver the brake cable through the two (2) slits in the hand brake assembly until the brake cable is free from the hand brake assembly (DETAIL “D”).

7. Remove the hand brake assembly from the handle bar.

8. Position the NEW hand brake assembly onto the handle bar.

NOTE: In order to perform the next step, the NEW hand brake assembly should be positioned close enough to the tiller so that there is approximately two (2) inches of slack in the brake cable.

9. Maneuver the brake cable through the two slits in the NEW hand brake assembly, making sure the ball at the end of the brake cable is in the proper position in the brake housing. Refer to DETAIL “D”.

10. Slide the NEW hand brake assembly away from the tiller, until it is in the original mounting position.

Disc Brake Shoes

Spring

Cam

Brake Arm

Disc Brake

Washer

Self-locking nut

FIGURE 5 - REPLACING DISC BRAKE ASSEMBL Y

11. Align the slit in the NEW adjusting nut with the brake cable, and position the NEW adjusting nut on the brake cable. Refer to DETAIL “C”.

12. Align the slit in the NEW cable lock with the brake cable, and position the NEW cable lock on the brake cable. Refer to DETAIL “C”.

13. Screw the NEW cable lock into the NEW adjust- ing nut and hand brake assembly. Refer to DETAIL “B”. Securely tighten.

5252

REPLACEMENT PARTS - PANTHER MX - 4 PROCEDURE 1 1

14. Install the NEW bolt securing the NEW hand

brake assembly to the handle bar. Refer to DETAIL “A”. Securely tighten.

Hand

Brake

Assembly

Handle

Bar

Bolt

DETAIL “A”

Hand

Adjusting Nut

Brake

Assembly

REMOVING/INSTALLING FRONT SHOCK ABSORBERS (FIGURE 7)

Removing

1. Separate the front frame assembly from the rear frame assembly. Refer to TRANSPORTING THE SCOOTER in PROCEDURE 10 of the Owner’s Manual, part number 1090132.

2. Remove the front wheels. Refer to STALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

3. Flip the front frame assembly onto its side.

4. Remove the TOP bolt on the right front shock absorber.

5. Remove the BOTTOM bolt on the right front shock absorber.

6. Slide the right front shock absorber away from the front frame assembly.

7. If necessary, repeat this procedure for the other front shock absorber.

REMOVING/IN-

R E P L A C E

E N T

P A R T S

Cable Lock

DETAIL “B”

Brake Cable

Slit In

Cable

Lock

Slit In

Adjusting

Nut

DETAIL “C”

Brake Cable

Hand

Brake

Assembly

Slits

DETAIL “D”

FIGURE 6 - REPLACING HAND BRAKE

ASSEMBL Y

Installing

1. Slide the right front shock absorber onto the front frame assembly, aligning the mounting hole in the bottom of the right front shock absorber with the mounting holes in the tie rod assembly.

CAUTION

DO NOT overtighten the bolt securing the right front shock absorber to the tie rod assembly. Otherwise, damage to the right front shock absorber may occur.

2. Install one (1) bolt through the BOTTOM mount- ing hole in the right front shock absorber and the BOTTOM mounting holes in the tie rod assembly. Torque the hex cap screws between 122 - 148 in./lbs.

3. Align the mounting hole in the TOP of the right front shock absorber with the mounting holes in the front frame.

CAUTION

DO NOT overtighten the bolt securing the right front shock absorber to the fr ont frame assembly. Otherwise, damage to the right front shock absorber may occur.

4. Install one (1) bolt through the TOP mounting hole of the right front shock absorber and the TOP mounting holes in the front frame assembly. Torque the hex cap screws between 122 - 148 in./lbs.

5353

P A N T H E R

PROCEDURE 11 REPLACEMENT PARTS - PANTHER MX - 4

R E P L A C E

E N T

P A R T S

P A

X 4

5. If necessary, repeat this procedure for the other front shock absorber.

6. Return the front frame assembly to the upright position.

7. Reinstall the front wheels. Refer to

REMOVING/ INSTALLING THE FRONT WHEELS in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

8. Reassemble the front frame assembly and the rear frame assembly. Refer to

TRANSPORTING THE SCOOTER in PROCEDURE 10 of the Owner’s Manual, part number 1090132.

Mounting Holes

Top Bolt

Front Shock

Absorber

Bottom Bolt

Tie Rod

Assembly

Front Frame

Assembly

Mounting Holes

FIGURE 7 - REMOVING/INST ALLING FRONT

SHOCK ABSORBER

REMOVING/INSTALLING REAR SHOCK ABSORBERS (FIGURE 8)

Removing

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

2. Remove the rear shroud. Refer to INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

3. Remove the TOP bolt on the right rear shock absorber.

REMOVING/

Installing

NOTE: When installing the bolts for the rear shock absorber, the T OP and BOTTOM bolts should be facing opposite directions.

1. Slide the right rear shock absorber onto the rear frame assembly, aligning the mounting hole in the BOTTOM of the right rear shock absorber with the mounting holes in the rear frame assembly.

CAUTION

DO NOT overtighten the bolt securing the right rear shock absorber to the rearframe assembly. Otherwise, damage to the right rear shock absorber may occur.

2. Install one (1) bolt through the BOTTOM mount- ing hole in the right rear shock absorber and the BOTTOM mounting holes in the rear frame assembly, making sure the bolt is facing AWAY from the controller. Torque the hex cap screws between 122 - 148 in./lbs.

3. Align the mounting hole in the TOP of the right rear shock absorber with the mounting holes in the rear frame.

CAUTION

DO NOT overtighten the bolt securing the right rear shock absorber to the rear frame assembly. Otherwise, damage to the right rear shock absorber may occur.

4. Install one (1) bolt through the TOP mounting hole in the right rear shock absorber and the TOP mounting holes in the rear frame assembly, making sure the bolt is facing TOW ARD the controller. Torque the hex cap screws between 122 148 in./lbs.

5. Repeat this procedure for the other rear shock absorber.

6. Reinstall the rear shroud. Refer to INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

7. Reinstall the seat. Refer to STALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

REMOVING/

REMOVING/IN-

4. Remove the BOTTOM bolt on the right rear shock

absorber.

5. Slide the right rear shock absorber away from the rear frame.

6. If necessary, repeat this process for the other rear shock absorber.

5454

REPLACEMENT PARTS - PANTHER MX - 4 PROCEDURE 1 1

Top

Bolt

Rear

Shock

Bottom

Absorber

Bolt

Rear Frame

Assembly

FIGURE 8 - REMOVING/INST ALLING REAR

SHOCK ABSORBER

R E P L A C E

E N T

P A R T S

P A N T H E R

55555555

PROCEDURE 12 OPTIONS

This Procedure Includes the Following:

Preparing the Scooter for Left Hand Operation

P T

N S

After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may occur.

Turn Power OFF and remove key from ignition. Disconnect battery harness from the motor lead.

WARNING

PREPARING THE SCOOTER FOR LEFT HAND OPERATION (FIGURE 1)

1. Remove the seat. Refer to REMOVING/INSTALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

2. Remove the rear shroud. Refer to STALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number 1090132.

REMOVING/IN-

8. While perfoming STEP 7, pull the YELLOW wire out from the back of the YELLOW or WHITE connector (depending on scooter model) of the tiller wiring harness.

9. Repeat STEPS 5-8 for the ORANGE wire coming out of the rear of the YELLOW or WHITE connector (depending on scooter model) of the tiller wiring harness.

10. Align the MALE pin of the YELLOW wire with the slot formerly occupied by the MALE pin of the ORANGE wire in the REAR of the YELLOW or WHITE connector (depending on scooter model) of the tiller wiring harness.

11. Push the MALE pin of the YELLOW wire forward through the slot until it “clicks” into place.

12. Repeat STEPS 10-11 to position the MALE pin of the ORANGE wire into the slot fromerly occupied by the MALE pin of YELLOW wire.

NOTE: WHEN the YELLOW or WHITE connector (depending on scooter model) of the tiller wiring harness and the YELLOW or WHITE connector (depending on scooter model) of the controller wiring harness are reconnected, the mating of the wires

3. Remove the batteries. Refer to STALLING BATTERIES WITH CABLES in PROCEDURE 4 of the Owner’s Manual, part number

1090132.

4. Peform one (1) of the following: ALL models EXCEPT the P ANTHER MX - 4 -

A. Disconnect the YELLOW connector of the

tiller wiring harness from the YELLOW connector of the controller wiring harness.

P ANTHER MX - 4 A. Disconnect the WHITE connector of the tiller

wiring harness from the WHITE connector of the controller wiring harness.

B. Gently pull open the hinged strain relief on

the rear of the WHITE connector of the tiller wiring harness.

5. Locate the YELLOW wire coming out of the rear of the YELLOW or WHITE connector (depending on scooter model) of the tiller wiring harness.

6. Insert a small, pointed tool into the FRONT of the YELLOW or WHITE connector (depending on scooter model) of the tiller wiring harness, directly under the MALE pin of the YELLOW wire.

7. Push up on and hold the plastic tang under the male pin of the YELLOW wire.

REMOVING IN-

coming out of the rear of the connectors should be YELLOW to ORANGE.

13. Perform one (1) of the following:

ALL models EXCEPT the P ANTHER MX - 4 A. Reconnect the YELLOW connector of the

tiller wiring harness to the YELLOW connector of the controller wiring harness.

P ANTHER MX - 4 A. Gently close the hinged strain relief on the

rear of the WHITE connector of the tiller wiring harness.

B. Reconnect the WHITE connector of the tiller

wiring harness to the WHITE connector of the controller wiring harness.

14. Reinstall the batteries. Refer to STALLING BATTERIES WITH CABLES in PROCEDURE 4 of the Owner’s Manual, part number

1090132.

15. Reinstall the rear shroud. Refer to INSTALLING THE REAR SHROUD in PROCEDURE 9 of the Owner’s Manual, part number

1090132.

16. Reinstall the seat. Refer to STALLING THE SEAT in PROCEDURE 5 of the Owner’s Manual, part number 1090132.

REMOVING IN-

REMOVING/

REMOVING/IN-

5656

OPTIONS PROCEDURE 12

17. Position the NEW Forward/Reverse sticker OVER the EXISTING Forward/Reverse sticker on the control panel (DETAIL “A”).

(ALL MODELS EXCEPT THE PANTHER MX - 4)

Yellow Connectors -

Controller Wiring

Harness

Yellow Connectors -

Tiller Wiring Harness

(P ANTHER MX - 4)

White Connector -

Tiller Wiring Harness

NOTE: The NEW Forward/Reverse sticker is also available as a purchase part.

Yellow Wire

Male Pin

Plastic Tang

Front

Yellow Connectors -

Tiller Wiring Harness

P T

N S

White Connector -

Controller Wiring

Harness

Hinged Strain

Relief

REAR

White Connector -

Tiller Wiring Harness

Yellow Wire

NEW Forward/

Reverse Sticker

Male Pin

Front

Plastic Tang

Position Here

EXISTING Forward/

Reverse Sticker

DETAIL “A”

FIGURE 1 - PREPARING THE SCOOTER FOR LEFT HAND OPERATION

Control Panel

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NOTES

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T E S

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WARRANTY

LIMITED WARRANTY

PLEASE NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE TO PRODUCTS MANUFACTURED AFTER JULY 4, 1975.

This warranty is extended only to the original purchaser/user of our products. This warranty gives you specific legal rights and you may also have other legal rights which vary

from state to state. Invacare warrants this product to be free from defects in materials and workmanship for a period

of eighteen (18) months on electrical and transaxle and three (3) years on frame from date of purchase. If within such warranty period any such product shall be pr oven to be defective, such product shall be repaired or replaced at Invacare's option. This warranty does not include any labor or shipping charges incurred in replacement part installation or repair of any such product. Invacare’s sole obligation and your exclusive r emedy under this warranty shall be limited to such repair and/or replacement.

For warranty service, please contact the dealer from whom you purchased your Invacar e product. In the event you do not receive satisfactory warranty service, please write directly to Invacare on the back cover, provide dealer’s name, address, date of purchase, indicate nature of the defect and, if the product is serialized, indicate the serial number. Do not return products to our factory without our prior consent.

A R R A N T Y

LIMITATIONS AND EXCLUSIONS: THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL NUMBERED PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEF ACED, PRODUCTS SUBJECTED TO NEGLIGENCE, ACCIDENT, IMPROPER OPERATION, MAINTENANCE OR STORAGE, PRODUCTS MODIFIED WITHOUT INVACARE’S EXPRESS WRITTEN CONSENT (INCLUDING, BUT NOT LIMITED TO, MODIFICA TION THROUGH THE USE OF UNAUTHORIZED PARTS OR A TT ACHMENTS; PRODUCTS DAMAGED BY REASON OF REPAIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC CONSENT OF INVACARE, OR TO A PRODUCT DAMAGED BY CIRCUMSTANCES BEYOND INVACARE’S CONTROL, AND SUCH EVALUATION WILL BE SOLELY DETERMINED BY INVACARE. THE WARRANTY SHALL NOT APPLY TO PROBLEMS ARISING FROM NORMAL WEAR OR FAILURE TO ADHERE TO THE THESE INSTRUCTIONS.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, IF ANY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P ARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE DURATION OF THE EXPRESSED WARRANTY PROVIDED HEREIN AND THE REMEDY FOR VIOLATIONS OF ANY IMPLIED WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT PURSUANT TO THE TERMS CONT AINED HEREIN. INVACARE SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES WHATSOEVER.

THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE/PROVINCIAL LAWS AND REQUIREMENTS.

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Invacare Corporation www.invacare.com

USA Canada

One Invacare Way 5970 Chedworth Way Invacare is a registered trademark of Invacare Corporation. Elyria, Ohio USA Mississauga, Ontario © 44036-2125 L5R 3T9, Canada

1999 Invacare Corporation

800-333-6900 905-890-8838 Form No. 99-188 Part No. 1091860 Rev C (1) 02/00

Invacare SX-3P, LX-3, SX-3, MX-4, LX-4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual