Service Manual
TM
LYNX /PANTHERTM
SERIES SCOOTERS
LYNX SX-3P
LYNX SX-3
LYNX LX-3
LYNX LX-3Plus
PANTHER LX-4
PANTHER MX-4
DEALER: KEEP THIS MANUAL.THE PROCEDURES
IN THIS MANUAL MUST BE PERFORMED BY AN
AUTHORIZED DEALER ONLY.
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TABLE OF CONTENTS
TABLE OF CONTENTS
NOTE: The procedures in this manual pertain to all five (5) scooter models EXCEPT where specified.
T
A
B
L
WARNING/SPECIAL NOTES .................. 2 PROCEDURE 7 - CONTROLLER ...........37
REMOVING/INSTALLING
CONTROLLER................................37
REMOVING/INSTALLING
CONTROLLER HARNESSES ..........39
REPLACING CIRCUIT BREAKER ......43
E
SPECIFICATIONS................................... 4
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PROCEDURE 1 - GENERAL GUIDELINES5
OPERATINGINFORMATION ................ 5
WARNING/CAUTIONLABEL
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LOCATION ....................................... 7
PROCEDURE 8 - REPLACEMENT
PARTS - LYNX SX - 3P .........................44
REPLACINGTILLERCHARGER
PROCEDURE 2 - SAFETY INSPECTION
MAINTENANCE/TROUBLESHOOTING. 8
SAFETYINSPECTIONCHECKLIST ...... 8
MAINTENANCE .................................. 9
LUBRICATIONPOINTS .....................10
PORT COVER ................................44
S
PROCEDURE 9 - REPLACEMENT
PARTS - LYNX - LX 3 ...........................45
REMOVING/INSTALLINGHEAD
PROCEDURE 3 - SEAT ......................... 11
REPLACINGSEATPOST ................... 11
LIGHT ASSEMBLY ..........................45
PROCEDURE 4 - TILLER.......................12
REPLACINGHANDGRIPS .................12
REPLACINGLEDCANOPY ................12
REPLACINGTHROTTLELEVER ........12
REMOVING/INSTALLINGTILLER
PROCEDURE 10 - REPLACEMENT
PARTS - PANTHER LX - 4 ....................46
REMOVING/INSTALLINGHEAD
LIGHT ASSEMBLY ............................46
REPLACING TILLER CHARGER PORT
COVER...........................................47
REPLACING CUSHION/FRONT
ASSEMBLY .....................................13
REMOVING/INSTALLING BOOT ........19
BUMPER ASSEMBLY......................47
PROCEDURE 5 - SHROUD/FORK/
WHEELS/TIE RODS ............................20
REPLACINGTIREANDTUBE .............20
REMOVING/INSTALLINGFRONT
SHROUD ASSEMBLY .....................20
REMOVING/INSTALLING FORK
WITH BEARING ASSEMBLY ...........22
REMOVING/INSTALLING FRONT
AXLE ASSEMBLY ...........................23
REPLACING TIE ROD ASSEMBLY ......25
REMOVING/INSTALLING SMALL
PROCEDURE 11 - REPLACEMENT
PARTS - PANTHER MX - 4 ...................48
REMOVING/INSTALLINGHEAD
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
TIE RODS .......................................28
REMOVING/INSTALLING LARGE
TIE RODS .......................................30
PROCEDURE 6 - TRANSAXLE/MOTOR/
BRAKE ...............................................32
REMOVING/INSTALLING
SHOCK ABSORBERS .....................54
PROCEDURE 12 - OPTIONS .................56
PREPARINGTHESCOOTERFOR
TRANSAXLE ASSEMBLY ................32
REPLACING MOTOR/BRAKE
ASSEMBLY .....................................35
REPLACING BRAKE RELEASE
LEFT HAND OPERATION ................48
NOTES..................................................58
WARRANTY ..........................................59
LEVER ASSEMBLY .........................36
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SPECIFICATIONS
SX-3P
SPECIFICATIONS
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LYNX (3-Wheel Models)
PANTHER (4-Wheel Models)
SX-3
LX-3
LX-3Plus
LX-4
MX- 4
Overall Length: 43.5-inches(104cm) 43.5-inches(104cm) 47-inches(119cm) 47-inches(119cm) 47.5-inches(125cm) 54-inches(137cm)
Overall Width: 23-inches (58cm) 23-inches(58cm) 25-inches(64cm) 25-inches(64cm) 25-inches(64cm) 26-inches(66cm)
Ground
Clearance:
3.5-inches(8.89cm)3.5-inches(8.89cm) 3-inches(7.62cm) 3-inches(7.62cm) 3.25-inches(8.26cm) 6-inches(15.24cm)
Seat Height
FromFloorPan:
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
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)
O
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Deluxe Seat:
N/A
N/A
15-inches(38cm) 15-inches(38cm) 16-1/2-inches(42cm) 17-inches(43cm)
16-inches(41cm) 16-inches(41cm) 17-1/2-inches(44cm) 18-inches(46cm)
17-inches(43cm) 17-inches(43cm) 18-1/2-inches(47cm) 19-inches(48cm)
18-inches(46cm) 18-inches(46cm) 19-1/2-inches(49cm)
Armpad to
Floor:
Fixed: 21-1/2-inches(55cm) 21-1/2-inches(55cm) 21-1/2-inches(55cm) 21-1/2-inches(55cm) 23-inches(58cm)
u22-1/2-inches(57cm) u22-1/2-inches(57cm)
N/A
Adjustable:
N/A
N/A
21-inches(53cm) 21-inches(53cm) 22-1/2-inches(57cm) 21-inches(53cm)
22-inches(56cm) 22-inches(56cm) 23-1/2-inches(60cm) 22-inches(56cm)
23-inches(58cm) 23-inches(58cm) 24-1/2-inches(62cm) 23-inches(58cm)
24-inches(61cm) 24-inches(61cm) 25-1/2-inches(65cm) 24-inches(61cm)
Weights:
Front Frame
Section:
RearFrame
Section:
Contour Seat
w/arms
Deluxe Seat
w/Arms
31-lbs (14 kg)
39 -lbs (17 Kg)
47 -lbs (21 kg)
47 -lbs (21 kg)
48 -lbs (22 kg)
39 -lbs (18 kg) 58 -lbs (26 kg)
N/A N/A
35 -lbs (16 kg) 43 -lbs (19 kg)
75 -lbs (34 kg)
35 -lbs (16 kg) 35 -lbs (16 kg)
22 -lbs (10 kg) 22 -lbs (10 kg)
38 -lbs (17 kg) 38 -lbs (17 kg)
22 -lbs (10 kg) 22 -lbs (10 kg)
N/A
2-lbs (1 kg)
N/A
2-lbs (1 kg)
14 -lbs (6 kg)
31-lbs (14 kg)
3 -lbs ( 1 kg)
23 -lbs (10 kg) 23 -lbs (10 kg)
31-lbs (14 kg)
3 -lbs ( 1 kg)
Rear Shroud
Batteries:(each) 14 -lbs (6 kg)
2 -lbs (1 kg)
4 -lbs (2 kg)
31-lbs (14 kg)
23-lbs (10 kg)
Total Weight
of Scooter
w/o Batteries: 90-lbs (41 kg)
98-lbs (44 kg)
*110-lbs (50kg)
*110-lbs (50kg)
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)
vWheel Size
Front:
Rear:
2 x 8-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) (10.16x33.02cm)
2-1/2x9-inches 2-1/2x9-inches 3x10-inches 3x10-inches 3x10-inches 4x13-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
(6.35x22.86cm) (6.35x22.86cm) (7.62x25.40cm) (7.62x25.40cm) (7.62x25.40cm) (10.16x33.02cm)
Max. Weight
Limitation:
250 lbs (114kg) 250lbs (114 kg ) 300lbs (136 kg ) 300lbs (136 kg ) 300 lbs (136 kg ) 400lbs (181kg)
LOW
HIGH
Maximum
Speed:
4-1/2 M.P.H.
7-1/4K.P.H.
4-1/2 M.P.H.
7-1/4 K.P.H
5 M.P.H.
8 K.P.H
5 M.P.H.
8 K.P.H
5-1/2 M.P.H. 5¼ M.P.H. 7¼ M.P.H.
9 K.P.H
8½ K.P.H 11¾ K.P.H
Max. Incline
and Stability:
o
o
o
o
o
o
8 incline
8 incline
8 incline
8 incline
8 incline
8 incline
uNOTE: with Optional Deluxe Seat.
*NOTE:TotalweightofscooterincludesContourSeat
Only. Add an additional 9-lbs for Deluxe Seat.
vNOTE: Flat free inserts are standard on all wheels.
4
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GENERAL GUIDELINES
PROCEDURE 1
This Procedure Includes the Following:
Operating Information
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Warning/Caution Label Location
OPERATING INFORMATION
GENERAL WARNINGS
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Pe rform a nc e a d justm e nts should ONLY b e m a d e b y p rofe ssiona ls of the he a lthc a re
fie ld o r p e rso ns fully c o nve rsa nt with this p ro c e ss a nd the d rive r's c a p a b ilitie s.
Inc o rre c t se tting s c o uld c a use injury to the d rive r, b ysta nd e rs, d a m a g e to the
p o we re d sc o o te r a nd surro und ing p ro p e rty.
DO NOT use pa rts, a c c e ssorie s, or a da pte rs othe r tha n those a uthorize d by Inva c a re .
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ELEC TRIC AL
Che c k to e nsure tha t a ll e le c tric a l c o nne c tio ns a re se c ure a t a ll tim e s.
Gro und ing Instruc tio ns:
DO NOT, unde r a ny c irc umsta nc e s, c ut or re move the round grounding prong from a ny
plug. Some de vic e s a re e quippe d with thre e -prong (grounding) plugs for prote c tion
a ga inst possible shoc k ha za rds. Whe re a two-prong wa ll re c e pta c le is e nc ounte re d, it
is the pe rsona l re sponsibility a nd obliga tion of the c ustom e r to c onta c t a qua lifie d
e le c tric ia n a nd ha ve the two-prong re c e pta c le re pla c e d with a prope rly grounde d
thre e -prong wa ll re c e pta c le in a c c orda nc e with the Na tiona l Ele c tric a l Code . If you
must use a n e xte nsion c ord, use ONLY a thre e -wire e xte nsion c ord ha ving the sa me or
highe r e le c tric a l ra ting a s the de vic e be ing c onne c te d.
BATTERIES
Only d e e p c yc le , se a le d c a se c onstruc tion b a tte rie s should b e use d in this d e vic e .
Ca re fully re a d b a tte ry/ ba tte ry c ha rg e r inform a tion p rior to insta lling , se rvic ing or op-
e ra ting your p owe re d sc oote r. In a d d ition, Inva c a re ha s p la c e d WARNING TAGS on
ba tte rie s a nd IDENTIFICATIONS TAGS on ba tte ry c a ble s. DO NOT re move the se ta gs.
EMI WARNING S
CAUTION: IT IS VERY IMPORTANT THAT YOU READ THIS INFORMATION REGARDING THE
POSSIBLE EFFECTS OF ELECTROMAGNETIC INTERFERENCE ON YOUR POWERED SCOOTER.
Ele c tro m a g ne tic Inte rfe re nc e EMI Fro m Ra d io Wa ve so urc e s.
Powe re d sc oote rs m a y b e susc e p tib le to e le c trom a g ne tic inte rfe re nc e (EMI), whic h
is inte rfe ring e le c trom a g ne tic e ne rg y (EM) e m itte d from sourc e s suc h a s ra d io
sta tions, TV sta tions, a m a te ur ra d io (HAM) tra nsm itte rs, two wa y ra d ios, a nd c e llula r
phone s. The inte rfe re nc e (from ra dio wa ve sourc e s) c a n c a use the powe re d sc oote r
to re le a se its b ra ke s, m ove b y itse lf, or m ove in uninte nd e d d ire c tions. It c a n a lso
p e rm a ne ntly d a m a g e the p owe re d sc oote r's c ontrol syste m . The inte nsity of the
inte rfe ring EM e ne rg y c a n b e m e a sure d in volts p e r m e te r (V/ m ). Ea c h p owe re d
sc oote r c a n re sist EMI up to a c e rta in inte nsity. This is c a lle d its "im m unity le ve l." The
highe r the immunity le ve l, the gre a te r the prote c tion. At this time , c urre nt te c hnology
is c a p a b le of a c hie ving a t le a st a 20 V/ m im m unity le ve l, whic h would p rovid e
use ful p rote c tion from the m ore c om m on sourc e s of ra d ia te d EMI.
The re a re a num b e r o f so urc e s o f re la tive ly inte nse e le c tro m a g ne tic fie ld s in the
e ve ryd a y e nviro nm e nt. So m e o f the se so urc e s a re o b vio us a nd e a sy to a vo id .
Othe rs a re no t a p p a re nt a nd e xp o sure is una vo id a b le . Ho we ve r, we b e lie ve
tha t b y fo llo wing the wa rning s liste d , yo ur risk to EMI will b e m inim ize d .
5
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PROCEDURE 1
GENERAL GUIDELINES
EMI WARNING S (C O NTINUED)
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The so urc e s o f ra d ia te d EMI c a n b e b ro a d ly c la ssifie d into thre e typ e s:
1) Ha nd-he ld Porta ble tra nsc e ive rs (tra nsmitte rs-re c e ive rs with the a nte nna mounte d
d ire c tly on the tra nsm itting unit. Exa m p le s inc lud e : c itize ns b a nd (CB) ra d ios,
"wa lkie ta lkie ," se c urity, fire , a nd p olic e tra nsc e ive rs, c e llula r te le p hone s, a nd
othe r p e rsona l c om m unic a tion d e vic e s. **NOTE: Som e c e llula r te le p hone s a nd
simila r de vic e s tra nsmit signa ls while the y a re ON, e ve n whe n not be ing use d;
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2) Me d ium -ra ng e m o b ile tra nsc e ive rs, suc h a s tho se use d in p o lic e c a rs, fire
truc ks, a m b ula nc e s, a nd ta xis. The se usua lly ha ve the a nte nna m o unte d o n
the o utsid e o f the ve hic le ; a nd
3) Long-ra nge tra nsm itte rs a nd tra nsc e ive rs, suc h a s c om m e rc ia l broa dc a st tra ns-
m itte rs (ra d io a nd TV b roa d c a st a nte nna towe rs) a nd a m a te ur (HAM) ra d ios.
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NOTE: Othe r type s of ha nd-he ld de vic e s, suc h a s c ordle ss phone s, la ptop c ompute rs,
AM/ FM ra d ios, TV se ts, CD p la ye rs, c a sse tte p la ye rs, a nd sm a ll a p p lia nc e s, suc h a s
e le c tric sha ve rs a nd ha ir d rye rs, so fa r a s we know, a re not like ly to c a use EMI
p rob le m s to your p owe re d sc oote r.
Po we re d Sc o o te r Ele c tro m a g ne tic Inte rfe re nc e (EMI)
Be c a use EM e ne rg y ra p id ly b e c o m e s m o re inte nse a s o ne m o ve s c lo se r to the
tra nsm itting a nte nna (so urc e ), the EM fie ld s fro m ha nd -he ld ra d io wa ve so urc e s
(tra nsc e ive rs) a re o f sp e c ia l c o nc e rn. It is p o ssib le to uninte ntio na lly b ring hig h
le ve ls o f EM e ne rg y ve ry c lo se to the p o we re d sc o o te r's c o ntro l syste m while
using the se d e vic e s. This c a n a ffe c t p o we re d sc o o te r m o ve m e nt a nd b ra king .
The re fo re , the wa rning s liste d a re re c o m m e nd e d to p re ve nt p o ssib le inte rfe re nc e
with the c o ntro l syste m o f the p o we re d sc o o te r.
Ele c troma gne tic inte rfe re nc e (EMI) from sourc e s suc h a s ra dio a nd TV sta tions, a ma -
te ur ra d io (HAM) tra nsm itte rs, two-wa y ra d ios, a nd c e llula r p hone s c a n a ffe c t p ow-
e re d sc oote rs. Following the wa rnings liste d should re duc e the c ha nc e of uninte nde d
bra ke re le a se or powe re d sc oote r m ove m e nt whic h c ould re sult in se rious injury.
1) Do no t o p e ra te ha nd -he ld tra nsc e ive rs (tra nsm itte rs re c e ive rs), suc h a s c iti-
ze ns b a nd (CB ra d ios, or turn ON p e rsona l c om m unic a tion d e vic e s, suc h a s
c e llula r p ho ne s, while the p o we re d sc o o te r is turne d ON;
2) Be a wa re o f ne a rb y tra nsm itte rs, suc h a s ra d io o r TV sta tio ns, a nd try to
a vo id c o m ing c lo se to the m ;
3) If uninte nd e d m o ve m e nt o r b ra ke re le a se o c c urs, turn the p o we re d sc o o te r
OFF a s soon a s it is sa fe ;
4) Be a wa re tha t a d d ing a c c e ssorie s or c om p one nts, or m od ifying the p owe re d
sc oote r, m a y m a ke it m ore susc e p tib le to EMI (Note : The re is no e a sy wa y to
e va lua te the ir e ffe c t on the ove ra ll im m unity of the p owe re d sc oote r); a nd
5) Re p o rt a ll inc id e nts o f uninte nd e d m o ve m e nt o r b ra ke re le a se to the p o w-
e re d sc oote r m a nufa c ture r, a nd note whe the r the re is a sourc e of EMI ne a rb y.
Im p o rta nt Info rm a tio n
1) 20 volts p e r m e te r (V/ m ) is a g e ne ra lly a c hie va b le a nd use ful im m unity le ve l
a g a inst EMI (a s of Ma y 1994) (the hig he r the le ve l, the g re a te r the p rote c tion);
2) The im m unity le ve l o f this p ro d uc t is unkno wn.
6
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GENERAL GUIDELINES
PROCEDURE 1
WARNING/ CAUTION LABEL LOCATION
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DELTA
TILLER
!
WARNING
!
WARNING
DO NOT ope ra te without the a nti-
tip tube s insta lle d.
Remove key from the ignition while scooter is
not in use. Otherwise, injury a nd/or da ma ge to
the scooter or surrounding property ma y occur.
60106X144
1090105
! WARNING
DO NOT ope ra te the sc oote r unle ss the tille r is in the loc ke d
position.
!
CAUTION
DO NOT le a n a ga inst or pull forwa rd on the tille r while mount-
ing or dismounting the sc oote r. Othe rwise , injury ma y oc c ur.
DO NOT lift sc oote r up by the
front or re a r shroud. Othe r-
wise , da ma ge to the sc oote r
The ma nufa c ture r disc la ims a ll re sponsibility for a ny pe rsona l
injury or prope rty da ma ge whic h ma y oc c ur a s a re sult of im-
ma y oc c ur.
1089265
prope r or unsa fe use of its produc ts.
1090104
7
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PROCEDURE 2
SAFETY INSPECTION/MAINTENANCE/TROUBLESHOOTING
This Procedure Includes the Following:
Safety Inspection Checklist
Maintenance
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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.
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Initial adjustments should be made to suit your personal body structure and preference. Thereafter follow
these maintenance procedures:
ITEM
INITIALLY
INSPECT/ADJUST
WEEKLY
MONTHLY
PERIODICALLY
GENERAL
O
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Scooter drives straight (no excessive drag/pull to one side).
X
X
X
X
X
BRAKE*
Does not bind or interfere with travel.
Brake easy to disengage/engage.
X
X
X
UPHOLSTERY (PROCEDURES 5 AND 6 OF THE
OWNER’S MANUAL**)
Inspect for rips, tears.
X
X
REAR WHEELS (PROCEDURE 9 OF THE OWNER’S
MANUAL**)
No excessive side movement or binding when raised and turned.
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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.
Loosen/tighten locknut if wheel wobbles noticeably or binds to a stop.
Wheel bearings are clean and free of moisture.
CAUTION: As with any vehicle, the wheels and tires should be
checked periodically for cracks and wear and should be replaced.
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X
X
X
X
X
X
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**).
Scooter stops completely when throttle is released
(Does not continue to roll as if throttle is activated).
X
X
X
X
SEAT (PROCEDURE 5 OF THE OWNER’S MANUAL**)
Inspect seat swivel for release and engagement.
Seat locks into the determined swivel positions.
X
X
X
X
X
TIRES (PROCEDURE 9 OF THE OWNER’S MANUAL**)
Inspect for flat spots and wear.
X
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.
Clean molded frame.
X
X
X
FRONT AND REAR SHOCKS - PANTHER MX-4 ONLY
Bolts are tight.
X
HEADLIGHTS (where applicable)
Inspect headlight bulbs for proper operation.
X
X
*NOTE:ThisincludesthemanuallyengagedbrakeonALL **NOTE:RefertotheOwner’sManual,partnumber1090132.
scooters AND the hand brake on the PANTHER MX-4
(Before10/00)ONLY.
8
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SAFETY INSPECTION/MAINTENANCE/TROUBLESHOOTING
PROCEDURE 2
MAINTENANCE
C AUTIO N
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Ensure tha t the c o ve r is re m o ve d fro m
the g re a se nip p le BEFORE op e ra tion of
the PANTHER MX-4 sc o o te r. Othe rwise ,
d a m a g e to the sc oote r m a y oc c ur.
WARNING
Afte r ANY a djustm e nts, re pa ir or se rvic e
a nd BEFORE use , m a ke sure tha t a ll
a tta c hing ha rdwa re is tighte ne d se c ure ly
- othe rwise , injury or da ma ge ma y oc c ur.
4. For the PANTHER MX-4 ONLY, remove the
cover from the grease nipple located on TOP of
the transaxle assembly (FIGURE 1).
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DO NOT ove r-tig hte n ha rd wa re a tta c h-
ing to the fra me . This c ould c a use da m-
a g e to the fra m e .
Periodic Maintenance Procedures
1. The wheels and tires should be checked periodi-
callyforcracksandwear, andshouldbereplaced
by a qualified technician.
Initial Maintenance Procedures
(FIGURE 1)
O
N
2. Regularly check for loose nuts and/or bolts in the
frontandrearwheels.Ifloose,havethemadjusted
by a qualified technician (PROCEDURE 9 of
Owner’s Manual, part number 1090132).
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.
3. Clean dirt, dust and grease from exposed com-
ponents.
2. Ensurethatbatteriesareproperlymaintainedand
charged as required (PROCEDURE 4 of
Owner’s Manual, part number 1090132).
M
A
I
3. Inspectbrakeforproperoperation(PROCEDURE3
of Owner’s Manual, part number 1090132).
N
T
E
N
A
N
C
E
Cover
Transaxle
Assembly
Grease
Nipple
FIG URE 1 - INITIAL MAINTENANC E PRO C EDURES
9
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PROCEDURE 2
SAFETY INSPECTION/MAINTENANCE/TROUBLESHOOTING
D. For Models LYNX SX-3P, LYNX SX-3,
LYNX LX-3, and LYNX LX-3 wheel Bearings
of Front Wheel.
Lubrication Points (FIGURE 2)
S
A
F
E
T
Y
1. Every six (6) months the following components
should be lubricated. Use a Teflon® lubricant.
(FIGURE2).
2. For all Models EXCEPT the PANTHER MX - 4:
A. Remove the four (4) bolts securing the
gearbox cover to the transaxle and remove
the gearbox cover.
A. SeatLever,ConnectingPin,andReleasePin.
B. Axle of Scooter.
I
C. Top of Seat Adaptor.
B. Lubricate the gears inside the transaxle with
N
S
P
E
C
T
I
Black Pearl Grease® OR equivalent.
STEP 1B
STEP 1D
STEPS 1A AND 1C
Seat
Plate
O
N
See
DETAIL
Axle of
Scooter
Top
"A"
Wheel
Bearings
Seat
Adaptor
M
A
I
STEP 2
N
T
E
N
A
N
C
E
DETAIL "A"
Connecting
Pin
Transaxle
Release
Pin
Bolts
(Only Two
(2) Shown)
Seat Lever
Gearbox Cover
FIGURE 2 - LUBRICATION POINTS
Teflon - Registered trademark of E.I. Du Pont Black Pearl Grease - Registered trademark of
Nemours and Company. Chevron Corporation.
10
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SEAT
PROCEDURE 3
4. Whileholdingtheswivelreleaseleverintheupward
position,inserttheNEWseatpostintotheseatframe.
This Procedure Includes the Following:
Replacing Seat Post
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.
WARNING
Afte r ANY a djustm e nts, re pa ir or se rvic e
a nd BEFORE use , m a ke sure tha t a ll
a tta c hing ha rdwa re is tighte ne d se c ure ly
- othe rwise injury or da ma ge ma y oc c ur.
S
E
A
T
5. Release the swivel release lever, allowing the
NEW seat post to lock into place.
6. Reinstalltheseat.RefertoREMOVING/INSTALLING
THE SEAT in PROCEDURE 5 of the Owner’s
Manual, partnumber1090132.
REPLACING SEAT POST
(FIGURE 1)
WARNING
Ensure tha t se a t is loc ke d into the forwa rd
p osition BEFORE a nd DURING op e ra tion
o f the sc o o te r. Othe rwise , injury to the
use r a nd / o r d a m a g e to the sc o o te r
m a y re sult.
Seat Frame
1. Removetheseat. RefertoREMOVING/INSTALLING
THE SEAT in PROCEDURE 5 of the Owner’s
Manual, partnumber1090132.
Swivel
Release
Lever
NOTE:Theswivelreleaseleverislocatedjustbeneath
the seat on the right side.
Seat Post
2. Pull the swivel release lever up.
3. Whileholdingtheswivelreleaseleverintheupward
position, pull the seat post out of the seat frame.
FIG URE 1 - REPLACING SEAT PO ST
11
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PROCEDURE 4
TILLER
3. Repeatthisprocedurefortheotherpointedlocking
tab of the LED canopy.
This Procedure Includes the Following:
Replacing Hand Grips
4. Remove the EXISTING LED canopy and the
EXISTINGrubbergasket.
Replacing LED Canopy
Replacing Throttle Lever
5. Discard the EXISTING LED canopy and the
EXISTINGrubbergasket.
T
I
Removing/Installing Tiller Assembly
Removing/Installing Boot
NOTE: Before installing the NEW LED canopy, be
sure the NEW rubber gasket is between the NEW
LED canopy and the front cover.
L
L
E
R
WARNING
Afte r ANY a djustm e nts, re pa ir or se rvic e
a nd BEFORE use , m a ke sure tha t ALL
a tta c hing ha rdwa re is tighte ne d se c ure ly
- othe rwise , injury or da ma ge ma y oc c ur.
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.
Turn Po we r OFF a nd re m o ve ke y fro m
ig nitio n. Disc o nne c t b a tte ry ha rne ss
fro m m o to r le a d .
LED Canopy
Pointed
Locking
REPLACING HAND GRIPS
(FIGURE 1)
Pointed
Locking
Tab
Tab
1. Graspthehandgripandtwistitoffofthehandlebar.
2. Slide the NEW hand grip over the handle bar.
Rubber
Gasket
3. Ifnecessary, repeatSTEPS1-2fortheotherhand
grip.
Hand Grip
Electronics
Board
Front
Cover
FIGURE 2 - REPLACING LED CANOPY
nd Grip
REPLACING THROTTLE LEVER
(FIGURE 3)
1. Remove the four (4) self-tapping screws and hous-
ings securing the cable cover to the tiller assembly.
FIGURE 1 - REPLACING HAND GRIPS
NOTE:Savethefour(4)selftappingscrewsandhous-
ings for reuse when installing the NEW throttle lever.
2. Slowly remove the cable cover from the tiller as-
semblyandallowittohangbytheconnectingwires.
REPLACING LED CANOPY
(FIGURE 2)
3. Remove the two (2) socket screws securing the
throttle lever to the potentiometer assembly.
NOTE:ThisprocedureappliestoallmodelsEXCEPT
the Panther MX - 4.
4. Remove the throttle lever from the potentiometer
assembly.
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. Whilesqueezingtheends, slowlypullthepointed
locking tab through the front cover and through
the electronics board.
12
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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
thespringonthepotentiometerassembly.(DETAIL“A”)
REMOVING/ INSTALLING TILLER
ASSEMBLY
WARNING
5. PositiontheNEWthrottleleveronthepotentiom-
eter assembly.
Ensure tha t tille r is prope rly a djuste d be -
fore d riving the sc oote r. Re fe r to TILLER
ADJUSTMENT in PROCEDURE 8 of the
Owne r’s Ma nua l, p a rt num b e r 1090132.
T
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6. Secure the NEW throttle lever to the potentiometer
assembly using the two (2) NEW socket screws.
Securelytighten.
Afte r m a king ANY tille r a ng le a d just-
m e nts a nd BEFORE use , the tille r MUST
b e se c ure ly lo c ke d into p o sitio n with
a d justm e nt p in p ro trud ing thro ug h the
a d justm e nt p la te .
7. Align the four (4) mounting holes in the cable cover
withthefour(4)mountingholesinthetillerassembly.
8. Securethecablecovertothetillerassemblyusing
the four (4) EXISTING self-tapping screws and
housings. Securely tighten.
Tiller
Front Cover
Housings
See
DETAIL "A"
Self
Tapping
Screws
Tiller
Adjustment
Plate
Adjustment
Pin
Spring
A fa ll from the scooter could occur ca using
bodily injury a nd/or da ma ge to the scooter.
Gently, push/pull a ga inst tiller to ensure tha t
the tiller is securely enga ged into the a djust-
ment pla te.
Handle Bar
Potentiometer
Assembly
Cable
Cover
NOTE: When removing the tiller assembly, perform
the following steps:
Self
Tapping
Screws
Socket
Screw
STEP 1: Determine the scooter model to be
serviced.
Housings
STEP 2: Carefully review the following chart to
determine the necessary sections and the
specific order in which these sections need to
be performed.
Tab
Throttle
Lever
Socket Screw
NOTE: The sections outlined below are to remove
the tiller assembly. To install the tiller assembly,
reverse the order of the outlined sections.
DETAIL "A"
Spring
Ends
SECTIONS TO BE
PERFORMED AND THE
PROPER ORDER
Tab
LYNX SX - 3
A
A
A
A
A
D
D
D
C
B
E
E
C
D
C
F
F
E
E
D
LYNX SX - 3P
LYNX LX - 3
Spring
F
F
E
Throttle
Lever
PANTHER LX - 4
PANTHER MX - 4
Potentiometer
Assembly
F
STEP 3: Perform the appropriate steps as
specified for the model.
FIGURE 3 - REPLACING THROTTLE LEVER
13
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PROCEDURE 4
TILLER
4. Separate the front frame assembly from the rear
frameassembly. RefertoTRANSPORTINGTHE
SCOOTER in PROCEDURE 10 of the Owner’s
Manual, part number 1090132.
Section A - Disassem bling/ Assem bling
Scooter (FIGURE 4)
DISASSEMBLING.
1. If necessary, remove the floor basket. Refer to
REMOVING/INSTALLING THE FLOOR BAS-
KETinPROCEDURE11oftheOwner’sManual,
part number 1090132.
5. Position the front frame assembly on its side.
T
I
NOTE: Note the position of the tie wraps before re-
moving.
L
L
E
R
2. Remove the batteries. Refer to REMOVING/IN-
STALLING THE BATTERIES WITH CABLES in
PROCEDURE 4 of the Owners Manual, part
number 1090132.
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 secur-
ing the brake cable to the underside of the front
frame assembly.
3. If necessary, remove the on - board battery
charger. Refer to REPLACING ON - BOARD
BATTERY CHARGER in PROCEDURE 11 of
the Owner’s Manual, part number 1090132.
8. Remove the tiller wiring harness from the retaining
tabs on the underside of the front frame assembly.
(LYNX SX - 3 AND LYNX SX - 3P)
(LYNX LX - 3)
Tiller
Wiring
Retaining Tab
Harness
Cable Tie
Retaining Tabs
Retaining Tab
Retaining
Tabs
Cable
Ties
Retaining
Tab
Tiller
Wiring
Harness
Cable Tie
Retaining
Tabs
Cable Ties
(PANTHER LX - 4)
(PANTHER MX - 4)
Tiller
Wiring
Harness
Tiller Wiring Harness
Brake Cable
Retaining Tabs
Cable Ties
Cable
Tie
Retaining
Tabs
Retaining
Tabs
Cable
Retaining Tabs
Ties
FIGURE 4 - DISASSEMBLING/ASSEMBLING SCOOTER
14
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TILLER
PROCEDURE 4
9. For PANTHER MX - 4, remove the brake cable 1. Remove the adjusting nut from the hand brake
from the retaining tabs on the underside of the
front frame assembly.
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.
10. Refer to the chart on page 11 of this manual to
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation of the tiller assembly.
T
I
3. Remove the spring.
4. Remove the brake arm joint from the disc brake
assembly.
L
L
E
R
ASSEMBLING.
1. Securethetillerwiringharness intheretainingtabs
on the underside of the front frame assembly.
NOTE: Save the hand brake cable assembly and all
components for reassembly.
2. For PANTHER MX - 4, secure the brake cable in
the retaining tabs on the underside of the front
frame assembly.
5. Refer to the chart on page 11 of this manual to
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation of the tiller assembly.
NOTE: Before installing the cable ties, be sure they
are in the proper positions.
CONNECTING.
1. Position the brake arm joint in the mounting hole
in the disc brake assembly.
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.
2. Position the spring between the tab on the rear
frame and the brake arm joint.
3. Slidethehandbrakecableassemblythroughthe
tab on the rear frame, the spring and the brake
arm joint.
5. Return the front frame assembly to the upright
position.
6. Reassemble the front frame assembly and the
rear frame assembly. Refer to TRANSPORT-
INGTHESCOOTER inPROCEDURE10ofthe
Owner’s Manual, part number 1090132.
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
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation of the tiller assembly.
7. Ifnecessary,reinstalltheon-boardbatterycharger.
Refer to REPLACING ON - BOARD BATTERY
CHARGER in PROCEDURE 11 of the Owner’s
Manual, part number 1090132.
8. Reinstall the batteries. Refer to REMOVING/IN-
STALLING THE BATTERIES WITH CABLES in
PROCEDURE 4 of the Owners Manual, part
number 1090132.
Rear Frame
Assembly
Hand
Brake
Cable
Disc Brake
Assembly
9. Reinstall the floor basket. Refer to REMOVING/
INSTALLING THE FLOOR BASKET in PRO-
CEDURE 11 of the Owner’s Manual, part num-
ber 1090132.
Assembly
Spring
Section B - Disconnecting/ Connecting
Hand Brake Cable Assem bly (FIGURE 5)
NOTE: This procedure applies to the PANTHER MX
- 4 ONLY.
Tab On
Rear Frame
Mounting Hole
Adjusting
Nut
DISCONNECTING.
NOTE: Note the distance that the adjusting nut is
threaded on the hand brake cable assembly before
removing for proper reinstallation.
Brake Arm Joint
FIGURE 5 - DISCONNECTING/
CONNECTING HAND BRAKE ASSEMBLY
15
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PROCEDURE 4
TILLER
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.
Section C - Disconnecting/ Connecting
Head light Assem bly (FIGURE 6)
DISCONNECTING.
1. For LYNX LX - 3 ONLY - slowly pull the head light
assembly away from the base handle bar joint.
4. Separate the head light assembly from the tiller
wiring harness.
T
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2. Pull back the plastic guards on the RED and
BLACK cables connecting the tiller wiring har-
ness to the head light assembly.
5. Refer to the chart on page 11 of this manual to
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation of the tiller assembly.
(PANTHER LX - 4)
(LYNX SX - 3P)
Tiller
Wiring
Harness
Head
light
Assembly
Red/Black
Cables
Plastic
Guards
Red/
Black
Cables
To Tiller
To Head
Wiring
Light
Harness
Red/Black
Cables
Assembly
Plastic
Guards
Metal
Connectors
Metal
Connectors
(PANTHER MX - 4)
Tiller
Wiring
Harness
Metal
Connectors
Head light
Assembly
Red/Black
Cables
Red/Black
Cables
Plastic
Guards
FIGURE 6 - DISCONNECTING/CONNECTING HEAD LIGHT ASSEMBLY
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TILLER
PROCEDURE 4
CONNECTING (FIGURE 6).
3. Push any remaining slack in the tiller wiring har-
ness through the hole in the shroud, until the wir-
ing harness is on the underside of the front frame
assembly (DETAIL “A”).
1. Connect the RED cable metal connector of the
head light assembly to the RED cablemetalcon-
nector of the tiller wiring harness.
2. Connect the BLACK cable metal connector of 4. Flip the front frame assembly onto its side.
T
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the head light assembly to the BLACK cable
metal connector of the tiller wiring harness.
5. Refer to the chart on page 11 of this manual to
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation of the tiller assembly.
3. Reposition the plastic guards on the RED and
BLACK cables connecting the tiller wiring har-
ness to the head light assembly.
DETAIL “A”
Hole In Shroud
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.
Tiller Wiring
Harness
Front Frame
Assembly
Section D - Disconnecting/ Connecting
Tiller Assem bly And Handle Bar J oint
(FIGURE 7)
DISCONNECTING.
1. Return the front frame assembly to the upright
position.
Large
Tiller Assembly
Washers
Base Handle
Bar Joint
2. Remove the bolt, small washer, two (2) large
washers and self-locking nut securing the base
handle bar joint to the tiller assembly.
Self-
locking
nut
3. Slowlypullthetillerassemblyawayfromthefront
frame assembly until there is no slack left in the
tiller wiring harness (DETAIL “A”).
Bolt
Small
Washer
4. Refer to the chart on page 11 of this manual to
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation of the tiller assembly.
Tiller Wiring
Harness
Boot
CONNECTING.
FIGURE 7 - DISCONNECTING/CONNECTING
TILLER ASSEMBLY AND HANDLE BAR JOINT
NOTE: To simplify this procedure, lay the tiller as-
sembly on the shroud and then align the necessary
components.
1. Alignthemountingholeinthetillerassemblywith
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 se c uring tille r a s-
se mbly to the ba se ha ndle ba r joint. The tille r
will bind a nd not work prope rly.
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.
17
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PROCEDURE 4
TILLER
Section F - Rem oving/ Installing Tiller
From / To Front Fram e Assem bly
(FIGURE 8)
Section E - Disconnecting/ Connecting
Base Handle Bar J oint From / To Front
Fram e Assem bly (FIGURE 7)
DISCONNECTING.
REMOVING.
1. Remove the two (2) bolts and self-locking nuts 1. Slowly pull the tiller wiring harness through the
T
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securing the base handle bar joint (and for the
LYNX LX - 3 ONLY, the head light assembly) to
the front frame assembly.
hole in the shroud assembly, until the tiller as-
sembly is free from the front frame assembly
(DETAIL “A”).
2. Refer to the chart on page 11 of this manual to 2. Pullthebasehandlebarjointfromthefrontframe
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation of the tiller assembly.
assembly (DETAIL “B”).
3. Removetheboot. RefertoREMOVING/INSTALL-
ING BOOT in this procedure of this manual.
4. Refer to the chart on page 11 of this manual to
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation 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.
INSTALLING.
1. Reinstalltheboot. RefertoREMOVING/INSTALL-
ING BOOT in this procedure of this manual.
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.
2. Positionthebasehandlebarjointinthefrontframe
assembly, makingsurethemountingholesinthe
base handle bar joint line up with the mounting
holes in the front frame assembly (DETAIL “A”).
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.
3. Slowly thread the tiller wiring harness through the
hole in the shroud, until most of the tiller wiring har-
nessisontheundersideofthefrontframeassembly.
4. Refer to the chart on page 11 of this manual to
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation of the tiller assembly.
4. Refer to the chart on page 11 of this manual to
determinewhichsection(s)needtobeperformed
next to successfully complete the removal/instal-
lation of the tiller assembly.
Tiller Assembly
Base Handle
Bar Joint
Self-
locking
Bolts
nuts
Head
Light
Front
Frame
Assembly
Assembly
(LYNX
Boot
LX - 3
ONLY)
FIGURE 7 - DISCONNECTING/
CONNECTING BASE HANDLE BAR JOINT
FROM/TO FRONT FRAME ASSEMBLY
18
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TILLER
PROCEDURE 4
DETAIL “A”
REMOVING/ INSTALLING BOOT
(FIGURE 9)
Tiller Wiring
Harness
Rem oving
Hole
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in this
procedure of this manual.
T
I
Shroud
Assembly
L
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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
DETAIL “B”
fork with bearing assembly.
2. Install the tiller assembly. Refer to REMOVING/
INSTALLING TILLER ASSEMBLY in this proce-
dure of this manual.
Base Handle
Bar Joint
Boot
Front Frame
Assembly
Fork With Bearing
Assembly
Boot
FIGURE 8 - REMOVING/INSTALLING TILLER
FROM/TO FRONT FRAME ASSEMBLY
FIGURE 9 - REMOVING/INSTALLING BOOT
19
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PROCEDURE 5
SHROUD/FORK/WHEELS/TIE RODS
B. PANTHER LX - 4:
S
H
R
O
U
D
/
This Procedure Includes the Following:
Replacing Tire And Tube
1. Remove the front head light assembly.
Refer to REMOVING/INSTALLING
FRONT HEAD LIGHT ASSEMBLY in
PROCEDURE 10 of this manual.
Removing/Installing Front Shroud Assembly
/
T
I
Removing/Installing Fork With Bearing
Assembly
C. PANTHER MX - 4:
F
E
Removing/Installing Front Axle Assembly
Replacing Tie Rod Assembly
1. Remove the front head light assembly.
Refer to REMOVING/INSTALLING
FRONT HEAD LIGHT ASSEMBLY in
PROCEDURE 11 of this manual.
O
R
K
/
W
H
E
E
L
R
O
D
S
Removing/Installing Small Tie Rods
Removing/Installing Large Tie Rods
6. Removethefrontshroudassemblyfromthefront
frame assembly.
WARNING
7. Note the position of the U-type plate nuts before
removing for proper reinstallation.
After ANY a djustments, repa ir or service a nd
BEFORE use, ma ke sure tha t a ll a tta ching ha rd-
wa re is tightened securely - otherwise injury or
da ma ge ma y oc c ur.
S
8. RemovetheU-typeplatenutsfromthefrontframe
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
plate nuts.
Turn Power OFF a nd remove key from ignition.
Disconnect ba ttery ha rness from motor lea d.
REPLACING TIRE AND TUBE
WARNING
This procedure MUST be performed by a n a u-
thorized Inva ca re dea ler or qua lified techni-
cia n.
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 :
REMOVING/ INSTALLING FRONT
SHROUD ASSEMBLY (FIGURE 1)
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.
Rem oving
1. Pullupontherugtoremoveitfromthefrontshroud
assembly.
B. PANTHER MX - 4 and PANTHER LX - 4:
2. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
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. Removetheboot.RefertoREMOVING/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.
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 mount-
ing holes in the front frame assembly.
NOTE:Four(4)mountingscrews, springwashersand
flat washers are required on the PANTHER LX - 4.
5. Perform one (1) of the following:
A. LYNXSX-3, LYNXSX-3PandLYNXLX-3:
1. Proceed to STEP 6.
4. Securethefrontshroudassemblytothefrontframe
using the two (2) mounting screws, spring wash-
ers and flat washers. Securely Tighten.
NOTE:Four(4)mountingscrews, springwashersand
flat washers are required on the PANTHER LX - 4.
20
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SHROUD/FORK/WHEELS/TIE RODS
PROCEDURE 5
5. Perform one (1) of the following:
C. PANTHER MX - 4:
S
H
R
O
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A. LYNX SX - 3, LYNX SX - 3P, LYNX LX - 3
and PANTHER LX - 4 :
1. Reinstall the front head light assembly.
RefertoREMOVING/INSTALLINGTHE
FRONT HEAD LIGHT ASSEMBLY in
PROCEDURE 11 of this manual.
1. Proceed to STEP 5.
/
T
I
B. PANTHER LX - 4:
6. Reinstalltheboot. RefertoREMOVING/INSTALL-
ING BOOT in PROCEDURE 4 of this manual.
1. Reinstall the front head light assembly.
RefertoREMOVING/INSTALLINGTHE
FRONT HEAD LIGHT ASSEMBLY in
PROCEDURE 10 of this manual.
F
E
O
R
K
/
7. Reinstall the tiller assembly. Refer to REMOV-
ING/INSTALLINGTILLERASSEMBLYinPRO-
CEDURE 4 of this manual.
R
O
D
S
W
H
E
E
L
8. Position the rug on the shroud assembly.
LYNX 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.
S
Mounting Screw
Front
Shroud
Assembly
Spring Washer
Flat Washer
U
U
Type
Plate
Nut
Type
Plate
Nut
PANTHER 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 ONLY)
(Required for
Mounting Screw
PANTHER LX - 4 AND
PANTHER MX - 4)
Spring Washer
Washer
Spring Washer
Front Shroud Assembly
Flat Washer
U
Type
Plate
Nut
FIGURE 1 - REMOVING/INSTALLING FRONT SHROUD ASSEMBLY
21
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PROCEDURE 5
SHROUD/FORK/WHEELS/TIE RODS
4. Secure the TOP bearing bushing by threading it
into the TOP bearing housing. Torque the TOP
bearing bushing between 26 - 39 in./lbs.
REMOVING/ INSTALLING FORK
WITH BEARING ASSEMBLY
(FIGURE 2)
S
H
R
O
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D
/
CAUTION
/
T
I
NOTE: This procedure applies to the LYNX SX - 3,
LYNX SX - 3P and the LYNX LX - 3 ONLY.
DO NOT ove rtighte n the be a ring ga p nut.
Othe rwise , da ma ge to the front fork a sse m-
bly ma y oc c ur.
Rem oving
F
E
O
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K
/
W
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E
L
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
5. Secure the bearing gap nut by threading it into
the front fork. Torque the bearing gap nut be-
tween 217 - 243 in./lbs.
R
O
D
S
2. Remove the front shroud assembly. Refer to
REMOVING/INSTALLING FRONT SHROUD
ASSEMBLY in PROCEDURE 5 of this manual.
NOTE: When reinstalling the front wheel, replace the
EXISTINGhardwarewiththeNEWhardwaresupplied.
6. Reinstall the front wheel. Refer to REMOVING/IN-
STALLINGTHEFRONTWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
3. Remove the front wheel. Refer to REMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
S
7. Reinstalltheshroudassembly. Referto REMOV-
ING/INSTALLING FRONT SHROUD ASSEM-
BLY in PROCEDURE 5 of this manual.
4. Remove the bearing gap nut from the front fork.
5. Remove the TOP bearing bushing from the TOP
8. Reinstall the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
bearing housing.
6. Remove the TOP bearing from the TOP bearing
housing.
Front Frame Assembly
Top
7. Slide the front fork, BOTTOM bearing and BOT-
TOM bearing bushing away from the front frame
assembly.
Bearing
Bearing
Bushing
Gap Nut
Front Fork
Facing
Top
Bearing
8. Remove the TOP and BOTTOM bearing hous-
ings from the front frame assembly.
Proper
Direction
Top Bearing
Installing
Housing
1. Secure the TOP and BOTTOM bearing housing
Front
Frame
Assembly
onto the front frame assembly.
NOTE: Before installing the front fork, be sure it is
facing the proper direction.
Bottom
Bearing
Housing
2. Slide the front fork with the BOTTOM bearing
and the BOTTOM bearing bushing through the
mounting hole in the front frame assembly.
Front of
Scooter
Bottom
3. Slide the TOP bearing over the top of the front fork
and into the TOP bearing housing.
Bearing
Back of
Scooter
Bottom
Bearing
Bushing
CAUTION
DO NOT overtighten the TOP be a ring bush-
ing. Otherwise, da ma ge to the front fork a s-
se mbly ma y occur.
FIGURE 2 - REMOVING/INSTALLING FORK
WITH BEARING ASSEMBLY
22
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SHROUD/FORK/WHEELS/TIE RODS
PROCEDURE 5
2. Secure the front axle assembly to the front frame
usingthewasherandself-lockingnut. Torquethe
locking nut between 108 - 135 in./lbs.
REMOVING/ INSTALLING FRONT
AXLE ASSEMBLY
S
H
R
O
U
D
/
NOTE: This procedure applies to the PANTHER LX
- 4 and the PANTHER MX - 4 ONLY.
3. Position the EXISTING washer and the right front
/
T
I
wheel axle assembly on the front axle assembly.
Panther LX - 4 (FIGURE 3)
CAUTION
F
E
REMOVING.
DO NOTovertighten the se lf-loc king nut se c ur-
ing the front a xle a sse mbly to the right front
whe e l a xle a sse mbly. Otherwise, da ma ge to
the front a xle a sse mbly ma y occur.
O
R
K
/
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLINGTILLERASSEMBLYinPRO-
CEDURE 4 of this manual.
R
O
D
S
W
H
E
E
L
2. Removetheshroudassembly. RefertoREMOV-
ING/INSTALLING SHROUD ASSEMBLY in
PROCEDURE 5 of this manual.
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.
3. Removethefrontwheels. Referto REMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
5. Repeat STEPS 3 - 4 for the left side of the front
axle assembly.
S
6. Return the front frame assembly to the upright
position
4. Position the front frame assembly onto its side.
5. Remove the self-locking nut and spacer secur-
ingthefrontaxleassemblytotherightfrontwheel
axle assembly.
7. Reinstall the front wheels. Refer toREMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
NOTE: Savetheself-lockingnut, spacerandwasher
for reuse when installing the NEW front axle assem-
bly.
8. Reinstall the front shroud assembly. Refer to
REMOVING/INSTALLING FRONT SHROUD
ASSEMBLY in PROCEDURE 5 of this manual.
6. Slide the right front wheel axle assembly and the
washer away from the front axle assembly.
9. Reinstall the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
7. Repeat STEPS 4 - 5 for the left side of the front
axle assembly.
Self-locking nut
Spacer
8. Remove the self-locking nut and three (3) wash-
ers securing the front axle assembly to the front
frame assembly.
Right Front Wheel
Axle Assembly
9. Slide the front axle assembly and washer away
from the front frame assembly.
INSTALLING.
NOTE: Position the two (2) washers between the
front frame assembly and the front axle assembly.
Washer
Front Frame
Washers
Assembly
1. Position the two (2) washers and front axle as-
sembly onto the front frame assembly.
CAUTION
DO NOTovertighten the self-locking nut secur-
ing the front a xle a sse mbly to the front fra me
a ssembly. Otherwise,damage to the front a xle
a ssembly ma y occur.
Front Axle
Assembly
Washer
Self-locking nut
FIGURE 3 - REMOVING/INSTALLING FRONT
AXLE ASSEMBLY - PANTHER LX - 4
23
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PROCEDURE 5
SHROUD/FORK/WHEELS/TIE RODS
Panther MX - 4 (FIGURE 4)
CAUTION
S
H
R
O
U
D
/
DO NOTovertighten the self-locking nut secur-
ing the tie rod a sse mbly to the right front a xle .
Otherwise, da ma ge to the tie rod a sse mbly
ma y occur.
REMOVING.
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
/
T
I
4. Securethetierodassemblyontotherightfrontaxle
using the EXISTING washer and self-locking nut.
Torque the self-locking nut between 17 - 30 in./lbs.
2. Remove the front shroud assembly. Refer to
REMOVING/INSTALLING FRONT SHROUD
ASSEMBLY in PROCEDURE 5 of this manual.
F
E
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K
/
W
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L
R
O
D
S
5. Repeat STEPS 1 - 4 to install the left front axle.
3. Remove the front wheels. Refer to REMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
6. Reinstall the front shock absorbers. Refer to RE-
MOVING/INSTALLING FRONT SHOCK AB-
SORBERS in PROCEDURE 11 of this manual.
4. Position the front frame assembly onto its side.
7. Return the front frame assembly to the upright
position
5. Remove the front shock absorbers. Refer to RE-
MOVING/INSTALLING FRONT SHOCK AB-
SORBERS in PROCEDURE 11 of this manual.
S
8. Reinstallthefrontwheels. RefertoREMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
NOTE: Save the self-locking nut, washer and spacer
for reuse when installing the NEW front axle assem-
bly.
9. Reinstalltheshroudassembly. RefertoREMOV-
ING/INSTALLING SHROUD ASSEMBLY in
PROCEDURE 5 of this manual.
6. Remove the self-locking nut and washer secur-
ing the right front axle to the tie rod assembly.
10. Reinstall the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
7. Slide the tie rod assembly and the spacer away
from the right front axle.
8. Remove the bolt, spring washer and washer secur-
ing the right front axle to the front frame assembly.
9. Remove the right front axle assembly.
Front Frame
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.
Washer
Bolt
Spring
CAUTION
Washer
Right Front Axle
DO NOT overtighten the bolt se c uring the right
front a xle to the front fra me a sse mbly. Other-
wise, da ma ge to the right front a xle ma y oc-
cur.
Mounting Pin
Spacer
Tie Rod Assembly
Washer
2. Secure the right front axle to the front frame as-
semblyusingthewasher, springwasherandbolt.
Torque the bolt between 191 - 226 in./lbs.
Self-locking nut
NOTE: Position the spacer between the top of the
right front axle and the tie rod assembly.
FIGURE 4 - REMOVING/INSTALLING FRONT
AXLE ASSEMBLY - PANTHER MX - 4
3. Slide the EXISTING spacer and the tie rod as-
sembly onto the mounting pin of the right front
axle.
24
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SHROUD/FORK/WHEELS/TIE RODS
PROCEDURE 5
15. Slide the NEW steering shaft with the NEW
BOTTOMbearingandtheNEWBOTTOMbear-
ing bushing into the front frame assembly.
REPLACING TIE ROD ASSEMBLY
S
H
R
O
U
D
/
NOTE: This procedure applies to the PANTHER LX
- 4 and the PANTHER MX - 4 ONLY.
16. Slide the NEW TOP bearing over the top of the
NEWsteeringshaftandintothe NEWTOP bear-
ing housing.
Panther LX - 4 (FIGURE 5)
/
T
I
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
F
E
CAUTION
O
R
K
/
W
H
E
E
L
DO NOT overtighten the TOP be a ring bush-
ing. Otherwise, da ma ge to the tie rod a sse m-
bly ma y occur.
R
O
D
S
2. Removetheshroudassembly. RefertoREMOV-
ING/INSTALLING SHROUD ASSEMBLY in
PROCEDURE 5 of this manual.
17. SecuretheNEWTOPbearingbushingbythread-
ing it into the NEW TOP bearing housing. Torque
the NEW TOP bearing bushing between 26 - 39
in./lbs.
3. Removethefrontwheels. Referto REMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
S
CAUTION
4. Position the front frame assembly onto its side.
DO NOTovertighten the be a ring ga p nut. Oth-
erwise, da ma ge to the tie rod a sse mbly ma y
occur.
5. Removethefrontaxleassembly.RefertoREMOV-
ING/INSTALLING FRONT AXLE ASSEMBLY,
PANTHER LX - 4 in this procedure ofthis manual.
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.
6. Removethetwo(2)hexcapscrewsandself-lock-
ing nuts securing the steering shaft to the U - plate
on the tie rod assembly.
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.
7. Remove the U - plate and the tie rod assembly
from the steering shaft.
8. Remove the bearing gap nut from the steering 20. Secure the NEW U-plate and the tie rod assem-
shaft.
bly 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.
9. Remove the TOP bearing bushing from theTOP
bearing housing.
10. Remove the TOP bearing from the TOP bearing
21. Reinstall the front axle assembly. Refer to RE-
MOVING/INSTALLINGFRONTAXLEASSEM-
BLY, PANTHER LX - 4 in this procedure of this
manual.
housing.
11. Remove the steering shaft, BOTTOM bearing
and the BOTTOM bearing bushing from the
BOTTOM bearing housing.
22. Return the front frame assembly to the upright
position.
12. Remove the TOP and BOTTOM bearing hous-
ings from the front frame assembly.
23. Reinstallthefrontwheels. RefertoREMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
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.
24. Reinstallthefrontshroudassembly. Referto RE-
MOVING/INSTALLING FRONT SHROUD AS-
SEMBLY in PROCEDURE 4 of this manual.
NOTE: Before installing the NEW steering shaft, be
sure it is in the proper direction (FIGURE 5).
25. Reinstall the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 3 of this manual.
25
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PROCEDURE 5
SHROUD/FORK/WHEELS/TIE RODS
Bearing Gap Nut
(STEPS 8 and 18)
S
H
R
O
U
D
/
Hex Cap Screws
(STEPS 6 and 20)
Top Bearing Bushing
(STEPS 9 and 17)
Top Bearing
(STEPS 10 and 16)
/
T
I
U - Plate
(STEPS 7 and 19)
Top Bearing Housing
(STEPS 12 and 13)
F
E
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K
/
W
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L
R
O
D
S
Front Frame Assembly
Self-locking nuts
(STEPS 6 and 20)
Bottom Bearing Housing
(STEPS 12 and 13)
Bottom Bearing
(STEPS 11 and 14)
Tie Rod Assembly
(STEPS 7 and 20)
S
Bottom Bearing Bushing
(STEPS 11 and 14)
Front Axle Assembly
FIGURE 5 - REPLACING TIE ROD ASSEMBLY - PANTHER LX - 4
11. Remove the steering shaft, BOTTOM bearing
andtheBOTTOMbearingbushingfromthefront
frame assembly.
Panther MX - 4 (FIGURE 6)
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
12. Remove the TOP and BOTTOM bearing hous-
ings from the front frame assembly.
2. Removethefrontshroudassembly. RefertoRE-
MOVING/INSTALLING FRONT SHROUD AS-
SEMBLY in PROCEDURE 5 of this manual.
13. Remove the self-locking nut and washer secur-
ingtherightfrontwheelaxletotherightfrontaxle.
14. Slide the right front wheel axle and the spacer
away from the right front axle.
3. Remove the front wheels. Refer to REMOVING/IN-
STALLINGTHEFRONTWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
15. Repeat STEPS 11-12 to remove the tie rod as-
sembly from the left front axle.
4. Position the front frame assembly onto its side.
16. Remove the tie rod assembly.
5. Remove the front shock absorbers. Refer to RE-
MOVING/INSTALLING FRONT SHOCK AB-
SORBERS in PROCEDURE 11 of this manual.
NOTE: Before installing the NEW tie rod assembly,
be sure it is in the proper direction (FIGURE 6).
6. Remove the small tie rod. Refer to REMOVING/
INSTALLING SMALL TIE RODS in this proce-
dure of this manual.
17. Position the NEW spacer between the top of the
right front axle and the right front wheel axle.
18. SlidetheNEWrightfrontwheelaxleandtheNEW
7. Remove the large tie rod. Refer to REMOVING/IN-
STALLING LARGE TIE RODS in this procedure of
this manual.
spacer onto the right front axle.
CAUTION
DO NOTovertighten the self-locking nut secur-
ing the tie rod a sse mbly to the right front a xle .
Otherwise, da ma ge to the tie rod a sse mbly
ma y occur.
8. Removethebearinggapnutfromthesteeringshaft.
9. Remove the TOP bearing bushing from the TOP
bearing housing.
10. Remove the TOP bearing from the TOP bearing
housing.
26
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SHROUD/FORK/WHEELS/TIE RODS
PROCEDURE 5
19. Secure the NEW tie rod assembly onto the right
front axle using the NEW washer and self-lock-
ingnut. TorquetheNEWself-lockingnutbetween
139 - 165 in./lbs.
CAUTION
S
H
R
O
U
D
/
DO NOTovertighten the be a ring ga p nut. Oth-
erwise, da ma ge to the tie rod a sse mbly ma y
occur.
/
T
I
20. Repeat STEPS 17-18 to attach the NEW tie rod
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.
assembly to the left front axle.
F
21. Secure the NEW TOP and BOTTOM bearing
E
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K
/
W
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L
housing onto the front frame assembly.
27. Reinstall the small tie rod. Refer to REMOVING/IN-
STALLING SMALL TIE RODS in this procedure of
this manual.
R
O
D
S
22. Slide the NEW BOTTOM bearing and the NEW
BOTTOM bushing onto the steering shaft.
28. Reinstall the large tie rod. Refer to REMOVING/
INSTALLING LARGE TIE RODS in this procedure
of this manual.
NOTE: Before installing the NEW steering shaft, be
sure it is facing toward the tie rods (FIGURE 6).
23. Slidethe NEWsteeringshaftwiththe NEWBOT-
TOM bearing and the NEW BOTTOM bushing
through the mounting hole in the front frame as-
sembly.
29. Reinstall the front shock absorbers. Refer to RE-
MOVING/INSTALLING FRONT SHOCK AB-
SORBERS in PROCEDURE 11 of this manual.
S
30. Return the front frame assembly to the upright
position.
24. Slide the NEW TOP bearing over the top of the
NEWsteeringshaftandintotheNEWTOPbear-
ing housing.
31. Reinstall the front wheels. Refer to REMOVING/IN-
STALLINGTHEFRONTWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
CAUTION
DO NOT overtighten the TOP be a ring bush-
ing. Otherwise, da ma ge to the tie rod a sse m-
bly ma y occur.
32. Reinstallthefrontshroudassembly. Referto RE-
MOVING/INSTALLING FRONT SHROUD AS-
SEMBLY in PROCEDURE 5 of this manual.
25. Securethe NEWTOPbearingbushingbyscrewing
it into the NEW TOP bearing housing. Torque the 33. Reinstall the tiller assembly. Refer to REMOV-
NEW TOP bearing bushing between 26 - 39 in./lbs.
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 5 of this manual.
Bearing Gap Nut
(STEPS 8 and 26)
Top Bearing
Right Front Axle
(STEPS 10 and 24)
Top Bearing Bushing
Spacer
(STEPS 14
and 18)
(STEPS 9 and 25)
Top Bearing Housing
(STEPS 12 and 21)
Steering Shaft
(Steps 11 and 23)
Right Front
Wheel Axle
(STEPS 14
and 18)
Front Frame Assembly
Bottom Bearing Housing
(STEPS 12 and 21)
Washer
(STEPS 13
and 19)
Bottom Bearing
(STEPS 11 and 22)
Self-locking nut
(Steps 13 and 19)
Small Tie Rod
(Removed)
Bottom Bearing Bushing
(STEPS 11and 22)
Large Tie Rod
(Removed)
FIGURE 6 - REPLACING TIE ROD ASSEMBLY - PANTHER MX - 4
27
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PROCEDURE 5
SHROUD/FORK/WHEELS/TIE RODS
REMOVING/ INSTALLING SMALL
TIE RODS
CAUTION
S
H
R
O
U
D
/
DO NOTovertighten the self-locking nutssecur-
ing the sma ll tie rod to the right front wheel a xle.
Otherwise, da ma ge to the tie rod ma y occur.
NOTE: This procedure applies to the PANTHER LX
- 4 and the PANTHER MX - 4 ONLY.
/
T
I
4. Secure the small tie rod to the right front wheel
axleusingthespringwasherandself-lockingnut.
Securely tighten. Torque the self-locking nut be-
tween 112 - 139 in./lbs.
Panther LX - 4 (FIGURE 7)
F
REMOVING.
E
O
R
K
/
W
H
E
E
L
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
R
O
D
S
5. Return the front frame assembly to the upright
position.
2. Removethefrontshroudassembly. RefertoRE-
MOVING/INSTALLING FRONT SHROUD AS-
SEMBLY in PROCEDURE 5 of this manual.
6. Reinstall the front wheels. Refer to REMOVING/IN-
STALLINGTHEFRONTWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
3. Removethefrontwheels. RefertoREMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 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.
S
8. Reinstall the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
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 reinstalla-
tion.
Self-locking nut
(STEP 5)
Spring Washer
(STEP 5)
NOTE: Save the self-locking nut and spring washer
for reuse when installing the NEW small tie rod.
U - Plate
5. Remove the self-locking nut and spring washer
securing the small tie rod to the U - plate.
Mounting
Small Tie Rod
Bolt
NOTE: Save the self-locking nut and spring washer
for reuse when installing the NEW small tie rod.
Mounting Bolt
Right
Front
Wheel
Axle
6. Remove the self-locking nut and spring washer se-
curing the small tie rod to the right front wheel axle.
Large Tie Rod
7. Remove the small tie rod.
INSTALLING.
Spring Washer
(STEP 6)
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.
Self-locking nut
(STEP 6)
CAUTION
DO NOT ove rtighte n the se lf-loc king nuts se -
c uring the sma ll tie rod to the U-pla te . Othe r-
wise , da ma ge to the tie rod ma y oc c ur.
FIGURE 7 - REMOVING/INSTALLING SMALL
TIE RODS - PANTHER LX - 4
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 REMOVING section of this pro-
cedure.
28
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SHROUD/FORK/WHEELS/TIE RODS
PROCEDURE 5
4. Align the mounting hole in the small tie rod with
the mounting hole in the steering shaft.
Panther MX - 4 (FIGURE 8)
S
H
R
O
U
D
/
REMOVING.
5. Position the small spacer between the small tie
rod and the steering shaft.
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
/
T
I
CAUTION
DO NOT overtighten the se lf-loc king nuts se -
c uring the sma ll tie rod to the the ste e ring
sha ft. Otherwise, da ma ge to the tie rod ma y
occur.
2. Remove the front shroud assembly. Refer to
REMOVING/INSTALLING FRONT SHROUD
ASSEMBLY in PROCEDURE 5 of this manual.
F
E
O
R
K
/
W
H
E
E
L
R
O
D
S
3. Remove the front wheels. Refer to REMOVING/
INSTALLINGTHEFRONTWHEELSinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
6. Secure the small tie rod to the steering shaft us-
ing the hex cap screw, small spacer and self-
locking nut. Torque the self-locking nut between
139 - 165 in./lbs.
4. Flip the front frame assembly onto its side.
7. Reinstall the front shock absorbers. Refer to RE-
MOVING/INSTALLING FRONT SHOCK AB-
SORBERS in PROCEDURE 11 of this manual.
5. Remove the front shock absorbers. Refer to RE-
MOVING/INSTALLING FRONT SHOCK AB-
SORBERS in PROCEDURE 10 of this manual.
S
8. Return the front frame assembly to the upright
position.
NOTE: Save the hex cap screw, small spacer and
self-locking nut for reuse when installing the NEW
small tie rod.
9. Reinstallthefrontwheels. RefertoREMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
6. Remove the hex cap screw, small spacer and
self-locking nut securing the small tie rod to the
steering shaft.
10. Reinstall the front shroud assembly. Refer to
REMOVING/INSTALLING FRONT SHROUD
ASSEMBLY in PROCEDURE 5 of this manual.
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.
11. Reinstall the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
NOTE: Save the hex cap screw, large spacer and
self-locking nut for reuse when installing the NEW
small tie rod.
Self-
locking
nut
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.
Self-
locking
nut
Large
Spacer
8. Remove the small tie rod.
Right
Front
Wheel
Axle
Steering Shaft
INSTALLING.
Small
Spacer
1. Align the mounting hole in the small tie rod with
the center mounting hole in the right front wheel
axle.
Hex Cap Screws
2. Position the large spacer between the small tie
rod and the front wheel axle.
CAUTION
DO NOTovertighten the self-locking nutssecur-
ing the sma ll tie rod to the right front wheel a xle.
Otherwise, da ma ge to the tie rod ma y occur.
Large Tie Rod
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 be-
tween 139 - 165 in./lbs.
FIGURE 8 - REMOVING/INSTALLING SMALL
TIE RODS - PANTHER MX - 4
29
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PROCEDURE 5
SHROUD/FORK/WHEELS/TIE RODS
3. Position the mounting bolt on the large tie rod in
the mounting hole in the right front wheel axle.
REMOVING/ INSTALLING LARGE
TIE RODS
S
H
R
O
U
D
/
CAUTION
NOTE: This procedure applies to the PANTHER LX
- 4 and the PANTHER MX - 4 ONLY.
DO NOT overtighten the se lf-loc king nuts se -
c uring the la rge tie rod to the right front whe e l
a xle . Otherwise, da ma ge to the tie rod ma y
occur.
/
T
I
Panther LX - 4 (FIGURE 9)
F
REMOVING.
E
O
R
K
/
W
H
E
E
L
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
4. Secure the large tie rod to the right front wheel
axleusingtheEXISTINGspringwasherandself-
locking nut. Torque the self-locking nuts between
112 - 139 in./lbs.
R
O
D
S
2. Remove the front shroud assembly. Refer to
REMOVING/INSTALLING FRONT SHROUD
ASSEMBLY in PROCEDURE 5 of this manual.
5. Return the front frame assembly to the upright
position.
6. Reinstallthefrontwheels. RefertoREMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
3. Removethefrontwheels. RefertoREMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
S
7. Reinstall the front shroud assembly. Refer to
REMOVING/INSTALLING FRONT SHROUD
ASSEMBLY in PROCEDURE 5 of this manual.
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.
8. Reinstall the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
5. Remove the self-locking nut and spring washer
securing the large tie rod to the left front wheel axle.
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.
Small Tie Rod
Right
Front
NOTE: Save the self-locking nut and spring washer
for reuse when installing the NEW large tie rod.
Wheel
Large Tie Rod
Axle
6. Remove the self-locking nut and spring washer
securing the large tie rod to the right front wheel
axle.
Spring Washer
(STEP 6)
7. Remove the large tie rod.
Self-locking nut
(STEP 6)
INSTALLING.
1. Position the mounting bolt on the large tie rod in
the mounting hole in the left front wheel axle.
Left
Front
Wheel
CAUTION
Axle
Spring Washer (STEP 5)
DO NOT overtighten the se lf-loc king nuts se -
c uring the la rge tie rod to the le ft front whe e l
a xle . Otherwise, da ma ge to the tie rod ma y
occur.
Self-locking nut (STEP 5)
FIGURE 9 - REMOVING/INSTALLING LARGE
TIE RODS - PANTHER LX - 4
2. Secure the large tie rod to the left front wheel
axleusingtheEXISTINGspringwasherandself-
lockingnut. Securelytighten. Torquetheself-lock-
ing 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.
30
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SHROUD/FORK/WHEELS/TIE RODS
PROCEDURE 5
4. Position the EXISTING spacer between the tie
Panther MX - 4 (FIGURE 10)
S
H
R
O
U
D
/
rod and the left front wheel axle.
REMOVING.
5. Align the mounting hole in the large tie rod with
the mounting hole in the left front wheel axle.
1. Remove the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
/
T
I
CAUTION
2. Remove the front shroud assembly. Refer to
REMOVING/INSTALLING FRONT SHROUD
ASSEMBLY in PROCEDURE 5 of this manual.
DO NOT overtighten the se lf-loc king nuts se -
c uring the la rge tie rod to the le ft front whe e l
a xle . Otherwise, da ma ge to the tie rod ma y
occur.
F
E
O
R
K
/
W
H
E
E
L
R
O
D
S
3. Remove the front wheels. Refer to REMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
6. Secure the large tie rod to the left front wheel
axleusingtheEXISTINGhexcapscrewandself-
locking nut. Torque the self-locking nuts between
139 - 165 in./lbs.
4. Flip the front frame assembly onto its side.
7. Reinstall the front shock absorbers. Refer to RE-
MOVING/INSTALLING FRONT SHOCK AB-
SORBERS in PROCEDURE 11 of this manual.
5. Remove the front shock absorbers. Refer to
REPLACEMENT PARTS - PANTHER MX - 4 in
PROCEDURE 11 of this manual.
S
8. Return the front frame assembly to the upright
position.
NOTE: Save the hex cap screw, spacer and self-lock-
ing nut for reuse when installing the NEWlarge tie rod.
9. Reinstallthefrontwheels. RefertoREMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
6. Removethehexcapscrew, spacerandself-lock-
ing nut securing the large tie rod to the left front
wheel axle.
NOTE: Before removing the hex cap screw, spacer
andself-lockingnut, besuretotakenoteoftheproper
mounting holes in the right front wheel axle.
10. Reinstall the front shroud assembly. Refer to
REMOVING/INSTALLING FRONT SHROUD
ASSEMBLY in PROCEDURE 5 of this manual.
NOTE: Save the hex cap screw, spacer and self-
locking nut for reuse when installing the NEW large
tie rod.
11. Reinstall the tiller assembly. Refer to REMOV-
ING/INSTALLING TILLER ASSEMBLY in PRO-
CEDURE 4 of this manual.
7. Removethehexcapscrew, spacerandself-lock-
ing nut securing the large tie rod to the right front
wheel axle.
Right Front
Wheel Axle
Self-locking nut
Self-locking nut
8. Remove the large tie rod.
Left Front
Wheel Axle
INSTALLING.
1. Position the EXISTING spacer between the tie
rod and the right front wheel axle.
Spacer
Large Tie
Rod
2. Align the mounting hole in the large tie rod with
the mounting hole noted in the REMOVING sec-
tion.
Spacer
Hex Cap Screw
CAUTION
DO NOT overtighten the se lf-loc king nuts se -
c uring the la rge tie rod to the right front whe e l
a xle . Otherwise, da ma ge to the tie rod ma y
occur.
Hex Cap Screw
FIGURE 10 - REMOVING/INSTALLING LARGE
TIE RODS - PANTHER MX - 4
3. Secure the large tie rod to the right front wheel
axleusingtheEXISTINGhexcapscrewandself-
locking nut. Torque the self-locking nuts between
139 - 165 in./lbs.
31
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PROCEDURE 6
TRANSAXLE/MOTOR/BRAKE
9. Removethetwo(2)bolts, washers, springwash-
ersandself-lockingnutssecuringthebracketand
rubber spacer located near the transaxle hous-
ing to the rear frame assembly.
This Procedure Includes the Following:
Removing/InstallingTransaxle Assembly
Replacing Motor/Brake Assembly
T
R
A
N
S
A
X
L
E
/
M
O
T
O
R
/
Replacing Brake Release Lever Assembly
10. Remove the bracket and rubber spacer located
near the transaxle housing.
WARNING
11. Slidethetransaxleassemblyoutoftherearframe
assembly.
Afte r ANY a djustme nts, re pa ir or se rvic e a nd
BEFORE use , ma ke sure tha t a ll a tta c hing
ha rdwa re is tighte ne d se c ure ly - othe rwise
injury or da ma ge ma y re sult.
INSTALLING.
1. Slide the transaxle assembly into the rear frame
assembly.
Turn Power OFF a nd remove key from ignition.
Disconnect ba ttery ha rness from motor lea d.
B
R
A
K
NOTE: Before installing the brackets, be sure they
are in the proper mounting positions.
REMOVING/ INSTALLING
TRANSAXLE ASSEMBLY
E
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.
Lynx SX - 3P, Lynx SX - 3, Lynx LX - 3,
Panther LX - 4 (FIGURE 1)
CAUTION
REMOVING.
DO NOT overtighten the two (2) bolts secur-
ing the bra cket a nd rubber spa cer to the rea r
fra me a ssembly. Otherwise, da ma ge to the
bra cket a nd rubber spa cer ma y occur.
1. Remove the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
2. Remove the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
3. Install the two (2) bolts, washers, spring washers
andself-lockingnuts. Torquethetwo(2)selflock-
ing nuts between 130 - 156 in./lbs.
3. Remove the batteries. Refer to REMOVING/IN-
STALLING THE BATTERIES WITH CABLES in
PROCEDURE 4 of the Owners Manual, part
number 1090132.
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.
4. Remove the rear wheels. Refer to REMOVING/IN-
STALLINGTHEREARWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
CAUTION
DO NOT overtighten the two (2) bolts secur-
ing the bra cket a nd rubber spa cer to the rea r
fra me a ssembly. Otherwise, da ma ge to the
bra cket a nd rubber spa cer ma y occur.
NOTE: For proper reinstallation, note the position of
the cable ties securing the transaxle assembly wires
before cutting.
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
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.
5. Cut the cable ties securing the transaxle assem-
bly wires to the rear frame assembly.
6. Disconnectthe WHITEconnectorofthetransaxle
assembly wiring harness from the WHITE con-
nector of the controller wiring harness.
NOTE: Before removing the brackets, take note of the
mounting position for proper reinstallation.
6. Connect the WHITE connector of the transaxle
assembly wiring harness to the WHITE connec-
tor of the controller wiring harness.
7. Removethetwo(2)bolts, washers, springwash-
ersandself-lockingnutssecuringthebracketand
rubber spacer located near the motor to the rear
frame assembly.
NOTE: Besurethecabletiesarepositionedasnoted
in STEP 5.
7. Secure the wires of the transaxle assembly wir-
ing harness to the rear frame assembly using
NEW cable ties.
8. Remove the bracket and rubber located near the
motor.
32
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TRANSAXLE/MOTOR/BRAKE
PROCEDURE 6
10. Reinstall the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
8. Reinstall the rear wheels. Refer to REMOVING/IN-
STALLINGTHEREARWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
T
R
A
N
S
A
X
L
E
/
11. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
9. Reinstall the batteries. Refer to REMOVING/IN-
STALLING THE BATTERIES WITH CABLES in
PROCEDURE 4 of the Owners Manual, part
number 1090132.
LYNX SX - 3P, LYNX SX - 3
M
O
T
O
R
/
B
R
A
K
Removing STEP 9, Installing STEP 3
Bolt
Bracket
Rubber Spacer
Washer
Removing STEP
Installing STEP 5
E
Spring Washer
Motor
Self-Locking Nut
Bolts
Transaxle Housing
White Connector (Disconnected)
Cable Tie
Washer
Spring Washer
Transaxle Assembly Wires
Rear Frame Assembly
Bracket
Self-Locking
Nut
Rubber Spacer
LYNX LX - 3, PANTHER LX - 4
Removing STEP 9, Installing STEP 3
Bracket
Bolt
Removing STEP 7, Installing STEP 5
Rubber Spacer
Motor
Washer
Spring Washer
Bracket
Self-locking nut
Bolts
Washer
Transaxle Housing
White Connector (Disconnected)
Cable Tie
Spring
Washer
Self-locking nut
Transaxle Assembly Wires
Rear Frame Assembly
Rubber Spacer
FIGURE 1 - REMOVING/INSTALLING TRANSAXLE ASSEMBLY - LYNX SX - 3P, LYNX SX - 3, LYNX
LX - 3 AND PANTHER LX - 4
33
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PROCEDURE 6
TRANSAXLE/MOTOR/BRAKE
Panther MX - 4 (FIGURE 2)
CAUTION
T
R
A
N
S
A
X
L
E
/
M
O
T
O
R
/
DO NOT overtighten the two (2) screws secur-
ing the bra cket a nd rubber spa cer to the rea r
fra me a ssembly. Otherwise, da ma ge to the
bra cket a nd rubber spa cer ma y occur.
REMOVING.
1. Remove the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
3. Secure the bracket and the rubber spacer to the
rear frame assembly using the two (2) screws
andself-lockingnuts. Torquethetwo(2)selflock-
ing nuts between 16 - 20 in./lbs.
2. Remove the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUD inPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
4. Align the mounting holes of the U - brace with the
mounting holes in the rear frame assembly.
3. Remove the batteries. Refer to REMOVING/IN-
STALLING THE BATTERIES WITH CABLE
ASSEMBLY in PROCEDURE 4 of the Owners
Manual, part number 1090132
B
R
A
K
5. PositiontherubberspacerbetweentheU-brace
and the rear frame assembly.
4. Remove the rear wheels. Refer to REMOVING/IN-
STALLING THE REAR WHEELS in PROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
CAUTION
E
DO NOT overtighten the two (2) bolts securing
the U - bra ce a nd rubber spa cer to the rea r
fra me a ssembly. Otherwise, da ma ge to the
U - bra ce a nd rubber spa cer ma y occur.
5. Remove the disc brake assembly. Refer to RE-
PLACING DISC BRAKE ASSEMBLY in PRO-
CEDURE 11 of this Manual.
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.
6. Remove the TOP bolts on the two (2) rear shock
absorbers (DETAIL “A”).
7. Rotate the top of the two (2) rear shock absorb-
ers away from the frame (DETAIL “A”).
7. Rotate the top of the two (2) rear shock assem-
blies toward the frame.
8. Disconnect the WHITE connectors of the
transaxle assembly from the WHITE connectors 8. Align the two (2) rear shock assemblies with the
of the control assembly.
two (2) mounting holes on the rear frame assem-
bly (DETAIL “A”).
9. Remove the two (2) bolts, spring washers, self-
locking nuts, and four (4) washers securing the 9. Secure the two (2) rear shock assemblies to the
U-brace and rubber spacer to the rear frame as-
sembly.
rear frame assembly using the existing screws
(DETAIL “A”). Securely tighten.
10. RemovetheU-braceandrubberspacerfromthe 10. Connect the WHITE connector of the transaxle
rear frame assembly.
assembly to the WHITE connector of the control
assembly.
11. Remove the two (2) screws and self-locking nuts
securingthebracketandrubberspacertotherear 11. Reinstall the disc brake assembly. Refer to RE-
frame assembly.
PLACING DISC BRAKE ASSEMBLY in PRO-
CEDURE 11 of this manual.
12. Remove the bracket and rubber spacer from the
rear frame assembly.
12. Reinstall the rear wheels. Refer to REMOVING/IN-
STALLINGTHEREARWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
13. Slide the transaxle assembly out of the rear frame
assembly.
13. Reinstall the batteries. Refer to REMOVING/IN-
STALLING THE BATTERIES WITH CABLES in
PROCEDURE 4 of the Owners Manual, part
number 1090132.
INSTALLING.
1. Slide the transaxle assembly into the rear frame
assembly.
2. Align the mounting holes in the bracket and the 14. Reinstall the rear shroud. Refer to REMOVING/
rubber spacer with the mounting holes in the rear
frame assembly.
INSTALLINGTHEREARSHROUD inPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
34
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TRANSAXLE/MOTOR/BRAKE
PROCEDURE 6
15. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEAT inPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
REPLACING MOTOR/ BRAKE
ASSEMBLY (FIGURE 3)
T
R
A
N
S
A
X
L
E
/
M
O
T
O
R
/
1
Remove the transaxle assembly. Refer to RE-
MOVING/INSTALLING TRANSAXLE ASSEM-
BLY in PROCEDURE 6 of this manual.
Top Bolt
2. Remove the four EXISTING (4) nylock socket
bolts that secure the motor/brake assembly to
the transaxle assembly.
Rear Shock
Absorbers
3. Remove the EXISTING motor/brake assembly
from the transaxle assembly.
4. Remove the EXISTING plate and bushing from
B
R
A
K
DETAIL “A”
the transaxle assembly.
5. Position the NEW plate in the transaxle.
6. Position the NEW bushing over the plate.
Bolts
E
7. Position the NEW motor/brake assembly so that
the mounting holes in the NEW motor/brake as-
sembly line up with the mounting holes in the
transaxle assembly.
Washer
U - Brace
8. Install the four (4) NEW nylock socket bolts that
securethemotor/brakeassemblytothetransaxle.
Torque the four (4) NEW nylock socket bolts be-
tween 156 - 191 in./lbs.
Rubber Spacer
Transaxle Assembly
9. Reinstall the transaxle assembly. Refer to RE-
MOVING/INSTALLING TRANSAXLE ASSEM-
BLY in PROCEDURE 6 of this manual.
White Connector
(Disconnected)
Motor/Brake
Assembly
Screw
Nylock Bolts
Rear
Frame
Assembly
Rear
Frame
Assembly
Washer
Rubber
Spacer
Spring
Washer
Plate
Bushing
Self-locking
nut
Bracket
Transaxle
Self-locking
nut
FIGURE 3 - REPLACING MOTOR/BRAKE
ASSEMBLY
FIGURE 2 - REMOVING/INSTALLING
TRANSAXLE ASSEMBLY - PANTHER MX - 4
35
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PROCEDURE 6
TRANSAXLE/MOTOR/BRAKE
3. Remove the socket screw and the bolt socket
securing the brake release lever to motor/brake
assembly.
REPLACING BRAKE RELEASE
LEVER ASSEMBLY (FIGURE 4)
T
R
A
N
S
A
X
L
E
/
For All Models EXCEPT Panther MX - 4
4. Remove the brake release lever.
1. Remove the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
5. Align the mounting holes in the NEW brake re-
leaseleverwiththemountingholesinmotor/brake
assembly.
2. Remove the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUD inPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
M
O
T
O
R
/
B
R
A
K
6. Secure the NEW brake release lever to the mo-
tor/brakeassemblyusingthe NEWsocketscrew
and bolt socket. Securely tighten.
7. Reinstall the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUD inPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
NOTE: Savethetwo(2)mountingscrewsandspring
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/
brake assembly.
E
8. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
4. Remove the brake cover from the motor/brake
assembly.
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.
Motor/Brake
Assembly
Brake
6. Remove the brake release lever.
Self-locking
nut
Release
Lever
7. Align the mounting hole in the NEW brake re-
lease lever with the mounting hole in the motor
brake assembly.
8. Secure the NEW brake release lever to the mo-
tor/brake assembly using the NEW mounting
screw and self-locking nut. Securely tighten.
Mounting
Screw
Brake
Cover
9. Align the two (2) mounting holes in the EXIST-
ING brake cover with the two (2) mounting holes
in the motor/brake assembly.
Spring Washers
Mounting Screws
PANTHER MX - 4
10. Secure the EXISTING brake cover to the motor/
brakeassemblyusingthetwo(2)EXISTINGmount-
ing screws and spring washers. Securely tighten.
Bolt
Socket
Brake Release Lever
Mounting Holes
11. Reinstall the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE Socket
9 of the Owner’s Manual, part number 1090132.
Motor/Brake
Assembly
Screw
12. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
Panther MX - 4
1. Remove the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
FIGURE 4 - REPLACING BRAKE RELEASE
LEVER ASSEMBLY
2. Remove the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
36
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CONTROLLER
PROCEDURE 7
CONNECTING.
1. Connect the following (FIGURE 1):
This Procedure Includes the Following:
Removing/Installing Controller
A. The RED and WHITE connectors to the slot
marked “B+” on the controller.
Removing/Installing Controller Harnesses
Replacing Circuit Breaker
C
O
N
T
R
O
L
B. The BLACK and GREEN connectors to the
slot marked “B-” on the controller.
WARNING
C. The BLACK connector to the slot marked
“M+” on the controller.
After ANY a djustments, repa ir or service a nd
BEFORE use, ma ke sure tha t a ll a tta ching ha rd-
wa re is tightened securely - otherwise injury or
da ma ge ma y oc c ur.
D. The RED connector to the slot marked “M-”
L
on the controller.
E
R
E. The housing of the main control wiring har-
Turn Power OFF and remove key from ignition.
Disconnectbatteryharnessfrom the motorlead.
ness to the slot marked “P2”on the controller.
ALL MODELS EXCEPT PANTHER MX - 4
REMOVING/ INSTALLING
CONTROLLER
Main Control
Housing
Red
Connector
Black
Connector
Disconnecting/ Connecting Controller
Wires (FIGURE 1)
“P2” Slot
Black And
Green
Connectors
DISCONNECTING.
1. Remove the seat. Refer to REMOVING/IN-
STALLINGTHESEATin PROCEDURE 5 of the
Owner’s Manual, part number 1090132.
2. Remove the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUDinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
“B-” Slot
“M-” Slot
Controller
“M+” Slot
“B+” Slot
3. Remove the transaxle assembly. Refer to RE-
MOVING/INSTALLING TRANSAXLE ASSEM-
BLY in PROCEDURE 6 of this manual.
Red And White
Connectors
PANTHER MX - 4
4. Disconnectthefollowingfromthecontroller(FIG-
URE 1):
“P2”
Slot
Main
Control
Housing
Black
And
A. The RED and WHITE connectors from the
slot marked “B+” on the controller.
Red
Connector
Green
Connectors
B. The BLACK and GREEN connectors from
the slot marked “B-” on the controller.
C. TheBLACKconnectorfromtheslotmarked
“M+” on the controller.
“B-” Slot
D. The RED connector from the slot marked
“M-” on the controller.
Black
Connector
E. The housing of the main control wiring har-
ness from the slot marked “P2” on the con-
troller.
“M-” Slot
Red And White
Connectors
“M+” Slot
“B+” Slot
FIGURE 1 - DISCONNECTING/
CONNECTING CONTROLLER WIRES
37
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PROCEDURE 7
CONTROLLER
2. Reinstall the transaxle assembly. Refer to RE- INSTALLING.
MOVING/INSTALLING TRANSAXLE ASSEM- 1. Perform one of the following:
BLY in the PROCEDURE 6 of this manual.
A. LYNXSX-3andLYNXSX-3P(FIGURE2):
3. Reinstall the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
5 of the Owner’s Manual, part number 1090132.
1. Gently slide the controller and the control-
ler plate onto the rear frame, making sure
thesupportontherearframeispositioned
in the slot on the controller plate.
C
O
N
T
R
O
L
L
E
R
4. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE9ofthe
Owner’s Manual, part number 1090132.
2. Align the mounting holes in the control-
ler plate with the mounting holes in the
controller.
Rem oving/ Installing Controller From /
To Controller Plate (FIGURE 2)
3. Insert the two (2) short screws through the
controllerandthecontrollerplate,andsecure
them with the washer and self-locking nut.
Securely tighten.
REMOVING.
1. Disconnectthecontrollerwires.RefertoDISCON-
NECTING/CONNECTING CONTROLLER
WIRES in this procedure of the manual.
4. Position the wires in the two (2) retaining
tabs.
2. Perform one (1) of the following:
5. Secure the wires to the two (2) retaining
A. LYNXSX-3 andLYNXSX-3P (FIGURE2):
tabs using NEW cable ties.
1. Cut the cable ties securing the wires to
the two (2) retaining tabs.
B. LYNX LX - 3 and PANTHER LX - 4 (FIG-
URE 2):
2. Remove the wires from the two (2) re-
taining tabs.
1. Gently slide the controller and the con-
troller plate onto the rear frame, making
sure the support on the rear frame is po-
sitioned in the slot on the controller plate.
3. Removethetwo(2)shortscrews, wash-
ers and self-locking nuts from the con-
troller assembly.
2. Align the mounting hole in the retaining tab
withthemountingholesinthecontroller plate
and the mounting holes in the controller.
4. Gently slide the controller and the con-
troller plate from the rear frame.
5. Separate the controller from the control-
ler plate.
3. Insert the long screw through the control-
ler, the controller plate and the retaining
tab, and secure it with the washer and
self-locking nut. Securely tighten.
B. LYNX LX - 3 and PANTHER LX - 4 (FIG-
URE 2):
4. Inserttheprovidedshortscrewthroughthe
controller and the controller plate, and se-
cureitwiththewasherandself-lockingnut.
Securely tighten.
1. Removetheshortscrew,washerandself-
locking nut from the controller assembly.
2. Removethelongscrew, washerandself-
locking nuts from the controller assem-
bly and the retaining tab.
C. PANTHER MX - 4 (FIGURE 2):
3. Remove the retaining tab from the con-
troller.
1. Position the controller on the rear frame
so that the mounting holes in the con-
troller align with the mounting holes in
the rear frame/controller plate.
4. Gently slide the controller and the con-
troller plate from the rear frame.
2. Insertthetwo(2)screwsthroughthecon-
trollerandtherearframe,andsecurethem
with the washers and self-locking nuts.
Securely tighten.
5. Separate the controller from the control-
ler plate.
C. PANTHER MX - 4 (FIGURE 2):
1. Remove the two (2) screws, washers,
andself-lockingnutsfromtherearframe.
2. Connect the controller wires. Refer to DISCON-
NECTING/CONNECTING CONTROLLER
WIRES in this procedure of the manual.
2. Remove the controller from the rear
frame/controller plate.
38
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CONTROLLER
PROCEDURE 7
REMOVING/ INSTALLING
CONTROLLER HARNESSES
LYNX SX - 3P AND LYNX SX - 3
Short
Screws
Washer
Controller
Lynx SX - 3P And Lynx SX - 3
(FIGURE 3)
C
O
N
T
R
O
L
Washer
REMOVING.
1. Disconnectthecontrollerwires.RefertoDISCON-
NECTING/CONNECTING CONTROLLER
WIRES in this procedure of the manual.
Retaining
Tab
Rear
2. Disconnect the RED and BLACK connectors of
the power wiring harnesses from the RED and
BLACK connectors of the controller wiring har-
nesses.
L
E
R
Frame
Support
Slot
Controller
Plate
3. Disconnectthe WHITEconnectorofthetransaxle
assembly wiring harness from the WHITE con-
nector of the controller wiring harness.
Self-locking
nuts
Retaining
Tab
NOTE: Note the positions of the metal connectors
before removing for proper reinstallation.
LYNX LX - 3 AND PANTHER LX - 4
Short
Screw
Long
Screw
4. Disconnect the metal connectors of the control-
ler wiring harnesses from the metal connectors
of the circuit breaker.
Washer
Washer
Controller
5. Disconnect the BLUE connector of the tiller wir-
ingharnessfromtheBLUEconnectorofthecon-
troller wiring harness.
Rear
6. Disconnect the YELLOW connector of the tiller
wiring harness from the YELLOW connector of
the controller wiring harness.
Frame
Retaining
Tab
Support
Slot
7. Cut the cable ties securing the transaxle wiring
harness to the rear frame.
Controller
Plate
Retaining
Tab
8. Cut the cable tie securing the power wiring har-
nesses and the tiller wiring harnesses to the rear
frame.
Self-locking nuts
9. Cut the cable tie securing the tiller wiring har-
nesses to the retaining tabs of the controller.
PANTHER MX - 4
10. Remove the tiller wiring harnesses from the retain-
ing tabs.
Self-locking
nuts
11. Remove the wiring harnesses from the scooter.
Controller
INSTALLING.
1. Position the tiller wiring harnesses in the retaining
tabs.
2. Secure the tiller wiring harnesses to the retaining
Washer
Screws
tabs using NEW cable ties.
Rear Frame/
Controller Plate
3. Secure the power wiring harnesses and the tiller
wiring harnesses to the rear frame using NEW
cable ties.
FIGURE 2 - REMOVING/INSTALLING
4. Securethetransaxlewiringharnessestotherear
CONTROLLER FROM/TO CONTROLLER PLATE
frame using NEW cable ties.
39
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PROCEDURE 7
CONTROLLER
5. Connectthe RED andBLACKconnectorsofthe
powerwiringharnessestothe REDandBLACK
connectors of the controller wiring harnesses.
8. Connect the BLUE connector of the tiller wiring
harness to the BLUE connector of the controller
wiring harness.
6. Connect the WHITE connector of the transaxle
assembly wiring harness to the WHITE connec-
tor of the controller wiring harness.
9. Connect the YELLOW connector of the tiller wir-
ing harness to the YELLOW connector of the
controller wiring harness.
C
O
N
T
R
O
L
L
E
R
NOTE: Be sure the metal connectors are in the po-
sitions noted in STEP 4 of REMOVAL.
10. Reinstall the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUDinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
7. Connect the metal connectors of the power wir-
ing harnesses to the metal connectors of the cir-
cuit breaker.
11. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
Blue Connectors - Tiller
Wiring Harness
Blue Connectors - Controller
Wiring Harness
Black Connectors -
Controller Wiring Harness
Yellow Connectors - Tiller
Wiring Harness
Black Connectors - Power
Wiring Harness
Yellow Connectors - Controller
Wiring Harness
Tiller Wiring Harness
Power Wiring Harness
Metal Connectors -
Circuit Breaker
Metal Connectors -
Controller Wiring Harness
Cable Tie
Red Connector - Controller
Wiring Harness
White Connector -
Controller Wiring Harness
Red Connector - Power
Wiring Harness
White Connector -
Transaxle Assembly
Retaining Tabs
Transaxle Wiring Harness
Tiller Wiring Harness
Cable Ties
Rear Frame
FIGURE 3 - REMOVING/INSTALLING CONTROLLER HARNESSES - LYNX SX - 3P AND LYNX SX 3
NOTE: Note of the positions of the metal connectors
before removing for proper reinstallation.
Lynx LX - 3 and Panther LX - 4
(FIGURE 4)
REMOVING.
4. Disconnect the metal connectors of the control-
ler wiring harnesses from the metal connectors
of the circuit breaker.
1. Disconnectthecontrollerwires.RefertoDISCON-
NECTING/CONNECTING CONTROLLER
WIRES in this procedure of the manual.
5. Disconnect the BLUE connector of the tiller wir-
ingharnessfromtheBLUEconnectorofthecon-
troller wiring harness.
2. DisconnecttheRED andBLACK connectorsofthe
power wiring harnesses from the RED and BLACK
connectors of the controller wiring harnesses.
6. Disconnect the YELLOW connector of the tiller
wiring harness from the YELLOW connector of
the controller wiring harness.
3. Disconnectthe WHITEconnectorofthetransaxle
assembly wiring harness from the WHITE con-
nector of the controller wiring harness.
40
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CONTROLLER
PROCEDURE 7
7. Cutthecabletiesecuringthetransaxle wiringhar- 5. Connect the WHITE connector of the transaxle
ness to the rear frame.
assembly wiring harness to the WHITE connec-
tor of the controller wiring harness.
8. Cut the cable tie securing the power wiring har-
nesses to the rear frame.
NOTE: Be sure the metal connectors are in the
positions noted in STEP 2 of REMOVAL.
C
O
N
T
9. Remove the tiller wiring harness from the retain-
ing tab.
6. Connect the metal connectors of the power wir-
ing harnesses to the metal connectors of the cir-
cuit breaker.
10. Remove the wiring harnesses from the scooter.
R
O
L
L
E
R
INSTALLING.
1. Position the tiller wiring harnesses in the retain-
ing tabs.
7. Connect the BLUE connector of the tiller wiring
harness to the BLUE connector of the controller
wiring harness.
2. Secure the power wiring harnesses to the rear 8. Connect the YELLOW connector of the tiller wir-
frame using NEW cable ties.
ing harness to the YELLOW connector of the
controller wiring harness.
3. Securethetransaxlewiringharnesstotherearframe
using a NEW cable tie.
9. Reinstall the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
4. Connectthe RED and BLACKconnectorsofthe
powerwiringharnessestothe REDandBLACK
connectors of the controller wiring harnesses.
10. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
Black Connectors -
Controller Wiring Harness
Black Connectors - Power
Wiring Harness
Metal Connectors -
Circuit Breaker
Power Wiring Harness
Cable Tie
Metal Connectors -
Controller Wiring Harness
Red Connector - Controller
Wiring Harness
Cable Tie
Transaxle Wiring Harness
Red Connector - Power
Wiring Harness
White Connector -
Transaxle Assembly
Tiller Wiring Harness
Retaining Tabs
White Connector -
Controller Wiring Harness
Blue Connectors - Controller
Wiring Harness
Blue Connectors - Tiller
Wiring Harness
Yellow Connectors - Tiller
Yellow Connectors - Controller
Wiring Harness
Wiring Harness
Rear Frame
FIGURE 4 - REMOVING/INSTALLING CONTROLLER HARNESSES - LYNX LX - 3 AND
PANTHER LX - 4
41
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PROCEDURE 7
CONTROLLER
9. Cut the cable tie securing the tiller wiring harness
to the rear frame.
Panther MX - 4 (FIGURE 5)
REMOVING.
10. Cut the cable tie securing the main control hous-
ing wiring harnesses to the retaining tab.
1. Disconnect the controller wires. Refer to DIS-
CONNECTING/CONNECTINGCONTROLLER
WIRES in this procedure of the manual.
C
O
N
T
R
O
L
L
E
R
11. Remove the wiring harnesses from the scooter.
2. DisconnectheREDandBLACKconnectorsofthe
powerwiringharnessesfromtheREDandBLACK
connectors of the controller wiring harnesses.
INSTALLING.
1. Position the metal connector wiring harnesses
in the retaining tab.
3. Disconnectthe WHITEconnectorofthetransaxle
assembly wiring harness from the WHITE con-
nector of the controller wiring harness.
2. Secure the metal connector wiring harness into
the retaining tab using NEW cable ties.
3. Securethepowerwiringharnessesandthemetal
connector wiring harness to the rear frame using
NEW cable ties.
NOTE: Note of the positions of the metal connectors
before removing for proper reinstallation.
4. Disconnect the metal connectors of the control-
ler wiring harnesses from the metal connectors
of the circuit breaker.
4. Secure the tiller wiring harness to the rear frame
using NEW cable ties.
5. Securethemaincontrolhousingwiringharnesses
5. Disconnect the WHITE connector of the tiller wir-
ing harness from the WHITE connector of the
controller wiring harness
to the retaining tab using a NEW cable tie.
6. Connectthe RED andBLACKconnectorsofthe
powerwiringharnessestothe REDandBLACK
connectors of the controller wiring harnesses.
6. Cutthecabletiesecuringpowerwiringharnesses
and the metal connector wiring harness to the
rear frame.
7. Connect the WHITE connector of the transaxle
assembly wiring harness to the WHITE connec-
tor of the controller wiring harness.
7. Cut the cable tie securing the metal connector
wiring harnesses to the retaining tab.
NOTE: Be sure the metal connectors are in the
positions noted in STEP 2 of REMOVAL.
8. Remove the metal connector wiring harnesses
from the retaining tab.
Metal Connectors -
Circuit Breaker
Tiller Wiring
Harness
Metal Connectors -
Controller Wiring Harness
White Connector -
Transaxle Assembly
Red Connector - Power
Wiring Harness
White Connector -
Controller Wiring Harness
Red Connector - Controller
Wiring Harness
Retaining Tabs
Cable Tie
Black Connectors - Power
Wiring Harness
Main Control
Wiring Harness
Black Connectors -
Controller Wiring Harness
White Connector -
Controller Wiring Harness
Metal Connector Wiring
Harness
Cable Ties
Power Wiring Harness
White Connector -
Transaxle Assembly
Retaining Tab
FIGURE 5 - REMOVING/INSTALLING CONTROLLER HARNESSES - PANTHER MX - 4
42
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CONTROLLER
PROCEDURE 7
8. Connect the metal connectors of the power wir- 10. Reinstall the rear shroud. Refer to REMOVING/IN-
ing harnesses to the metal connectors of the cir-
cuit breaker.
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
9. Connect the WHITE connector of the tiller wiring 11. Reinstall the seat. Refer to REMOVING/IN-
C
O
N
T
harness to the WHITE connector of the control-
STALLING THE SEATinPROCEDURE5ofthe
ler wiring harness
Owner’s Manual, part number 1090132.
R
O
L
L
E
R
REPLACING CIRCUIT BREAKER
(FIGURE 6)
Nut
Washer
Note: Note the proper positions of the metal connec-
tors before removing for proper reinstallation.
Rear
Frame
Assembly
1. Remove the RED and BLACK metal connec-
tors of the power cables from the metal connec-
tors of the circuit breaker.
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.
Metal
Connectors
5. Positionthe NEW circuitbreakersothatitpasses
through the mounting hole in the rear frame as-
sembly.
Red/Black Metal
Connectors
6. Position the NEW washer on the circuit breaker.
Power
Cables
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.
FIGURE 6 - REPLACING CIRCUIT BREAKER
8. Connectthe RED andBLACKconnectorsofthe
powercablestothemetalconnectorsontheNEW
circuit breaker as noted from STEP 1.
43
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PROCEDURE 8
REPLACEMENT PARTS - LYNX SX - 3P
Self-locking
Mounting
Holes
This Procedure Includes the Following:
Replacing Tiller Charge Port Cover
nuts
R
E
P
L
A
C
E
M
E
N
T
Tiller
Charger
Port Cover
WARNING
After ANY a djustments, repa ir or service a nd
BEFORE use, ma ke sure tha t a ll a tta ching ha rd-
wa re is tightened securely - otherwise injury or
da ma ge ma y oc c ur.
Turn Powe r OFF a nd re move ke y from igni-
tion. Disc onne c t ba tte ry ha rne ss from the
motor le a d.
Mounting
Screws
Tiller
Assembly
P
A
R
T
FIGURE 1 - REPLACING TILLER CHARGER
PORT COVER
REPLACING TILLER CHARGER
PORT COVER (FIGURE 1)
S
NOTE: Save the two (2) mounting screws and self-
locking nuts for reuse when installing the NEW tiller
charger port cover.
1. Remove the two (2) mounting screws and self-
locking nuts securing the tiller charger port cover
to the tiller assembly.
2. Removethetillerchargerportcoverfromthetiller
assembly.
L
Y
N
X
3. AlignthemountingholesintheNEWtillercharger
port cover with the mounting holes in the tiller
assembly.
4. Secure the NEW tiller charger port cover to the
tillerassemblyusingthetwo(2)EXISTINGmount-
ingscrewsandself-lockingnuts. Securelytighten.
S
X
3
P
44
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REPLACEMENT PARTS - LYNX LX - 3
PROCEDURE 9
This Procedure Includes the Following:
Removing/Installing Head light Assembly
R
E
P
L
A
C
E
M
E
N
T
Tiller
Wiring
Harness
WARNING
After ANY a djustments, repa ir or service a nd
BEFORE use, ma ke sure tha t a ll a tta ching ha rd-
wa re is tightened securely - otherwise injury or
da ma ge ma y oc c ur.
Head
light
Assembly
Turn Powe r OFF a nd re move ke y from igni-
tion. Disc onne c t ba tte ry ha rne ss from the
motor le a d.
Plastic
Guards
P
A
R
T
Red/
Black
Cables
REMOVING/ INSTALLING HEAD
LIGHT ASSEMBLY (FIGURE 1)
Red/Black
Cables
S
Rem oving
Metal
Connectors
NOTE: Partial disassembly of the tiller assembly is
required to remove the head light assembly.
FIGURE 1 - REMOVING/INSTALLING HEAD
LIGHT ASSEMBLY
1. PerformSECTIONS “A”and“D”inREMOVING/
INSTALLING TILLER ASSEMBLY in PROCE-
DURE 3 of this manual.
2. Pull back the plastic guards on the RED and
BLACK cables connecting the tiller wiring har-
ness to the head light assembly.
L
Y
N
X
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.
L
X
3
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 REDcablemetalcon-
nector 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 har-
ness to the head light assembly.
4. Perform SECTIONS “D” and “A” in PROCE-
DURE 3 - REMOVING/INSTALLING TILLER
ASSEMBLYintheTILLERsectionofthismanual.
45
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PROCEDURE 10
REPLACEMENT PARTS - PANTHER LX - 4
5. Repositiontheplasticguardsoverthemetalcon-
nectors on the RED and BLACK cables con-
necting the tiller wiring harness to the head light
assembly (DETAIL “A”).
This Procedure Includes the Following:
Removing/Installing Head Light Assembly
Replacing Tiller Charge Port Cover
R
E
P
L
A
C
E
M
E
N
T
6. Return the front frame assembly to the upright
position.
Replacing Cushion/Front Bumper Assembly
WARNING
After ANY a djustments, repa ir or service a nd
BEFORE use, ma ke sure tha t a ll a tta ching ha rd-
wa re is tightened securely - otherwise injury or
da ma ge ma y oc c ur.
P
A
R
T
Turn Powe r OFF a nd re move ke y from igni-
tion. Disc onne c t ba tte ry ha rne ss from the
motor le a d.
S
REMOVING/ INSTALLING HEAD
LIGHT ASSEMBLY (FIGURE 1)
Red/Black
Cables
Rem oving
1. Flip the scooter onto its side.
To Tiller
To Head
Wiring
2. Pull back the plastic guards on the RED and
BLACK cables connecting the tiller wiring har-
ness to the head light assembly (DETAIL “A”).
Light
Harness
Assembly
Plastic
P
A
N
T
H
E
R
Guards
Metal
Connectors
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”).
DETAIL “A”
4. Remove the bolt, self-locking nut, spring washer,
and washer securing the head light assembly to
the front frame assembly.
L
X
4
Bolt
5. Separate the head light assembly from the front
frame assembly.
Head light
Assembly
Installing
1. Align the bolt in the head light assembly with the
mounting holes in the front frame assembly.
2. Securetheheadlightassemblytothefrontframe
assembly using the washer, spring washer and
self-locking nut. Securely tighten.
Front Frame
Assembly
3. Connect the RED cable metal connector of the
head light assembly to the RED cablemetalcon-
nector of the tiller wiring harness (DETAIL “A”).
4. Connect the BLACK cable metal connector of
theheadlightassemblytotheBLACKcablemetal
connectorofthetillerwiringharness(DETAIL“A”).
Washer
Spring Washer
Self-locking nut
FIGURE 1 - REMOVING/INSTALLING HEAD
LIGHT ASSEMBLY
46
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REPLACEMENT PARTS - PANTHER LX - 4
PROCEDURE 10
5. Secure the NEW cushion to the front frame as-
semblyusingthetwo(2) NEWmountingscrews,
spring washers and washers. Securely tighten.
REPLACING TILLER CHARGER
PORT COVER (FIGURE 2)
R
E
P
L
A
C
E
M
E
N
T
NOTE: Save the two (2) mounting screws and self-
locking nuts for reuse when installing the NEW tiller
charger port cover.
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.
1. Remove the two (2) mounting screws and self-
locking nuts securing the tiller charger port cover
to the tiller assembly.
2. Position the mounting tape on the bottom of the
front shroud assembly.
2. Remove the tiller charger port from the tiller as-
sembly.
3. Position the NEW bumper on the mounting tape
P
A
R
T
3. AlignthemountingholesintheNEWtillercharger
port cover with the mounting holes in the tiller
assembly.
on the front shroud assembly.
Mounting
s
Spring Washers
Washers
4. Secure the NEW tiller charger port cover to the
tillerassemblyusingthetwo(2)EXISTINGmount-
ingscrewsandself-lockingnuts. Securelytighten.
S
Front
Frame
Assembly
Mounting
Holes
Tiller
Charger
Port Cover
P
A
N
T
H
E
R
Cushion
DETAIL “A”
Mounting
Screws
Tiller
Assembly
FIGURE 2 - REPLACING TILLER CHARGE
PORT COVER
Front Shroud
Assembly
L
X
4
REPLACING CUSHION/ FRONT
BUMPER ASSEMBLY (FIGURE 3)
Rem oving The Front Bum per Assem bly
Mounting Tape
Front Bumper
CUSHION (DETAIL “A”).
1. Position the scooter on its side.
DETAIL “B”
2. Remove the two (2) mounting screws, spring
washers and washers securing the cushion to
the front frame assembly.
FIGURE 3 - REPLACING CUSHION/FRONT
BUMPER ASSEMBLY
3. Remove the cushion from the front frame as-
sembly
4. Alignthetwo(2)mountingholesintheNEWcush-
ion with the mounting holes in the front frame
assembly.
47
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PROCEDURE 11
REPLACEMENT PARTS - PANTHER MX - 4
8. Remove the two (2) self-locking nuts, three (3)
washers,springwasher,springandthelongscrew
securing the bottom of the head light assembly to
the bracket on the front frame assembly.
This Procedure Includes the Following:
Removing/Installing Head Light Assembly
Replacing Tail Light Assembly
R
E
P
L
A
C
E
M
E
N
T
9. Remove the head light assembly from the front
shroud assembly.
Replacing Tail Light Cable
Replacing Disc Brake Assembly
Replacing Disc Brake Shoes
Installing
Replacing Hand Brake Assembly
Rmoving/Installing Front Shock Absorbers
Removing/Installing Rear Shock Absorbers
1. Positiontheheadlightassemblythroughthefront
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.
P
A
R
T
WARNING
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.
After ANY a djustments, repa ir or service a nd
BEFORE use, ma ke sure tha t a ll a tta ching ha rd-
wa re is tightened securely - otherwise injury or
da ma ge ma y oc c ur.
S
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.
Turn Powe r OFF a nd re move ke y from igni-
tion. Disc onne c t ba tte ry ha rne ss from the
motor le a d.
4. Position the long screw through the bottom hole
on the head light assembly.
5. Position the spring and one (1) washer on the
longscrewsothatthespringisbetweenthehead
light assembly and the bracket on the front frame
assembly.
REMOVING/ INSTALLING HEAD
LIGHT ASSEMBLY (FIGURE 1)
P
A
N
T
Rem oving
6. Position the long screw so that it passes through
the bracket on the front frame assembly.
H
E
R
1. Separate the front frame assembly from the rear
frameassembly. RefertoTRANSPORTINGTHE
SCOOTER in PROCEDURE 10 of the Owner’s
Manual, part number 1090132.
7. Secure the long screw to the bracket assembly
using one (1) spring washer and self-locking nut.
Securely tighten.
M
X
4
2. Flip the front frame assembly onto its side.
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.
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.
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 con-
nector 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.
11. Connect the BLACK cable metal connector of
theheadlightassemblyintheBLACKcablemetal
connector of the tiller wiring harness.
6. Removethefrontbumperandrubberspacerfrom
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.
12. Reposition the plastic guards on the RED and
BLACK cables connecting the tiller wiring har-
ness to the head light assembly.
NOTE: Beforeremovingthemountinghardwarefrom
the long screw, be sure to take note of the proper
position for each components.
48
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REPLACEMENT PARTS - PANTHER MX - 4
PROCEDURE 11
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.
15. Return the front frame assembly to the upright
position.
R
E
P
L
A
C
E
M
E
N
T
16. Reassemble the front frame assembly and the
rear frame assembly. Refer to TRANSPORT-
INGTHESCOOTERinPROCEDURE10ofthe
Owner’s Manual, part number 1090132.
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.
Spring
Washer
Red/Black
Cables
Front Shroud Assembly
Washer
Tiller
Wiring
Harness
Plastic
Guards
Washer
P
A
R
T
Screws
Plate
Screw
S
Rubber
Spacer
Metal
Connectors
Washer
Red/Black
Cables
Self-
locking
nut
Spring
Washer
Spring
Washer
P
A
N
T
H
E
R
Front
Bumper
Bracket
Washer
Spring
Head light
Assembly
M
X
4
Self-locking
nut
REMOVING, STEPS 7-8/
INSTALLING, STEPS 2-7
Washers
Long Screw
FIGURE 1 - REMOVING/INSTALLING HEAD LIGHT ASSEMBLY
49
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PROCEDURE 11
REPLACEMENT PARTS - PANTHER MX - 4
Locking Tabs
(Squeeze Together)
REPLACING TAIL LIGHT
ASSEMBLY (FIGURE 2)
R
E
P
L
A
C
E
M
E
N
T
1. Remove the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUDinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
Cables
Tail Light
Assembly
Rubber
Spacer
2. Disconnect the tail light assembly from the tail light
cable by performing STEPS 2-3 in REPLACING
TAILLIGHTCABLEinthisprocedureofthismanual.
Steel Plate
3. From outside of the rear shroud, grasp the lock-
ing tabs on the back of the tail light assembly,
and squeeze them together.
Rear Shroud
P
A
R
T
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.
S
FIGURE 2 - REPLACING TAIL LIGHT
ASSEMBLY
5. Remove the steel plate from the inside of the rear
shroud.
6. Align the NEW tail light assembly with the hole in
REPLACING TAIL LIGHT CABLES
(FIGURE 3)
the rear shroud.
NOTE: To ensure the tail light assembly is installed
securely, be sure to position the rubber spacer be-
tween the OUTSIDE of the rear shroud and the tail
light assembly.
1. Remove the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUDinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
P
A
N
T
H
E
R
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.
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.
8. Thread the cables of the NEW tail light assembly
through the NEW steel plate, and position the
NEWsteelplateoverthelockingtabsontheNEW
tail light assembly
M
X
4
4. Remove the tail light cable.
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.
5. Position the RED cable connector of the NEW
tail light assembly in the RED cable metal con-
nector of the of the tail light cable.
10. Reinstall the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
6. Positionthe BLACK cableconnectoroftheNEW
taillightassemblyintheBLACKcablemetalcon-
nector 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/
INSTALLINGTHEREARSHROUDinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
50
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REPLACEMENT PARTS - PANTHER MX - 4
PROCEDURE 11
Plastic
Tail Light
Guards
Cable
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.
R
E
P
L
9. Reconnect the hand brake cable assembly. Re-
fer to REMOVING/INSTALLING TILLER AS-
SEMBLY, SECTION “B” - DISCONNECTING/
CONNECTINGHANDBRAKECABLEASSEM-
BLY in PROCEDURE 4 of this manual.
A
C
E
M
E
N
T
Metal
Connectors
Tail Light
Assembly
10. Reinstall the rear wheels. Refer to REMOVING/IN-
STALLINGTHEREARWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
Red And Black
Cables
P
A
R
T
11. Reinstall the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
Rear Shroud
S
FIGURE 3 - REPLACING TAIL LIGHT CABLES
12. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
REPLACING DISC BRAKE
ASSEMBLY (FIGURE 4)
Rem oving The Disc Brake Assem bly
1. Remove the seat. Refer to REMOVING/IN-
STALLINGTHESEATin PROCEDURE 5 of the
Owner’s Manual, part number 1090132.
P
A
N
T
H
E
R
Spring
Washers
2. Remove the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
Disc Brake
Hex
Assembly
3. Remove the rear wheels. Refer to REMOVING/IN-
Cap
Screws
STALLINGTHEREARWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
Transaxle
Assembly
M
X
4
4. Disconnect the hand brake cable assembly.
Refer to REMOVING/INSTALLING TILLER AS-
SEMBLY, SECTION “B” - DISCONNECTING/
CONNECTINGHANDBRAKECABLEASSEM-
BLY in PROCEDURE 4 of this manual.
Spring
Washers
FIGURE 4 - REPLACING DISC BRAKE
ASSEMBLY
5. Remove the four (4) hex - cap screws and spring
washers securing the discbrakeassemblytothe
transaxle assembly.
REPLACING DISC BRAKE SHOES
(FIGURE 5)
6. Remove the disc brake assembly.
1. Remove the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
7. Align the NEW disc brake assembly with the
mounting holes in the transaxle assembly.
2. Remove the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUDinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
CAUTION
DO NOT ove rtighte n the four (4) he x c a p
screws securing the disc bra ke a sse mbly to
the tra nsa xle a ssembly. Otherwise, da ma ge
to the disc bra ke a sse mbly ma y oc c ur.
3. Remove the rear wheels. Refer to REMOVING/
INSTALLING THE REAR WHEELS in PROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
51
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PROCEDURE 11
REPLACEMENT PARTS - PANTHER MX - 4
4. Disconnect the hand brake cable assembly. Re- 15. Reinstall the seat. Refer to REMOVING/IN-
R
E
P
L
A
C
E
M
E
N
T
fer to REMOVING/INSTALLING TILLER AS-
SEMBLY, SECTION “B” - DISCONNECTING/
CONNECTINGHANDBRAKECABLEASSEM-
BLY in PROCEDURE 4 of this manual.
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
REPLACING HAND BRAKE
ASSEMBLY (FIGURE 6)
5. Remove the self-locking nut and washer secur-
ing the brake arm to the cam.
1. Remove the bolt securing hand brake assembly
NOTE: Save the spring for reuse when installing the
NEW disc brake shoes.
to the handle bar. Refer to DETAIL “A”.
2. Unscrew the adjusting nut from the cable lock
6. Removethespringsecuringthetwo(2)discbrake
shoes to the brake disc.
and hand brake assembly. Refer to DETAIL “B”.
3. Aligntheslitinthecablelockwiththebrakecable,
P
A
R
T
7. Remove the two (2) disc brake shoes.
and remove the cable lock. Refer to DETAIL “C”.
8. Position the two (2) NEW disc brake shoes on
4. Align the slit in the adjusting nut with the brake
cable, and remove the adjusting nut. Refer to
DETAIL “C”.
the disc brake and around the cam.
S
9. Secure the NEW disc brake shoes to the disc
brake using the EXISTING spring.
NOTE: Note the position of the the hand brake as-
sembly before removing for proper reinstallation.
10. Position the brake arm so the two (2) mounting
holes in the brake arm align with the cam.
5. Slide the hand brake assembly toward the tiller
until there is slack in the brake cable.
CAUTION
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 (DE-
TAIL “D”).
DO NOT overtighten the se lf loc king nut se-
curing the bra ke a rm to the ca m. Otherwise,
da ma ge to the bra ke a rm ma y occur.
P
A
N
T
H
E
R
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.
7. Remove the hand brake assembly from the
handle bar.
8. Positionthe NEW handbrakeassemblyontothe
12. Reconnect the hand brake cable assembly. Re-
fer to REMOVING/INSTALLING TILLER AS-
SEMBLY, SECTION “B” - DISCONNECTING/
CONNECTINGHANDBRAKECABLEASSEM-
BLY in PROCEDURE 4 of this manual.
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.
M
X
4
13. Reinstall the rear wheels. Refer to REMOVING/IN-
STALLINGTHEREARWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
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”.
14. Reinstall the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
10. Slide the NEW hand brake assembly away from
the tiller, until it is in the original mounting position.
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”.
Disc Brake Shoes
Spring
Disc Brake
12. AligntheslitintheNEWcablelockwiththebrake
cable, and position the NEW cable lock on the
brake cable. Refer to DETAIL “C”.
Cam
Brake Arm
13. Screw the NEW cable lock into the NEW adjust-
ing nut and hand brake assembly. Refer to DE-
TAIL “B”. Securely tighten.
Washer
Self-locking nut
FIGURE 5 - REPLACING DISC BRAKE ASSEMBLY
52
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REPLACEMENT PARTS - PANTHER MX - 4
PROCEDURE 11
14. Install the NEW bolt securing the NEW hand
brake assembly to the handle bar. Refer to DE-
TAIL “A”. Securely tighten.
REMOVING/ INSTALLING FRONT
SHOCK ABSORBERS (FIGURE 7)
R
E
P
L
Rem oving
1. Separate the front frame assembly from the rear
frameassembly. RefertoTRANSPORTINGTHE
SCOOTER in PROCEDURE 10 of the Owner’s
Manual, part number 1090132.
A
C
E
M
E
N
T
Hand
Brake
Assembly
Handle
Bar
2. Remove the front wheels. Refer to REMOVING/IN-
STALLINGTHEFRONTWHEELSinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
Bolt
P
A
R
T
3. Flip the front frame assembly onto its side.
DETAIL “A”
4. Remove the TOP bolt on the right front shock
absorber.
Hand
Brake
Assembly
Adjusting Nut
S
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.
Cable Lock
Installing
P
A
N
T
H
E
R
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.
DETAIL “B”
Brake Cable
CAUTION
DO NOT ove rtighte n the bolt se c uring the
right front shoc k a bsorbe r to the tie rod a s-
se mbly. Othe rwise , da ma ge to the right front
shoc k a bsorbe r ma y oc c ur.
M
X
4
Slit In
Slit In
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.
Adjusting
Cable
Lock
Nut
DETAIL “C”
3. Align the mounting hole in the TOP of the right
front shock absorber with the mounting holes in
the front frame.
Brake Cable
Hand
Brake
Assembly
CAUTION
DO NOT ove rtighte n the bolt se c uring the
right front shoc k a bsorbe r to the front fra me
a sse mbly. Othe rwise , da ma ge to the right
front shoc k a bsorbe r ma y oc c ur.
Slits
4. Install one (1) bolt through the TOP mounting hole
of the right front shock absorber and the TOP
mountingholesinthefrontframeassembly.Torque
the hex cap screws between 122 - 148 in./lbs.
DETAIL “D”
FIGURE 6 - REPLACING HAND BRAKE
ASSEMBLY
53
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PROCEDURE 11
REPLACEMENT PARTS - PANTHER MX - 4
5. If necessary, repeat this procedure for the other
front shock absorber.
Installing
R
E
P
L
NOTE: When installing the bolts for the rear shock
absorber, the TOP and BOTTOM bolts should be
facing opposite directions.
6. Return the front frame assembly to the upright
position.
A
C
E
M
E
N
T
7. Reinstallthefrontwheels. RefertoREMOVING/
INSTALLING THE FRONT WHEELS in PRO-
CEDURE 9 of the Owner’s Manual, part number
1090132.
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.
8. Reassemble the front frame assembly and the
rear frame assembly. Refer to TRANSPORT-
INGTHESCOOTER inPROCEDURE10ofthe
Owner’s Manual, part number 1090132.
CAUTION
DO NOT ove rtighte n the bolt se c uring the
right re a r shoc k a bsorbe r to the rea rfra me
a sse mbly. Othe rwise , da ma ge to the right
re a r shoc k a bsorbe r ma y oc c ur.
P
A
R
T
Mounting Holes
Top Bolt
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 as-
sembly, makingsuretheboltisfacing AWAY from
thecontroller.Torquethehexcapscrewsbetween
122 - 148 in./lbs.
S
Front Shock
Absorber
Bottom Bolt
3. Align the mounting hole in the TOP of the right
rear shock absorber with the mounting holes in
the rear frame.
P
A
N
T
H
E
R
CAUTION
Front Frame
Assembly
Tie Rod
Assembly
DO NOT ove rtighte n the bolt se c uring the
right re a r shoc k a bsorbe r to the re a r fra me
a sse mbly. Othe rwise , da ma ge to the right
re a r shoc k a bsorbe r ma y oc c ur.
Mounting Holes
FIGURE 7 - REMOVING/INSTALLING FRONT
SHOCK ABSORBER
4. Install one (1) bolt through the TOP mounting
holeintherightrearshockabsorberandtheTOP
mountingholesintherearframeassembly, mak-
ing sure the bolt is facing TOWARD the control-
ler. Torque the hex cap screws between 122 -
148 in./lbs.
M
X
4
REMOVING/ INSTALLING REAR
SHOCK ABSORBERS (FIGURE 8)
Rem oving
5. Repeat this procedure for the other rear shock
absorber.
1. Remove the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
6. Reinstall the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUDinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
2. Remove the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUDinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
7. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
3. Remove the TOP bolt on the right rear shock
absorber.
4. RemovetheBOTTOMboltontherightrearshock
absorber.
5. Slide the right rear shock absorber away from
the rear frame.
6. Ifnecessary, repeatthisprocessfortheotherrear
shock absorber.
54
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REPLACEMENT PARTS - PANTHER MX - 4
PROCEDURE 11
Top
Bolt
R
E
P
L
A
C
E
M
E
N
T
Rear
Shock
Absorber
Bottom
Bolt
Rear Frame
Assembly
P
A
R
T
FIGURE 8 - REMOVING/INSTALLING REAR
SHOCK ABSORBER
S
P
A
N
T
H
E
R
M
X
4
55
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PROCEDURE 12
OPTIONS
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.
This Procedure Includes the Following:
Preparing the Scooter for Left Hand
Operation
9. Repeat STEPS 5-8 for the ORANGE wire com-
ing out of the rear of the YELLOW or WHITE
connector (depending on scooter model) of the
tiller wiring harness.
WARNING
O
P
T
I
O
N
S
After ANY a djustments, repa ir or service a nd
BEFORE use, ma ke sure tha t a ll a tta ching ha rd-
wa re is tightened securely - otherwise injury or
da ma ge ma y oc c ur.
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
WHITEconnector(dependingonscootermodel)
of the tiller wiring harness.
Turn Powe r OFF a nd re move ke y from igni-
tion. Disc onne c t ba tte ry ha rne ss from the
motor le a d.
PREPARING THE SCOOTER FOR
LEFT HAND OPERATION
(FIGURE 1)
11. Push the MALE pin of the YELLOW wire for-
ward 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 occu-
pied by the MALE pin of YELLOW wire.
1. Remove the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
NOTE: WHEN the YELLOW or WHITE connector
(depending on scooter model) of the tiller wiring har-
ness and the YELLOW or WHITE connector (de-
pending on scooter model) of the controller wiring
harness are reconnected, the mating of the wires
coming out of the rear of the connectors should be
YELLOW to ORANGE.
2. Remove the rear shroud. Refer to REMOVING/IN-
STALLINGTHEREARSHROUDinPROCEDURE
9 of the Owner’s Manual, part number 1090132.
3. Remove the batteries. Refer to REMOVING IN-
STALLINGBATTERIESWITHCABLESinPRO-
CEDURE 4 of the Owner’s Manual, part number
1090132.
13. Perform one (1) of the following:
ALL models EXCEPT the PANTHER MX - 4 -
A. Reconnect the YELLOW connector of the
tiller wiring harness to the YELLOW connec-
tor of the controller wiring harness.
4. Peform one (1) of the following:
ALL models EXCEPT the PANTHER MX - 4 -
A. Disconnect the YELLOW connector of the
tiller wiring harness from the YELLOW con-
nector of the controller wiring harness.
PANTHER MX - 4 -
A. Gently close the hinged strain relief on the
rear of the WHITE connector of the tiller wir-
ing harness.
PANTHER MX - 4 -
A. Disconnect the WHITE connector of the tiller
wiring harness from the WHITE connector
of the controller wiring harness.
B. Reconnect the WHITE connector of the tiller
wiring harness to 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.
14. Reinstall the batteries. Refer to REMOVING IN-
STALLINGBATTERIESWITHCABLESinPRO-
CEDURE 4 of the Owner’s Manual, part number
1090132.
5. Locate the YELLOW wire coming out of the rear
of the YELLOW or WHITE connector (depend-
ing on scooter model) of the tiller wiring harness.
15. Reinstall the rear shroud. Refer to REMOVING/
INSTALLINGTHEREARSHROUDinPROCE-
DURE 9 of the Owner’s Manual, part number
1090132.
6. Insert a small, pointed tool into the FRONT of the
YELLOW or WHITE connector (depending on
scootermodel)ofthetillerwiringharness, directly
under the MALE pin of the YELLOW wire.
16. Reinstall the seat. Refer to REMOVING/IN-
STALLING THE SEATinPROCEDURE5ofthe
Owner’s Manual, part number 1090132.
7. Push up on and hold the plastic tang under the
male pin of the YELLOW wire.
56
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OPTIONS
PROCEDURE 12
17. Position the NEW Forward/Reverse sticker NOTE: The NEW Forward/Reverse sticker is also
OVER the EXISTING Forward/Reverse sticker available as a purchase part.
on the control panel (DETAIL “A”).
(ALL MODELS EXCEPT THE PANTHER MX - 4)
O
P
T
I
O
N
S
Yellow Wire
Male Pin
Plastic Tang
Front
Yellow Connectors -
Tiller Wiring Harness
Yellow Connectors -
Yellow Connectors -
Controller Wiring
Tiller Wiring Harness
Harness
(PANTHER MX - 4)
White Connector -
Tiller Wiring Harness
Hinged Strain
Relief
REAR
White Connector -
Tiller Wiring Harness
White Connector -
Controller Wiring
Yellow Wire
Harness
NEW Forward/
Reverse Sticker
Male Pin
Front
Plastic Tang
Position Here
Control Panel
EXISTING Forward/
Reverse Sticker
DETAIL “A”
FIGURE 1 - PREPARING THE SCOOTER FOR LEFT HAND OPERATION
57
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NOTES
NOTES
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N
O
T
E
S
58
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WARRANTY
LIMITED WARRANTY
PLEASE NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLI-
CABLE TO PRODUCTS MANUFACTURED AFTER JULY 4, 1975.
W
A
R
R
A
N
T
This wa rra nty is e xte nde d only to the origina l purc ha se r/use r of our produc ts.
This wa rra nty give s you spe c ific le ga l rights a nd you ma y a lso ha ve othe r le ga l rights whic h va ry
from sta te to sta te .
Inva c a re wa rra nts this produc t to be fre e from de fe c ts in ma te ria ls a nd workma nship for a pe riod
of e ighte e n (18) months on e le c tric a l a nd tra nsa xle a nd thre e (3) ye a rs on fra me from da te of
purc ha se . If within suc h wa rra nty pe riod a ny suc h produc t sha ll be prove n to be de fe c tive , suc h
produc t sha ll be re pa ire d or re pla c e d a t Inva c a re 's option. This wa rra nty doe s not inc lude a ny
la bor or shipping c ha rge s inc urre d in re pla c e me nt pa rt insta lla tion or re pa ir of a ny suc h produc t.
Inva c a re ’s sole obliga tion a nd your e xc lusive re me dy unde r this wa rra nty sha ll be limite d to suc h
re pa ir a nd/or re pla c e me nt.
Y
For wa rra nty se rvic e , ple a se c onta c t the de a le r from whom you purc ha se d your Inva c a re prod-
uc t. In the e ve nt you do not re c e ive sa tisfa c tory wa rra nty se rvic e , ple a se write dire c tly to Inva c -
a re on the ba c k c ove r, provide de a le r’s na me , a ddre ss, da te of purc ha se , indic a te na ture of the
de fe c t a nd, if the produc t is se ria lize d, indic a te the se ria l numbe r. Do not re turn produc ts to our
fa c tory without our prior c onse nt.
LIMITATIONS AND EXCLUSIONS: THE FOREGOING WARRANTY SHALL NOT APPLY TO SERIAL NUM-
BERED PRODUCTS IF THE SERIAL NUMBER HAS BEEN REMOVED OR DEFACED, PRODUCTS SUBJECTED
TO NEGLIGENCE, ACCIDENT, IMPROPER OPERATION, MAINTENANCE OR STORAGE, PRODUCTS
MODIFIED WITHOUT INVACARE’S EXPRESS WRITTEN CONSENT (INCLUDING, BUT NOT LIMITED TO,
MODIFICATION THROUGH THE USE OF UNAUTHORIZED PARTS OR ATTACHMENTS; PRODUCTS DAM-
AGED 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 IN-
STRUCTIONS.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IM-
PLIED WARRANTIES, IF ANY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FIT-
NESS FOR A PARTICULAR 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 CONTAINED HEREIN. INVACARE SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCI-
DENTAL DAMAGES WHATSOEVER.
THIS WARRANTY SHALL BE EXTENDED TO COMPLY WITH STATE/PROVINCIAL LAWS AND REQUIRE-
MENTS.
59
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Invacare Corporation
USA
Canada
One InvacareWay
Elyria,Ohio USA
44036-2125
5970 ChedworthWay
Mississauga, Ontario
L5R 3T9, Canada
905-890-8838
Invacare is a registered trademark of Invacare Corporation.
©
1999 Invacare Corporation
800-333-6900
Form No.99-188 Part No.1091860 Rev C (1) 02/00
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