Electric Bicycle Owner Manual

Transcription

1 X-Treme TM Electric Mped XB-610 Electric Bicycle Owner Manual Read this manual cmpletely befre riding yur electric bicycle 1

2 Cntents Table f Cntents Riding Safety 4-6 Prduct Features 7 Package Cntents... 8 Installatin Instructins Frnt Wheel & Brake. 8 Handle Bar Installatin.. 9 Trunk/Pedals/Mirrr Installatin Battery Cnnectin & Initial Charging Instructins 11 Tire Inflatin. 12 Prduct Specificatin Operatin 13 Riding Tip Checklist.. 13 Battery Charging & Safety Basic Maintenance & Schedule Other Infrmatin. 16 Hw T Instructins Hw T Fix Wbbly Handle Bars. 17 Hw T Center Handle Bars. 17 Hw T Remve Hub Mtr 17 Hw T Replace Cntrller Hw T Replace Rear Inner Tube. 18 Hw T Replace Dash 18 Hw T Check Brake Safety Switch Hw T Adjust Drum Brakes 18 Hw T Install Bearings 18 Hw T Replace/Install Thrttle Hw T Align Frnt Frks. 19 Hw T Test Rear Wheel & Cntrller. 19 Hw T Check Vltage

3 Hw T Test Mtr Sensrs Trubleshting Scter Wn t Run, Charger Light Stays Green.. 21 Scter Wn t Run, Charger Light Stays Red & Green 21 Is It My Thrttle Or My Cntrller? Thrttle Vltage Test. 22 Intermitted Pwer Lss N Pwer After Fully Charging, Pwers Only Fr Shrt Distance Use 25 Scter On, Wn t Run. 26 Scter Will Nt Mve.. 26 Charger Hub Mtr Tests Diagrams Wiring Diagram 29 Battery Wiring Diagram 30 Supprt.. 31 DO NOT RETURN TO STORE! D nt use this vehicle fr the first time until yu have inflated the tires t the crrect PSI and cmpletely charged the battery. Failure t fllw these instructins may damage yur vehicle and vid yur warranty. CALL TOLL FREE OR GO ONLINE Fr General Infrmatin r Parts Visit RIDING 3

4 RIDING SAFETY Like any sprt, biking carries the risk f injury and damage. By chsing t ride the electric bicycle, yu assume all respnsibility fr these risks. Thus, yu need t knw and practice the rules f safe and respnsible riding. YOUR INSURANCE POLICIES MAY NOT PROVIDE COVERAGE FOR ACCIDENTS INVOLVING THE USE OF THIS ELECTRIC BICYCLE. TO DETERMINE IF COVERAGE IS PROVIDED YOU SHOULD CONTACT YOUR INSURANCE COMPANY OR AGENT. Safety Basics: D s and Dn ts The D s Always cnduct a Safety Check befre yu ride yur electric bicycle. Be thrughly familiar with the cntrls f yur electric bicycle. Always wear an apprved helmet when riding yur electric bicycle. Fllw the helmet manufacturer s instructins fr fit, use and care f yur helmet. Always keep bdy parts and ther bjects away frm the spinning wheels f yur electric bicycle. Always wear shes that will stay n yur feet and will stay n the flrbard. Wear bright, visible clthing that is nt s lse that it can catch n mving parts f the electric bicycle r bjects at the side f the rad r trail. Think abut yur speed, and keep yur speed cnsistent with safe perating cnditins. The Dn ts Never ride with headphnes. They mask traffic sunds, distract yu frm cncentrating n yur surrundings, and their wires can tangle in the mving parts f the electric bicycle, causing yu t lse cntrl. Never carry a passenger. The maximum carrying capacity is 300 lbs. Never ride bareft r wearing sandals. Dn t jump with yur electric bicycle. It puts great stress n everything frm frame and frks t drive train. Riders wh insist n jumping their electric bicycle risk serius damage t their electric bicycle as well as t themselves. Never carry anything which bstructs yur visin r yur cmplete cntrl f the electric bicycle r which culd becme entangled in the mving parts f the electric bicycle. Never hitch a ride by hlding n t anther vehicle. 4

5 Never ride yur electric bicycle while under the influence f alchl r ther drugs. If pssible, avid riding in bad weather, when visibility is bscured, at dusk r in the dark, r when yu are very tired. Each f these cnditins increases the risk f accident. Never allw children t ride. Never allw thers t ride withut reading and understanding these instructins. Operating Reminders and Suggestins Review all instructins carefully befre riding the electric bicycle. Fllw all rules and regulatins in yur area fr perating a mtrized bicycle. Obey the same rad laws as all ther rad vehicles, including yielding the right-f-way t pedestrians, and stpping at red lights and stp signs. Ride predictably and in a straight line. Never ride against traffic. Ride defensively. T ther rad users, yu may be hard t see. Cncentrate n the path ahead. Avid pthles, gravel, dirt, wet rad, il, curbs, speed bumps, drain grates and ther bstacles. Be alert fr unexpected events, such as pening car drs r cars backing ut f cncealed driveways. Be extra careful at intersectins and when preparing t pass ther vehicles. Dn't carry packages r passengers that will interfere with yur visibility r cntrl f the bike. Dn't use items that may restrict yur hearing. Maintain a cmfrtable stpping distance frm all ther riders, vehicles and bjects. Safe braking distance and frces are subject t the prevailing weather and rad cnditins. Wet Weather Riding Wet weather impairs tractin, braking and visibility, bth fr the rider and fr ther vehicles sharing the rad. The risk f accident is dramatically increased in wet cnditins. In wet weather yu need t take extra care. In wet cnditins, the stpping pwer f yur brakes (as well as the brakes f ther vehicles sharing the rad) is dramatically reduced. This makes it harder t cntrl speed and easier t lse cntrl. T make sure that yu can slw dwn and stp safely in wet cnditins, apply yur brakes earlier and mre gradually than yu wuld under nrmal, dry cnditins. Decrease yur riding speed, avid sudden braking, and take crners with additinal cautin. Keep in mind that there is a direct, but inverse, relatinship between speed and cntrllability. Be mre visible n the rad. Wear reflective clthing and use safety lights. Pthles and slippery surfaces such as lane markings and train tracks all becme mre hazardus when wet. Night Riding A rider is very difficult fr mtrists t see at dusk, at night, r at ther times f pr visibility. If yu must ride under these cnditins, check and be sure yu cmply with all lcal laws abut 5

6 night riding; fllw the Rules f the Rad, and take the fllwing precautins: Make sure that yur electric bicycle is equipped with crrectly psitined and securely munted reflectrs. Make sure yur clthing r carg des nt bstruct a reflectr r light. Wear light clred, reflective clthing and accessries, any reflective device r light surce that mves will help yu get the attentin f appraching mtrists, pedestrians and ther traffic. Ride slwly. Avid hazards, such as pthles and curbs. Avid areas f heavy traffic, dark areas, and rads with higher speed than limited. If pssible, ride n rutes already familiar t yu. Ride at night nly if necessary. Slw dwn and use familiar rads with street lighting, if pssible. Other Imprtant Reminders The battery des NOT require deep discharging. If yur electric bicycle is put int strage, re-charge its battery at least nce every 90 days. D nt stre yur electric bicycle in direct sunlight fr an extended time. Stre yur electric bicycle in a dry place. Expsing yur electric bicycle t rain, snw, r ther precipitatin may result in damage. 6

7 Prduct features 7

8 Package Cntents: Electric Bicycle 48V 20AH Charger Left & Right Mirrrs Frnt Tire Frnt Fender Left & Right Ft Pedals Ignitin Keys Ft Pad Trunk User Manual Preparatin fr Assembly A. Remve the cardbard cartn expsing the steel frame crate. B. Remve the blts hlding the tp and side center pst n the steel frame. Remve the tp & center pst and set aside. See page 9 number 2-1 C. Bend the frnt and back frame sides dwn t the grund s they are ut f the way. D. T assist with assembling the frnt wheel remve the wire ties hlding the frnt axle (leave the rear axle wire ties cnnected fr stability). E. Remve all prtective packaging. F. Remve Axle frm frnt frk & shipping crate and set aside, d nt discard. G. Find a slid square bject abut 10 t 12 high and with assistance raise the frnt f the bike and place it under the flr bard battery cmpartment. This will allw fr easier frnt wheel installatin. H. Remve blt frm handle bar stem and place handle bars nt steering shaft. This will give extra brake cable length fr installing the brake drum n the wheel and frk. I. Remve the screw hlding the frnt brake assembly n the frk. Install frnt wheel and brakes per instructins belw Page 8 8

9 1.) INSTALLATION OF FRONT WHEEL AND BRAKE. 1. Insert brake hub nt wheel as shwn abve. 2. Slide wheel int frnt frks being sure t align brake hub bracket with right side frk. See image belw. (When sitting n bike, frnt brake is n riders left side f frnt wheel) 3. Slide axle thru left frk, then spacer befre inserting it int the left side f frnt wheel. 4. Secure with nut n right side (brake side) and tighten securely 5. With frnt wheel installed prceed t munt the frnt fender. The furth screw fr the fender is in the plastic bag with the trunk blts. 9

10 2.) HANDLEBAR INSTALLATION 1. Lcate and remve the handlebar blt, washer & nut as shwn. Fr access t the nut n the back side, turn the handlebars fully t the right. 2. Slide handlebars ver pst in the crrect psitin, then insert the blt & cncave washer int the frnt (speedmeter side) f the handlebars and secure with nut n the back (riders side). Cncave washer shuld be partially inserted int the handlebar and make cntact with internal pst t be tightened prperly and securely. 3. Using tw 14mm wrenches place ne n the frnt blt frm the tp and the secnd n the nut by reaching up frm the bttm under the fairing. Carefully tighten checking t cnfirm cncave washer is placed crrectly in the slt. Cnnecting Instrument Panel The instrument panel is lcated in the seat strage cmpartment, use key t pen. 1) Six pin cnnectr n instrument panel cnnects t six pin cnnectr n wire harness n tp f the handlebars. 2) Tw pin cnnectr with ne Black wire n instrument panel cnnects t tw pin cnnectr with ne Grey wire n wire harness. (Sme unit may have ne extra cnnectr n the instrument panel. If it has a tw pin female cnnectr with Red and Purple wires it is left empty and nt used.) ** Befre munting the instrument cluster cnfirm all wire cnnectins are firmly tgether and cnnectr cvers placed ver terminals securely. 10

11 3-5.) TRUNK/PEDALS & MIRROR INSTALLATION 3. Attach trunk t back carg rack using the fur (4) enclsed blts/nuts & washers. Secure t rack with the washers & nuts n the underside. 4. Attach left & right ft pedals accrding t crrect side by lining up pedal with bearing n pedal shaft and snap int place. 5. Mirrrs are lcated inside the trunk. Screw left & right mirrrs int place and adjust t apprpriate riding psitin. ***Mirrrs install with an upward angle; D nt try t frce hrizntal. 11

12 6.) BATTERY CONNECTION & INITIAL CHARGING 1. Remve battery pack and lcate plug. 2. Plug battery wire int battery pack and reinstall battery pack under ft plate. 3. IMPORTANT: Cmpletely charge battery fr a maximum f 8 hurs befre use. DO NOT CHARGE FOR MORE THAN 8 HOURS AS THIS CAN DAMAGE BATTERIES. Main Fuse Main fuse is lcated inside battery case under flr mat. 7.) TIRE INFLATION Finally, inflate bth tires t the minimum recmmended tire pressure depending n the number f riders that will be using the bike. Recmmended tire pressure is between PSI. We d nt recmmend filling tire beynd 45 psi. * Be sure t check all nuts, screws and terminals n the bike fr tightness and prper fit befre riding. 12

13 Prduct Specificatins 1. Wire diagram 2. Specificatins Battery Vltage 48Vlt Dc,20Ah Mtr Wattage 600W Wheel Size 16 inch Tp Speed 35km/h Charging Time 6-8h Distance f full charge 50km Battery charging cycles <300 times Max rider weight 300lbs Tw rider Yes Left and Right Indicatrs Yes Rear View mirrrs Yes 13

14 Operatin Yur new Electric Bicycle/scter is a revlutinary new transprt prduct using a sealed lead acid batteries and a super high efficiency electric hub mtr designed t ASSIST in the prpulsin f yu and yur bicycle. It is imprtant t nte the fllwing riding guidelines t ensure yu get the best pssible experience frm yur electric bicycle. Riding tip checklist A) When starting ff frm a stand still pedal the bicycle up t speed then engage thrttle fr best results. B) On inclines pedaling will be required t maintain mmentum. C) Remember perfrmance f the bike is directly related t weight f the rider and any baggage/lad tgether with the charge in the batteries. D) Ensure batteries are fully charged prir t riding. E) Never let the batteries fully discharge. This will reduce battery and bike perfrmance. F) If yur bike is equipped with lights we recmmend yu ride with them switched n at all times t increase visibility fr yu and ther rad users. Battery Charging and & Battery Safety Charging figure 1-4 Charging (see figure 1-4) A. Ensure bike is turned ff and key is remved. B First cnnect t the battery charger t the charging scket lcated belw the frnt f the seat. (Optinally, yu can als remve the battery pack and charge utside f the bike if preferred) C. Then insert the pwer plug n the battery charger int 110v pwer utlet. 14

15 D. While charging the light n the battery charger will illuminate Red. E. When fully charged the light will illuminate Green. F. NEVER CHARGE FOR OVER 8 HOURS. DAMAGE MAY OCCUR TO BATTERY G. Always charge the bike in a well ventilated area prtected frm bad weather & wet cnditins. NEVER CHARGE THE BIKE INSIDE YOUR HOME ONLY CONNECT THE BATTERY CHARGER LEAD TO THE BIKE CHARGER INLET. NEVER CONNECT ANY OTHER POWER SOURCE TO THE BIKE CHARGER INLET. Battery Charging Safety Ntes 1) While charging the Battery, keep the key switch OFF. 2) Verify that yu are using the crrect charger fr yur vehicle, and that the charger input pwer is cmpatible the huse current in yur area. 3) Keep the charger and battery away frm water t prevent electrical shck and shrting. The charger is intended fr indr use nly. 4) Read the charger label t learn abut the charger indicatr lights, and their meanings. 5) Generally, a shrt drive will require a shrt time t re-charge, and a lng ride will require a lnger time. A cmplete (90%) discharge may require 6 hurs t recharge. T prevent electrlysis (battery fluid lss by hydrgen generatin,) d nt charge fr lnger than eight hurs. WARNING D nt place the battery near heat r fire. D nt expse the chargers t water. Maintenance ----Basic 1. Yur bike cmes with a 30amp fuse, pre-installed at the factry and is lcated inside the battery bx. 2. Clean Chain Regularly. 3. Ensure Tires are inflated t PSI. 4. Adjust Brake tensin via adjusting screws lcated at Brake lever r n Brake cntrl lever. 5. Ensure regular servicing accrding t the schedule. 6. D nt attempt t change any electrnic cmpnents except changing light bulbs. 7. DO nt attempt t mdify, pen r perfrm maintenance n the Hub Mtr. 8. Any attempt t mdify electrical cmpnents will vid the warranty unless specifically requested by a X-treme Scters representative. 15

16 Maintenance ----Schedule Service Interval Daily Mnthly Every 6 Yearly Mnths Inspect Tires fr wear and Yes Yes Yes Yes cnditin and inflatin Check and adjust Brake Yes Yes Yes Yes Check peratin f all lighting Yes Yes Yes Yes and hrn devices. Replace glbes if necessary Test Battery Capacity Yes Yes Replace Wheel Baring Grease Yes Full Brake Pad Change ver Yes Check cnditin and trque settings f wheel nuts and suspensin frks Yes Yes Other Helpful Instructins Pedals 1. Use a pedal wrench f 16mm spanner t tighten pedals. 2. Check and tighten pedal crank blts with 14mm scket. Tires 1. Inflate tire using a pump t 35-45psi. Remember lwer tire pressures will negatively impact perfrmance by causing t much resistance, but ver inflating may cause the tube t burst. Chain 1. Give the train a light drp f bicycle chain il r sewing il. D nt use RP7 type lubricants. 16

17 Hw T Fix Wbbly Handle Bars 1. Remve the instrument panel by taking ut the six (6) screws frm the bttm and discnnecting the wire cnnectrs 2. Lk at the blt that clamps the handle bars t the steering stem: is the gld spacer seated crrectly? 3. Tighten the blt by using tw 14mm wrenches ne frm abve n the frnt f the blt and the ther by reaching up under the wheel well t hld the nut in place while the frnt ne tightens the bld snuggly. 4. Check handle bars fr secure fit. If still wbbly remve blt, reset handle bars and tighten. Having the blt securely tight will eliminate the handle bars frm wbbling. Hw T Center Handle Bars 1. First remve the dash. Yu shuld nt have t remve it cmpletely, but at least split it s yu may access the space in the center f the handle bar. 2. In the center f the handle bar yu will see the head f a small blt. 3. Lsen this blt up slightly until the handle bars can mve t the crrect psitin. 4. When the bars are aligned prperly tighten the blt. 5. Reassemble the dash pieces. Hw T Remve Hub Mtr 1. Remve the tw nuts n each side f the mtr. 2. Remve brake adjustment nut and remve brake cable frm brake hub. 3. Remve brake hub lck nut where it attaches t frame. 4. Remve axle lck plate by remving the #10 blt n each side. 5. Fllw the mtr wires up under the rear fender, it will cnnect t quick discnnects and unplug the cables. 6. Fllw the chain up t the pedal sprcket and mve the chain ff f sprcket. Use the pedals t turn until the chain is ttally ff f the sprcket. Then remve the sprcket ff f wheel sprcket. 7. Remve wheel mtr frm scter. Hw T Replace Cntrller 1. Remve the Battery Pack frm the scter and set aside until new cntrller is installed. 2. Open the seat and remve the fur (4) seat barrel screws, tw (2) near the Latch and tw (2) in Frnt. 17

18 3. Remve entire Seat and Seat Barrel frm scter. 4. Unscrew yur ld cntrller frm the frame - Leave wires cnnected. 5. Munt the New Cntrller in its lcatin. 6. Transfer One Cnnectr at a time frm the ld cntrller t the new cntrller. 7. Re-install Battery. 8. With drive wheel nt tuching any surface Test Run and cnfirm all functins are wrking. 9. Re-assemble and test ride. 10. This is als a gd time t perfrm the recmmended maintenance as listed in the Handbk. Hw T Replace Rear Inner Tube 1. Remve the seat and seat barrel. 4 screws need t be remved, 2 by the hinge and 2 dwn inside and remve frm scter. 2. Fllw the wire cming ut f side f mtr and cut the tie straps leading up the cntrller. 3. Remve the wheel nuts and remve the brake adjustment nut and remve the wheel. 4. Let all air ut f tire and use either a tire wrench r cuple dull screw drivers t remve tire bead frm ne side f rim t remve and install the tube. 5. Install in reverse rder make sure that the mtr nuts are n extremely tight, use a 2 1/2' crescent wrench t tighten them. Hw T Replace Dash 1. First remve the fur screws n the black gseneck cver belw the handle bars. 2. Then yu will be able t remve the headlight faring. It will slide dwn and frward. 3. Unhk the wires t the headlight and set the headlight faring aside. 4. Then yu remve 5 screws n the back f the handle bars. 5. There is 1 screw n the frnt f the handle bars, als remve that. 6. Remve the mirrrs frm the scter by turning cunterclckwise. 7. Nw the handle bar faring is ready t be remved, Start n the left side by where yu remved the mirrr. Gently pull the frnt and back f the handle bar fairing apart. It shuld snap apart fairly easily. Wrk yur way acrss until the tp is cmpletely apart. 8. Remve and replace. 9. Reverse the rder t reassemble. Hw T Check Brake Safety Switch 1. First remve frnt fairing and check the thrttle cnnectr and brake cnnectrs fr lse 18

19 cnnectin. Tug n each wire t make sure its lcked int the cnnectr. 2. Open seat and remve the 4 blts that attaches the seat barrel t the scter. 2 blts n each side f the seat latch and the ther 2 are in dwn in bttm frnt f seat barrel. Lift ff the seat and seat barrel as ne piece. 3. Lcatin f brake safety cnnectin: Yu shuld see a bx with several wires cming ut f it. Yu will als see these wires g int quick discnnects and lcate a 4 wire plug. There will nly be ne and n the cntrller side f the cnnectr the wire clrs are: Yellw, Red, Black and Green. On the ppsite side the clrs are Blue, Green with Yellw stripe, Gray and Green. Unplug the cnnectr and lcate the Blue wire, n the ppsite side f the wire ges int the male cnnectr we will need t unlck the gld pin t remve the wire frm the cntrller. Hw T Adjust Drum Brakes 1. Lsen the brake handle adjustment n handlebars t fully utward. Lcate the brake cable adjustment screw and screw this in all the way. 2. Fllw yur brake cable t the brake caliper. There will be a small nut hlding the metal cable t the caliper arm. Lsen this nut, mve the brake arm while hlding the cable tight until the brake just starts t drag when the tire is turned ff the grund. Tighten the lck nut back dwn nt the cable. 3. Next fine tune the adjustment by screwing the cable tensin screw utward t pull n brake line until prper braking is achieved. 4. Lck this psitin dwn by tightening the nuts. 5. Avid adjusting brakes n handlebars because there is a safety switch built int the handles t kill mtr while using the brakes. Hw T Install Bearings 1. Remve the rear wheel. 2. Remve the ld bearing. T d this, yu will need t insert smething, like a screw driver, frm the ppsite side and simply push it ut. 3. Put the new bearings in. Yu will want t use smething like a rubber mallet s yu d nt crack the bearings. Set the wheel n a flat, absrbent surface, like a wrk bench. Tap the bearing int the wheel evenly. 4. Re-install the tire and test ride. Hw T Replace/Install Thrttle 1. Remve six Phillips head screws frm handlebar cver. 19

20 2. Unplug six pin and ne pin cnnectrs frm instrument panel. 3. Fllw wire frm thrttle husing t white cnnectr and unplug, (shuld be 3-pin cnnectr with black, red and white wires). 4. Lsen small allen head blt frm thrttle husing and slide thrttle frm handlebar. Hw T Align Frnt Frks 1. Remve the dash n the backside. Find the 12mm blt in the center f the handlebars and lsen it. 2. Take a hammer and hit this blt. Stand with the frnt tire between yur legs. Hld the tire with yur legs and turn the handlebars int psitin. 3. Tighten the 12mm blt and reassemble the dash. Hw T Test Rear Wheel & Cntrller Place scter up n center kickstand, turn scter ignitin in the "ON" psitin. Spin rear wheel by hand and check t see if it falls in ne f the fllwing cnditins: A.) Wheel spins with slight resistance Cntrller culd need replaced B.) Wheel spins hard like brake engaged Cntrller and mtr culd need replaced C.) Wheel spins Jerky Cntrller and mtr culd need replaced Hw T Check Vltage Tls Needed: Multi-meter t read VDC First be sure the battery cnnectr frm the scter is firmly attached t the battery case. Leave all cnnectrs cnnected when measuring the vltage by sliding yur meter prbes int where the wires g n the backside f the cnnectrs. Battery Pwer vdc per battery min = +50vdc t turn n the cntrller. 1. Acrss the large Red & Black wires cming ut f the cntrller is main pwer leads. Shuld have +50vdc here. Thrttle measurement: Leave cnnectr cnnected while measuring. 1. Lcate the thrttle cnnectr n the cntrller, it will be a red cnnectr with 3 wires cming ut f it f RED, BLACK & GREEN. Put yu Black meter prbe in n the black wire. Insert Red prbe in n the red wire and turn the scter in the ON psitin. These wires are the 5v 20

21 supply t the thrttle, and shuld be within this range ( ) Nw remve the red prbe frm the Red wire and put it n the Green wire and need 2 recrded readings n thrttle and 100% thrttle. Shuld be 0 Thrttle and 100% Thrttle. 2. Ignitin Check: Place Black meter prbe n main BLACK battery wire n the cntrller. Lcate the 2 wire cnnectr with Orange and Blue wire frm cntrller. Insert Red meter prbe n Orange wire and shuld have +50vdc. Insert Red meter prbe n the Blue wire and shuld nly have +50vdc when the ignitin key switch is in the ON psitin. 3. DC/DC cntrller check. This is the smaller silver bx under the headlight assembly and has 3 wires cming ut f it. Red & Black wire shuld have 48vdc with the key n, and Yellw and Black shuld have 12vdc befre and after the Glass Fuse. The DC/DC Cntrller pwers accessries like the lights, hrn etc. Hw T Test Mtr Sensrs Srt ut the mtr's wiring. There is eight wires ttal, r leads, running frm the mtr t the cntrller. Three larger wires pwer the mtr and are larger (16 AWG): Green, Blue, and Yellw. Tw wires pwer the sensrs and are smaller: Red and Black. And three wires cnnect the sensrs t the cntrller: Green, Blue, and Yellw. All 5 small wires are cnnected t ne white quick discnnect. Fr this prject, we are cncerned nly with the smaller wires f Green, Yellw and Blue. Nw, there are tw methds used t determine a bad cnnectin r which f the three sensrs have failed. Bth require the mtr t be fully assembled. The first is t simply run the mtr while ne sensr lead is discnnected, refer t sectin-a belw n hw t d this, then again fr the secnd lead, and a third time fr the last lead. If ne sensr is dead (and that's yur nly prblem), yu'll see that discnnecting ne r the ther f the gd sensrs prevents the mtr frm turning altgether, while discnnecting the bad ne has n effect at all--it still sputters. If that didn't wrk, try this secnd methd. It is mre cmplex, but useful t identify a bad cntrller vs. the mtr, and mre nuanced issues r prblems stemming frm multiple failures. Remve the 3 small wires frm the 5 wire cnnectr leaving the red and black wire attached. While the mtr is cnnected t the cntrller, pwered, and at rest--r, alternatively, pwered 21

22 with +5 vlts frm a wrkbench pwer supply--set up a multi-meter t mnitr the sensr's utput n ne f the 3 wires. Cnnect the Black Vltmeter Lead t the small black wire by inserting the prbe in where the wire ges int the cnnectr. Attach the Red Vltmeter t ne f the 3 wires t be tested. IMPORTANT: DO NOT let any f the small wires tuch each ther r will blw the sensr. Turn the mtr by hand very slwly while watch the vltmeter. It shuld pulse t 5vdc when active and 0vdc when nt. Repeat this step fr ther 2 wires. If all three wires Green, Blue and Yellw pulses 5vdc then the mtr is gd and cntrller is bad. Sectin-A: D nt have scter pwered up. Lcate the white quick 5 wire cnnecter leading frm the cntrller t the mtr and unplug cnnectr. With a small ice pick r large needle inserted t unlck the lck tab ne f the gd pins. And pull the wire ut f the cntrller and recnnect the cnnectr. Tape ff the gld pin s yu can prtect it. Return t abve instructins abve. Trubleshting: Scter Wn t Run, Charger Light Stays Green When yu plug yur charger int yur scter and the wall utlet the charger light stays green. This is telling me that smewhere between charger scket, cntrller, fuse hlder and batteries yu have an pen circuit. Please remve the flr plate and check the wires in this area. Yu may find a wire that is nt cnnected, a cnnectr that is nt pushed tgether prperly r a fuse hlder that is nt letting the fuse cnnect prperly. Trubleshting: Scter Wn t Run, Charger Light Stays Red & Green When yu plug yur charger int yur scter and the wall utlet the charger light stays green. This is telling me that smewhere between the batteries, fuse, and charger scket yu have an pen circuit. Please remve the flr plate and check the wires in this area. Yu may find a wire that is nt cnnected, a cnnectr that is nt pushed tgether prperly r a fuse hlder that is nt letting the fuse cnnect prperly. Trubleshting: Is It My Thrttle Or My Cntrller? (These tests require a digital VOM) Mst E-scter thrttles use 'Hall-effect' devices, nt ptentimeters (rhestats). A Hall-effect device is a chip that respnds t a mvable magnet. If yu have a digital VOM (I wuld nt use an 22

23 analg resistance meter f any kind, as it culd damage the chip if it's a Hall-effect chip), yu can test whether it's a ptentimeter r nt. If it is, yu shuld get 5K hms acrss red and black, and f curse, 0-5K frm red r black t the third wire (usually green r yellw). If it isn't, yu'll get readings in the meghms in ne directin and n cnnectin in the ther in sme cases. A better test if yu have a digital VOM, is t push the prbes int the back f the thrttle cnnectr at the cntrller while it is cnnected. Turn the scter n, and perate the thrttle. Yu shuld get near zer t near 4 r 5 vlts between the black and third wire (green r yellw). These vltages wrk fr mst scters, but nt all. Sme thrttles use 0-24 vlts, and sme use a negative vltage (the thrttle 'sinks' current). Yu shuld als check the brake inhibit switch (there shuld be a wire cable cming frm yur brake handle), t see if it is making and breaking cntinuity. The brake inhibit switch turns the thrttle ff when yu put the brakes n. It functins like a 'kill switch' shuld anything g wrng. Yu shuld als test the key switch in the same way. Yu can test the mtr by jumping frm the batteries t the mtr, but be aware that it will make a large spark, r yu can test the vltage at the mtr cnnectr while turning the rear wheel backwards. The mtr shuld generate a small negative vltage that varies with the speed it is turning. A smell test is als cnclusive prf that yu have a damaged cntrller r mtr. If yu can get yur nse clse t ne r the ther and it smells like badly burnt brccli, it's burnt ut. Of curse it culd als be burnt ut and nt smell, but if it smells it's burnt ut. Trubleshting: Thrttle Vltage Test Fllw thrttle wires until yu find its white cnnectr. Yu will be testing the Red, Green, and Black wires. Set yur meter t test DC vlts. Blck rear wheel ff the grund s scter will nt take ff. Turn the scter n. Place the red meter test lead n the Red wire and the black meter lead n the Black wire. The meter shuld measure +5 vlts. Nw place the meter red lead n the Green wire. With ut turning the thrttle yu shuld read arund +0.8 vlts. Nw turn the thrttle wide pen. Yu shuld nw read arund +4 vlts. If everything else pwers up n the scter and yu d nt have +5 vlts between the Red and Black wire the cntrller is bad. If yu did nt get the +.8 t +4 vlts then the thrttle is bad. Trubleshting: Intermitted Pwer Lss While ding each f the steps yu are t g and test drive the scter t make it cutut like it was ding. Yu will need a vltmeter fr electrical readings and will als require a pwer crd that is 23

24 used n a cmputer which has the same type f plug that will plug int the charger prt, with a wire length f 2' and cut wire and discard the rest. What we are ging t d is attach the vltmeter leads t this cmputer wire and plug int the scket t watch actual vltage while riding and munting the vltmeter is a spt and secure it s it desn't mve but be able t watch it while n test runs. I have prvided a drawing f this called vltmeter cnnectin.jpg abve. 1. First pull up battery pack and pull the main pwer crd ut f scket n battery pack t kill all pwer. 2. Unplug the Large Red and Orange 2 wire cnnectr n cntrller. This cnnectin is fr the Ignitin switch test, n the side that has the Red and white wire by lking dwn inside yu will see 2 silver pins and there is a little tab that yu push twards the pin and the wire will cme ut f the cnnectr. Take a piece f wire abut the same dia. as the range wire apprximately 4" lng and strip the insulatin ff each end abut 3/4" lng. Take ne end f the jumper wire and wrap arund the pin where the wire is crimped n t. Then the ther end f jumper t the white wire and reinsert it back int the white cnnectr. Yu may need t pull ut the little lck tab s it will lck int place. Reattach the cnnectr back nt the cntrller, as shwn in my drawing abve. Plug yur crd int the charger scket fr the vltmeter, just set the seat and seat barrel in the scter withut blting it. When ready plug the main battery crd in bttm f battery and turn yur vltmeter n. The scter will cme as sn as yu plug it in and may spark a little this nrmal. G fr test ride. If yu get same results f still kicking ut, just unplug main pwer crd and plug in t turn it back n. Trubleshting: N Pwer In this situatin we will assume that the battery has been charged r allwed t stand fr several hurs (a battery will nrmally self-charge up t a pint and make the scter pwer up fr a fair distance). There are generally tw main suspects: 1. First suspect is a lse r brken cnnectin. Take the tp r deck ff t see the wiring and inspect it fr any lse r brken cnnectins n the battery, switch, cntrller, etc. 2. Secnd pssibility is the cntrller bx has failed. Since the cntrller is the heart f the system it can fail in many ways t prevent current frm being supplied t the mtr. 3. Other less likely suspects can be: A battery that is cmpletely pen, supplying n current and pssible even testing as having n vltage. It can be very briefly shrted with a wire t see if an arc is prduced, revealing current is present. See Belw fr mre advice n batteries. It is als pssible t have a bad brake lever r thrttle since bth have wiring and switches r 24

25 variable cntrls. The brake lever has a pwer cut-ff switch. The thrttle variably cntrls the speed f the scter. The scter On/Off switch can be defective. Withut a gd switch the scter has n pwer, but the test f this is the pwer light. Des the pwer light cme n when the switch is activated t the On psitin? Trubleshting: After Fully Charging, Pwers Only Fr Shrt Distance Use 1. Suspect the battery charger r the battery as the primary cause f shrt distance riding after a lengthy r full charge. If yur battery charger des nt have charging indicatr lights then yu may nt be charging the battery at all if the charger is defective. 2. The battery may be self-charging t nly abut 60% n its wn. If the battery is getting ld then it may nt be able t hld a full charge and the battery will need replacement. When suspected yu can very briefly arc acrss the battery terminals with an insulated wire t see if it prduces a nice arc.. It is als pssible t test sme individual battery 12 vlt cells using 12 vlt mtrs r lights that will shw yu the available current capability. Is the 12 vlt light dim n a charged battery? Des the 12 vlt mtr run slwly when cnnected t the cell? Similar type tests can be perfrmed using a 24 vlt battery cell, t. WARNING! Batteries cntain acid that can explde, r the vaprs ignite frm an arc. Batteries prduce current and vltage that can burn yu when a shrted circuit ccurs. Be abslutely sure yu knw what yu are ding befre trying any tests t eliminate a cmpnent frm cnsideratin f being defective!!! 3. Yu can take the battery t a shp capable f testing the battery under a laded cnditin. Fully charge the battery and carefully remve it. Let a technician determine the cnditin f the battery fr yu. 4. We recmmend a high quality Battery Charger as sld n ur scter parts page. Yu can purchase by visiting ur website at r cntacting ur Parts Department at (253) r by at part@x-tremescters.cm. 25

26 Trubleshting: Scter On, Wn t Run A) If the scter is mving when yu turn the key t the n psitin withut turning the thrttle yu will need t replace the thrttle r cntrl bx. B) If scter takes ff withut turning the key t n yu need t replace the cntrl bx. Trubleshting: Scter Will Nt Mve Scter nt mving and Lights d nt wrk using battery, but lights d wrk when yu plug the charger int the side f the scter and als plug the charger int the wall-scter will nt mve at all and all lights d nt wrk (lights d wrk when yu plug the charger int wall): A) N fuse in fuse assembly= add ne f the fuses includes with the scters B) Bad Fuse= unscrew the cap nly n the fuse hlder. Remve the fuse and make sure that the fuse is nt blwn (a gd fuse will have a slid wire frm ne end t the ther, a bad fuse=the wire inside is brken) C) Bad fuse hlder = fuse assembly may be cracked r have a bad cnnectin within it. D) Bad cntrl bx E) Pssibly bad battery, althugh this is rare. F) Wires behind fuse assembly have cme ff due t imprper replacement f fuses r lse wire cnnectins t the battery. This is always due t the custmer rtating the whle fuse assembly (when changing fuses) and twisting the 2 wires that are in the back f the fuse hlder. Yu must pen up scter and reattach these wires t back f fuse assembly r t battery and cntrl bx. If this is the prblem the lights WILL wrk when yu have the charger plugged in. Trubleshting: Charger The charger is a handy tester t check the wiring cnnectins n the battery pack all the way thru the fuse hlder int the cntrller. Sme chargers have a single light and sme have 2 lights n them. When plugged int the wall yu will either have a GREEN light r a GREEN/RED light. Check with the supplied manual fr light status cnditins. Then when yu plug int the scter the charger shuld change state indicating batteries fund and charge mde started and the lights 26

27 shuld change t RED r RED/RED. If yu plug the charger int the scter and n change appears, this means that yu have an pen circuit which culd be a fuse nt installed r pwer plug nt plugged int bttm f battery pack r a bad cnnectin. All Chargers shuld change state even fr a few minutes if batteries are fully charged. When the batteries are dne charging the lights will g back t the state f GREEN r GREEN/RED means dne charging. Trubleshting: Hub Mtr Tests 1. With any ne f the three sensrs discnnected the mped will run very jerky. It may stp but will start again if the thrttle is release and then turn. 2. If tw r mre sensrs are discnnected the mtr will nt start. 3. If tw f the sensr leads are swapped arund the mtr will try t run but hardly mves. Cntrller is lst as t mtr psitin. 4. If any f the mtr leads are discnnected the mtr will nt run. 4. If the thrttle is turned all the way pen and the wheel is nt allwed t turn the cntrller will shut ff pwer within a few secnds. The thrttle must be released t reset. 5. When the thrttle is held wide pen and the scter is nly allw t barely mving the cntrller will cntinue t supply full pwer and the wires will get very ht. (wires may melt if this is dne fr very lng) Sensr Test: Use a digital vltmeter set t read hms fr these test. Discnnect all mtr wires frm the cntrller. The red lead f the vltmeter must be psitive when using the hm scale. Place the black meter lead n the black sensr lead fr the next fur tests. If the sensrs are gd yu shuld get arund these readings. There shuld nt be a great amunt f difference. 1. Place the red meter lead n the red sensr wire. (7-20meg hms) 2. Place the red meter lead n the yellw sensr wire. (Infinite) 3. Place the red meter lead n the green sensr wire. (Infinite) 4. Place the red meter lead n the blue sensr wire. (Infinite) Place the red meter lead n the black sensr lead fr the next three tests. 5. Place the black meter lead n the yellw sensr wire. (Arund 4 meg.) 6. Place the black meter lead n the green sensr wire. (Arund 4 meg.) 7. Place the black meter lead n the blue sensr wire. (Arund 4 meg.) Test all sensr leads frm lead t lead. All readings shuld be infinite. Use a digital vltmeter set t read DC vlts fr these test. Mtr wires must be cnnected t the cntrller fr these tests. Mped s pwer switch must be n during this test. 1. Test between the red and black sensr leads. (5 vlts) If yu d nt have +5 vlts check the sensr cnnectr. Make sure it is pushed tgether all the way. Check fr brken r shrted wiring. The cntrller may have failed. 27

28 2. Place the negative lead f the meter int the sensr cnnectr where the black wire is lcated. Place the psitive meter lead int the sensr cnnectr where the green wire is lcated. Slw rtate the tire. The meter shuld alternate between 5 vlts and 0 vlts if the sensr is gd. Test the ther tw sensr wires the same way. If the vltage reads 0 r 5 vlts and des nt change check the sensr cnnectr again. Causes fr this may be a brken wire, r the Hall Effect sensr may have failed. If all three sensr s read 5 vlts with n change the grund wire may be brken. If all three sensr s read 0vlts with n change the psitive wire may be brken. Mtr Winding Test: Test all mtr leads frm lead t lead. All readings shuld be.6-.7 hms. Cntrller Test: Discnnect all the mtr wires frm the cntrller t run these test. Set the vlt-meter t read hms. If yur meter des nt aut-range set meter t 20K hms. Check between the red and black pwer wires. Meter shuld nt shw lw resistance. Meters that will aut-range will g up t arund 4 meg. after the capacitr has charged. Place the negative lead f the vltmeter n the black cntrller wire that wuld g t the battery negative. Place the red lead n ne f the cntrller s leads ging t the mtr. Cntrller mtr leads will be the yellw, blue, and green leads that are nt in the white cnnectr. Yu shuld get clse readings as yu switch between the leads Place the red lead f the vltmeter n the red lead f the cntrller wire that wuld g t the battery psitive. Place the black meter lead n ne f the cntrller s leads ging t the mtr. Yu shuld get clse readings as yu switch between the leads. If yu get a lt f difference between readings f the mtr leads the cntrller is be bad. Cmmn Causes T Cmplaints: Any custmer cmplaints f jerky mtr r mtr nt running have the custmer check the sensr and mtr cnnectins at the cntrller and at the cnnectrs at the rear f the mped. If this desn t help g t steps ne r tw belw. 1. If the custmer cmplains that the mped is stuttering r jerking and mving slwly the mst likely cause is that a mtr sensr has failed and the mtr will need t be replaced. 2. If the custmer cmplains the mped shuts ff during hard acceleratin then starts again if the thrttle is released and then turned gently. The batteries either need t be charged r ne r mre f the batteries are bad. On a 48 vlt system the mped has a cutff vltage f 42 vlts. If the vltage t the cntrller drps belw 42 vlts fr mre than a half secnd, the cntrller will stp delivering pwer t the mtr. 3. If the custmer states the mped has pwer and the batteries are fully charged but will nt run. We will need bth the cntrller and mtr sent back t us s we can check them ut. Mst likely ne f them has failed but it culd als be a bad thrttle. 28

29 29

30 Battery Wiring Diagram 30

31 DO NOT RETURN TO STORE! IF YOU NEED HELP CALL TOLL FREE OR GO ONLINE Fr General Infrmatin r Parts Visit 31 Revised 9/08/11