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10/22/2007 |
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More Electric Scooter Maintenance & Tips
1) Scooter takes off - will not stop
A) If the scooter is moving when you turn the key to the on position without turning the throttle you will need to replace the throttle or control box.
B) If scooter takes off without turning the key to on you need to replace the control box
2) Scooter not moving and Lights do not work using battery, but lights do work when you plug the charger into the side of the scooter and also plug the charger into the wall-Scooter will not move at all and all lights do not work (lights do work when you plug the charger into wall):
A) No fuse in fuse assembly= add one of the fuses includes with the scooters
B) Bad Fuse= unscrew the cap only on the fuse holder. Remove the fuse and make sure that the fuse is not blown (a good fuse will have a solid wire from one end to the other, a bad fuse=the wire inside is broken)
C) Bad fuse holder = fuse assembly may be cracked or have a bad connection within it .
D) Bad control box
E) Possibly bad battery, although this is rare.
F) Wires behind fuse assembly have come off due to improper replacement of fuses or loose wire connections to the battery. This is always due to the customer rotating the whole fuse assembly (when changing fuses) and twisting the 2 wires that are in the back of the fuse holder. You must open up scooter and reattach these wires to back of fuse assembly or to battery and control box. If this is the problem the lights WILL work when you have the charger plugged in.
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3a) Scooter not moving and Lights do not work when using battery, and lights do not work when you plug it into the wall-Scooter will not move at all and all lights do not work (lights also do not work when you plug the charger into wall):
A) Bad ignition switch almost always- if you open the panel under the ignition switch and connect the 2-wire coming from below the ignition switch. to each other, this will bypass the switch. If the scooter then works then you know that you either have a bad ignition switch or bad connection going to the ignition switch. If this is the problem the lights WILL NOT work when you have the charger plugged in.
3b) Scooter not moving/ Lights & horn work only with battery charger connected.
A) MOST COMMON=Usually bad engine. First check the accelerator bar (throttle) below see 4B To check the engine, plug the engine directly to the battery. If the engine is working then it is not a bad engine. Sometimes you will smell a burning smell if it is a burned out engine or maybe you recall a noise coming from the engine before the scooter stopped running.
B) Accelerator bar=Throttle bar as you rotate the accelerator bar the lights on the console for speed should light up gradually if the accelerator bar is GOOD. If they do not light up then there is a problem with the accelerator bar or the connection of the accelerator bar to the control box. If the lights do light up gradually as you turn the throttle then it is probably a Battery problem and not a throttle problem. To replace the throttle, use an Allen wrench to remove the screw under the old throttle, then cut the wires on the new and old throttles and splice the wires together.
C) IF THE CHAIN TURNS but the scooter does not go forward then it is a problem with rear clutch bearing which is a brass color (it attaches directly to the side of the rear sprocket) and it needs to be replaced.
D) Maybe the control box needs to be replaced or there is a bad connection in the wiring going to the motor or to the control box.
4) Scooter going slow:
A) Motor is bad=THIS IS THE MOST COMMON REASON. Maybe the scooter goes fast if you lift the back wheel off the ground, but very slow when you sit on it. Sometimes you will smell the engine burning or you will hear it making a clicking noise.
B) Battery needs to be recharged
C) It may be too cold to operate the scooter. The scooter runs very slow at 40 degrees Fahrenheit or colder. The battery does not output much current at low temperatures. It is too cold to operate.
D) Maybe one of the batteries needs to be replaced check output of battery with an electrical meter=VERY DOUBTFUL unless battery is 9 months old. In our first 4 months we have not had any bad batteries.
E) Scooter is braking so the brakes need to be adjusted If you are simply pushing the scooter when the ignition switch is turned off and the scooter very hard to push= then you know that the scooter is always braking. To fix it - On the back wheel, loosen the nut, which is about 1 inch from the end of the brake wire. Then flex the brake handle. Then adjust the brake and tighten the nut back on.
F) The rear chain sprocket and the sprocket on the end of the motor are not properly lined up. You have to loosen the two outer nuts on the back wheel axle and adjust the back tire so that the chain lines up straight
G) The chain is too loose or the chain is too tight. Loosen up the nuts on the back axle and move the back wheel forwards to tighten the chain or backwards to loosen the chain.
H) Make sure the tires have sufficient air but this usually is not the problem.
I) Maybe bearings are worn out. Sometimes you can disconnect the chain and spin the back wheel and still hear the problem bearing.
5) Brakes not braking:
A) On the back wheel, loosen the nut, which is about 1 inch from the end of the brake wire back by the back wheel. Then flex the brake handle on the left handle bar to loosen the brake wire. Tighten the nut back nut after adjusting the brake. (To make the scooter brake more easily, use a pair of pliers to pull the wire out further from the nut and then tighten the nut to hold the wire in place).
B) Brake not working brake drum threads are stripped where drum screws onto the wheel.
6) Grinding Noise in rear
A) MOST COMMON= motor is making noise replace motor. If you take off the chain and run the scooter, does it still make a noise=if so, then it is definitely the motor
B) Bearings damaged in rear wheel replace bearings
C) The chain is too loose or the chain is too tight. Loosen up the nuts on the back axle and move to back wheel to tighten or loosen the chain
D) The rear chain sprocket and the sprocket on the end of the motor are not properly lined up. You have to loosen the two outer nuts on the back wheel axle and adjust the back tire so that the chain lines up straight.
7) Scooter seems fine until sat on , then will not go or pops fuse .
a) most common fix- front tire-fork is backwards, loosen clamp on post and spin tire-fork around.
8)Tire problems
A) Tire will not inflate broken inner tube. You will either have to replace the inner tube, which is available at at our website or at a local store like, Wal-Mart, K-Mart or Pep Boys.
B) Tire is wobbly or when inflating the tire the tire comes off the rim you probably have a Happy Tire brand of tire and you will have to replace it because the bead of the tire is not seating against the rim as you inflate it.
9) Scooter will not charge- after charging for 8 hours, the scooter does not show a full charge (the lights are not all lit up).
A) Charger may be bad. Replace charger. THIS IS MOST COMMON.
B) Charger connection on scooter is bad- usually a wire on the back of this charger connection is not attached to the assembly
C) Maybe the connection problem from the charger wire to the control box
D) Maybe the control box is bad.
E) Rarely, one of the 2 cells of batteries are bad
10) The seat post or front post will not tighten
A) The clamp is not all the way at the bottom of the post. Move it to the bottom of the post and retighten.
B) The clamp L-shaped screw can be tightened and tightened but it does not appear to be getting tighter. You have to hold the bolt head with a pair of pliers while you twist the other end of the screw with your hand.
12) Scooter will not go up hills
A) Too much weight on scooter. It is not intended to carry weight much higher than its load capacity up a slope.
13) All lights work, but the power and speed gauges (where provided) do not work- check to see if the wires are all plugged into the circuit board which is in the headlight structure.
14) Scooter will not shut off even after you remove the keys Need to replace control box
15) Scooter takes off when you turn on the key (without turning the control handle) Need to replace control handle or control box in some models (no springs on front forks and no shock absorber under the seat).
16) Luggage box lock falling off replace the luggage box lock with a similar one that is held in place by a clip. The ones with screws are falling off.
17) Front headlight is not working Replace bulb to the front headlight
BASIC REPAIRS ON THE SCOOTERS
A) To get inside the scooter body under the seat you do not need to remove the 4 locknuts on the bottom of the scooter. Just open the battery cover and if neccessary remove the batteries to access the control box and the motor.
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