SECTION 2: ESR 750 ELECTRIC MODEL
Contents
1. Bolt motor mount M6x18 72 GSR1045 3 8 24 x 3 Button Head 4 40 6133 Socket head 1 73 GSR1014 Spacer Wheel to sprocket 4 Bolt motor mount M6x35 Set screw for sprocket 41 1401 SHCS 1 74 6006 M5 x 8 1 dal N 0 o 75 6009 15 Sprocket 15 tooth 425 1 42 TB1028 3 8 x 78 i 1 76 GSR1013 1 Sprocket 76 tooth alum 1 43 6102 Chain guide plastic 1 E A aT E 44 6 Electric Mot 1 ubber Plug installs into Bee ectne DOT 78 6003 rear of pan holds data plug 1 Revised on 11 3 2005 2 10 Service Manual Section 2 2 ESR750 6107R Battery Pan ESR750 and ITEMS NOT SHOWN ON PARTS ILLUSTRATION 79 6107 EX not Sport Red or Black 1 Foam Pad 1 8 thiek 1081 Brake Cable 38 H 48 C 1 80 6120C installs under batteries 2 1063 Yellow Warning Sticker 1 RipDempan dus 1064 Red Warning Sticker 1 81 6131 Square 2 x2 w center hole 4 Sticker Greta T Bar Plastic insulation tape 1061 ad 1 white prevents short p 82 6121 between pan amp batteries 2 1053 Large Zip Tie black 8 1 Foam Rubber Tape 1 4 x 1053S Small Zip Tie black 4 2 1 2 sold per ft 1065 Sticker www goped com 1 83 6119C Also used on deck 88 1068 Sticker made in USA 1 Battery HR6 12 T2 SLA 6002 A C power cord 72 1 84 6005 ESR750 amp Sport2. 1 Check to make sure wires are correctly attached to motor 2 Measure voltage at motor wires while operating throttle Make sure reading is about 24V at full throttle 1 Check for throttle or ON OFF switch malfunction 2 Open pan and check if power is getting to controller Controller should be receiving about 24V Disconnect throttle at 8 pin connector and install new throttle If that does not solve the problem the fault may be in the controller EEE Disconnect ON OFF at 2 pin connector and install new ON OFF If a known good ON OFF switch isn t available you can short the two metal pins in the wire coming from the controller When the circuit is completed the controller should click and turn on If that does not solve the problem the fault may be in the controller Remove deck Inspect wires to be sure that all connections are still attached With meter measure voltage across each battery Voltage should be approximately 12V Solution If 24V is found and wires are properly connected motor must be malfunctioning If 24V is NOT found at motor then throttle or controller is malfunctioning If problem wasn t found with step 1 or 2 controller may be malfunctioning If the controller is suspected install a known good controller to see if the problem is solved If the controller is suspected install a known good controller to see if the problem is solved If connectors are off reinstall and glue with silicone
3. Not EX 4 Sticker Goped decal Battery connector Joins 6010 metallic for side of pan 2 each pair of batteries Old Sticker ESR750 installs style was 4 long wire Now 6011 on tail of frame 1 85 6126 a small metal tab is used 2 Sticker Chrome Decal E E 6012 ESR750 for slide tube 1 87 1404 Bolt rear axle 5 8 18 x 7 5 1 Heat Shrink tubing for 5 5 0 E 6022 throttle wire connection 1 Lower hinge FTG assy 6033 Sticker CE for europe 1 100 1043 Aluminum 1 Old A C inlet Used on early Bolt lower hinge FTG 6108 ESRs with Old charger 0 101 1004 5 16 24 1 Old On Off Switch Used on Lower hinge FTG clear early ESRs placed on left 102 1043A anodized aluminum 1 6110 side of T bar 0 Wedge lug lower hinge Old Charger LED board 103 1045 FTG 1 Used on early ESRs 104 1056 Handle hinge pin 1 Installed between Old 5 E 8 5 6116 charger and controller 0 Chain 25 Hard 106 link Old Charger Used on early 106 6103 ESR750 amp EX not Sport 1 ESRs This charger does not have U shaped 6118 aluminum housing 0 THE FOLLOWING ITEMS ARE ON PAGE 2 5 6129 Sticker HOT for motor 1 Battery HR9 12 T2 larger 6160 White Red warning sticker 1 108 6005B batterv EX and upgrade 4 9031 User Manual ESR 1 109 1006ES Deck Spacer 1 thick wood 1 Sticker Goped Installs on 110 E1006F Deck no grip tape 1 4 thick 1 Ender 1 Bolt deck mount 1 4 20 x 2 1 4 Torx Flat Head thread 111 6114B cutting
4. you can make a simple tool to make this task easier Simply cut the shape out of a rigid metal or plastic sheet perhaps 1 8 thick Make sure you clean the tool off thoroughly so that no particles are left behind in the motor Motor Reassembly With the Comm End reassembled drop the four brush springs into the holder and then push the brushes down on top of the springs Use the tool described above or something similar to hold the brushes in place as shown in Figure 6 2 5 Service Manual Section 2 ESR750 amp ESR750Ex Put the Armature through the Field and place them both down onto the Comm End as shown in Figure 7 Make sure that you have both end oriented correctly Use the marks you scribed across the Field and End Caps to realign the ends with the Field Pull the tool out and allow the field to drop all the way down onto the Comm End You may need to help guide the two long threaded rods through the holes on the Drive End You may also need to help align the end of the armature into the bronze bushing in the Comm end Once the three sections are assembled recheck your rotation to make sure your scribed marks are aligned Then install the lock washers and nuts Torque to 25 39 in lbs Turn the output shaft and make sure the motor spins There will be drag from the magnets but you should be able to turn the shaft by hand Motor Reinstallation Reinstall the motor in the scooter frame Reinstall
5. and the motor Field Those marks will help you re align the rotation of the end caps during re assembly Proper alignment is important for good motor performance If the end caps are improperly twisted the motor will run less efficiently Now you are ready to open the motor up Looking again at Figure 3 you will see two small hex nuts which are part of the motor Remove those nuts and the lock washers behind them Now you can pull the motor apart into three parts as shown in Figure 1 You might need to tap GENTLY on the finned Comm End to separate it from the Motor Field When you separate the motor the brushes will be pushed out of the holder by the four brush springs Be careful not to lose the springs mm De Figure 4 Inspect the armature The epoxy which is orange in this photo will probably be much darker in color This is a normal effect caused by brush dust Inspect the face of the commutator for any bad segments The segments are the pie shaped copper portions of the commutator A bad segment will look much different than the rest of the commutator It will be blackened or discolored That is indicative of a broken connection in the winding Also check the bearing which is in the billet aluminum Drive End plate Figure 5 2 3 Service Manual Section 2 ESR750 amp ESR750Ex MAMA Ba qe Brush Spring Brushes Brush Holder Now inspect the Comm End Figure 5 The four brushes should have been pushed up and poss
6. to insure that they do not come back off If batteries are bad replace the entire battery pack not just one cell 2 13 Service Manual Section 2 ESR750 amp ESR750Ex Problem Action Solution Charger problems 00200000 jj Background Power flows from the inlet plug 110V or 220V AC to the charger Then 24V DC power flows from the charger to the small LED board Then 24V DC power flows from the LED board to the Controller The power passes through the controller to the batteries The batteries are wired into two individual 24V batterv packs which are in parallel There are short connection wires between each set of batteries If one of those wires is disconnected the scooter WILL run on half the batteries with 50 of normal range Those connection wires should have silicone adhering them in place to prevent accidental disconnection Testing the charging system When testing the charging system for proper operation it is a good idea to first disconnect the batteries so that you do not get a false voltage reading from the batteries After the batteries are disconnected vou can individuallv measure the voltage across both sets of batterv wires With the charger plugged in the voltage to the batteries should be about 24V If you do not read approximately 24V going to the batteries then there is a breakdown somewhere in the system A LED on side of pan will not light when cord 1 The outlet in the wall may be off Plug in a lamp to plugged in
7. tool size T30 4 114 9004 Seat with hardware 1 115 1094 Seat post aluminum 1 116 1095 Seat post collar 1 ESR9002BK Seat frame 117 ESR9002CR Black or Candy Red 1 118 6305 Neoprene rubber foot 1 119 1097 Bolt 5 16 24 x 1 5 SHCS 1 120 7025 Nut 5 16 24 nylock 1 121 6119 Toe Guard black 1 Revised on 11 3 2005 2 11 Service Manual Section 2 ESR750 amp ESR750Ex Problem Action Solution Acceleration and hill climbing greatly reduced Disconnect chain from motor Use an amp meter to If draw exceeds 4 2amps motor is malfunctioning from when scooter was new Change was rapid measure amp draw at full throttle and no load at a and power loss may be 50 full charge Draw should not exceed 4 2amps Range is extremely low May have reduced 1 JA motor malfunction could cause abnormally high If draw exceeds 4 2amps motor is malfunctioning suddenly from one trip to the next current draw Use amp meter to measure draw as described above 2 A battery wire could have become disconnected Open Pan and inspect for disconnected battery wires causing the scooter to run on only 2 batteries instead of 4 o 3 Batteries could be old and need replacement In this case the range degradation would be gradual not immediate eplace batteries Motor is making noise but scooter will not move Check drive sprocket set screw If the screw has Put drop of Blue Loctite on set screw and re tighten or operates intermittently loosened up it could
8. 7 Pro Clamp CNC d Billet Aluminum Complete Assembly 210220 Slide Tube Clamp Installs on the bottom of alll T bar Slide tubes T bar must be removed for installation Tightening clamp removes some forward back handlebar looseness GSR1048A 20 long reinforced with wood dowel reinforced with wood dowel 2 9 Service Manual Section 2 2 ESR750 Item Part Description Qty Controller board left side of B 0 1 7 pan with attached wires Front fork bearing kit 2 This is the current version 4 1028 bearings 2 cups 1 nut 0 5 1028N Head set Fork nut 1 controllers available 6 10288 Head set bearing single 2 45 61138 Ask Customer Service 1 Head set Bearing cup Screw controller mount f 10280 single 2 46 6115 6 x 5 8 Hex washer head 4 8 1411 Carrv Loop nvlon 1 Wire DC interconnect 6109 ESR Throttle Lever See 47 6148 Controller to NEW charger 1 6110A identification chart to select Charger New stvle with 9 6110B correct model 1 48 6118A aluminum U housing 1 10 1049 Grip Set 1 Screw Charger Mount 11 1048L Brake Lever Left 1 49 6013 10 32 x 5 16 hex wshr head 4 50 6108A A C Inlet for new charger 1 15 GSR1041 T bar anod
9. Service Manual Section 2 ESR750 amp ESR750Ex SECTION 2 ESR 750 ELECTRIC MODEL This section contains parts illustrations parts lists as well as troubleshooting information for the Electric Go Ped models ESR750 ESR750Ex and their motor Paragraph Page 2 1 ESR750 amp ESR750Ex Motor Service ss ssesseseennnazsnnnnnzzsnannnzzonsnnnnzznsnnnnzzsnanannzannnanna 2 1 2 2 ESR750 amp ESR750 Ex Parts Illustration 6 0 6660 0 666 2 7 2 3 ESR750 and Batterty Upgrade Kit Parts Illustration ss 2 8 2 4 ESR seat attachment Parts Illustration wisisidusessisusdeastasdsandsnsesasesusovanseneddsnadunsianssnaavsnasawaisn 2 8 2 5 1 14100 R T ORE ATE E AEE 2 9 2 6 ESR EA 2 10 2 7 ESR troubleshooting 16 i irka EEE RENTIS 2 2 2 1 1514750 amp ESR750Ex Motor Service The ESR750 motor is a brush DC motor It consists of a Field steel tube and magnets an Armature rotating portion and Comm End brush assembly and finned heat sink Figure fil shows the major motor components disassembled Figure 1 Service Manual Section 2 ESR750 amp ESR750Ex To remove the motor from the ESR frame first turn off the ON OFF switch then disconnect the motor wires from the Comm End shown in Figure 2 You will n
10. ad motor shorted connection to motor or controller Do Poor Motor Open IL JBadmotor Loose broken connection to motor or controller Do Poor Overtemperature l JExcessive Use Excessive ambient temperature or controller MI ChargerOvervoltage Jl Battery Charger 1010000000 Po Charge Mode Time Out JI Probably a bad battery Et o fe Internal Controller Fault ER ENE Doo 8 fo Throttle Failband Throttle control is malfunctioning loose broken cable controller PO tte Controller Fatt Controler 2 14
11. be slipping on the motor shaft This problem is sometimes be misdiagnosed as electrical DeckRemoval 0 f While working on an ESR you might find it necessary to remove the deck The first several hundred ESRs which were produced have had the decks sealed to the aluminum pans with clear silicone It is pretty easy to remove the deck but the first time you do it can be a little tricky First remove the four deck bolts Now start by running a razor blade all the way around the scooter in the joint between the wood deck and the aluminum pan This will begin to cut the silicone Next take a long flat blade screw driver and start to pry the deck up at the FRONT of the scooter The electronics are all the rear of the scooter As you pry the deck up you will be able to see more of the silicone Cut the silicone with the razor The more you cut the more you ll be able to raise the deck Gradually work your way around the deck until enough of the silicone it cut for the deck to be removed Service Manual Section 2 ESR750 amp ESR750Ex Problem Scooter will not operate A Throttle LEDs DO turn on and clicking IS heard from pan when on OFF switch IS operated The clicking noise is the relay on the controller board It should click when the ON OFF switch is operated B Throttle LEDs do NOT turn on and or clicking is NOT heard from pan when on OFF switch IS operated Faulty throttle suspected Batteries bad or disconnected Action
12. eed to pull back the rubber boots and remove the two outer 4 20 nuts Do NOT remove the two inner nuts which are behind the two terminal rings Next disconnect the small plastic two wire connector which is for the motor thermostat The connector has a locking tab which can easily be released with a small flat head screwdriver or even a small zip tie Figure 2 Next remove the fender and look at the Drive End as shown in Figure 3 Remove the chain and drive sprocket The sprocket is held on with a small set screw Once the set screw is removed you might need a sprocket puller to easily slide it off the shaft Now remove the M6x35 bolt shown black in this photo which retains the motor into the frame Last slide the motor out of the frame A piece of adhesive backed plastic may have been used between the motor and the inside of the tube to shim the motor in the frame You will need to reuse or replace that shim It is used to prevent the motor from vibrating or rattling in the frame You may need to twist the motor or tap GENTLY with a rubber mallet to remove the motor Be careful with the motor The brush card holder and the magnets can both be broken if abused Figure 3 2 2 Service Manual Section 2 ESR750 amp ESR750Ex Once the motor is removed you should scribe lines on the motor field and the motor end caps for easy reassembly On the bottom of the motor simply scribe small marks across the joint between each end cap
13. ibly out of the brush holder by the four springs Make sure the brushes are moving freely and are not stuck in the holder Inspect the brushes When new they are 4 tall If the brushes are less than 225 tall they should be replaced Brush life will probably be at least 750 hours of use Inspect the brush holder for cracks or signs of overheating or deformation If necessary disassemble the Comm End First turn the Comm End over to the finned side and remove the two 4 20 flanged nuts from the terminal studs Remove and save the two black plastic flanged washers which are below the nuts Next turn the comm end back over and remove the two Philips Head screws from the brush holder Be sure to save the washers and remember their locations The Comm End is now fully disassembled Note the location and routing of the brushes and wires before removing them FYI The small electrical component epoxied into the end cap is the thermostat It should not be removed Comm End Reassembly Place the brush holder into the end cap Place the brushes in their holders the way you found them and place the terminal studs through the holes in the end cap If you install the brushes wrong the motor may run in reverse or not at all Don t install the brush springs yet Hold the parts in place with your hand and flip the end cap over Install the two black plastic flanged washers and then install the two 4 20 flanged nuts That will hold the bru
14. ized 24 75 1 51 6136 Pop rivet for A C Inlet 2 16 1060 Safety Spring 1 Pol fender mount 10 32 x 17 1022 Slide Tube Assmbly 1 52 6016 lt is Head type 2 1 olt fender mount M4x l 53 6015 Socket Head 1 Front Pork single sided 54 6008 l Fender rear ESR750 amp EX 1 MD1027CR 10 wheel Maddog brake 55 2001 Deck Grip Tape Set 1 19 MD1027BK Candy Red or Black 1 p ap a ot Wee ee TESRIODICR Frame ESR750 xX 0 21 1083A Maddog Brake Caliper 1 57 ESR1001BK Candy Red or Black 1 Spacer wheel bearing Kickstand complete black 7 23 6128 with spring and rubber foot 1 60 5000 Mag Rim 10 P 10 2 Bolt 20 x 1 5 Button 61 Briog8A PT 9 vag 5 24 GSR1035 Head for kickstand mount 2 Wheel 10 PT 2pcs 25 1076 Washer SAE flat 3 62 2026M Magnesium 20 2 a7 SEG ont 7 ETT 7 63 BF1058T Inner Tube 10 PT 2 olt front axle 5 8 18 x Eae Bolt deck mount 14 20 x 64 BF 10590 Tire no tube Powerplay TT 2 1 3 4 Torx Flat Head thread 5 front wheel t 28 6114 cutting tool size T30 4 F Bar Rio MeO pie ILA p r Bolt 3 8 24 x 3 5 Low hex 29 E1006 bin TETTO 1 67 1088 head front wheel assy 4 0 l 5 68 8008 Nut 3 8 24 center lock 8 Brake Disc hardened 38 KN1009 Nut 18520 NylOck 69 8003SS stainless steel 2 E E E 70 BF1037 Nut axle 5 8 18 nvlock 2 38 1026 Nut M6 low nvlock 1 Spacer rear axle stepped Washer axle 1 OD x 5 8 71 6127 for fender 1 39 BF1036 ID x Dop l 2 Bolt Rear wheel assembly
15. make sure it is live 2 The A C cord may be bad Try using a cord known to be good or test the cord with a multimeter 3 Charger may be malfunctioning Remove deck and If no 24V output carefully check 110V A C wires between with scooter plugged in carefully measure for 24V charger and plug receptacle If no problem found replace output from Charger 2 wire connector not 3 wire charger If 24V present go to next test 4 Charger LED board may be malfunctioning Measure Replace LED board if necessary for 24V output from LED board to controller It will be necessary to disconnect the LED board from the controller to perform this test B LED goes to green immediately after plugging in There is probably a disconnection somewhere scooter even though batteries are known to be between the LED board and the batteries The LED discharged board may be disconnected from controller the controller may be disconnected from batteries or the short wires connecting the batteries may be off Check all those connections Error Codes The ESR controller is very advanced and has self diagnostic features If the ESR senses a problem it will alert the rider similar to a check engine light in a car The warning comes in the form of flashing codes on the Flux Capacitor LEDs The codes are listed below for your reference These codes can also be retrieved and reset using the Go Prammer Do FaultCode OJ To Problem jj PossibleCause DO HO f l Witor Short B
16. mp type amperage probe over one of the two motor wires but not both wires You may need to remove the deck to install the clamp probe If using the Go prammer use the instruction manual to switch to the CURRENT parameter under the Debug Menu Run the motor at full throttle with no load and measure the amperage draw It should be less than 4 2amps If you are using the Go prammer to measure current use the chart in the instruction manual to translate the reading on the screen into amperage 2 6 00E 96 12001200 7 220 P OSLASA CT 0 JDNUDW 991449 Section 2 2 ESR750 amp ESR750 EX Service Manual Revised October 26 2005 ESR 50EX and Battery Upgrade Kit Part 6600 ESR750 and ESR75OEX Seat Does not fit ESR Sport Part ESR9001BK Black Part ESR9001CR Candy Red Also available 9101BK Seat Bag 9068 Seat Rack 2 8 Section 2 2 ESR750 amp ESR750EX Service Manual Revised October 26 2005 Other Available Accessories Part BF1127B Bothie two sided fork Available In Black Not available in Candy Red to match ESRs Includes new axle bolt and spacer Wider High Performance Handlebar Parts must be purchased Separately Some older ESRs may have too short a throttle wire for the tall configuration shown Vertical tube can be cut shorter if necessary 2009D Crossbar and Pad Assembly Anodized aluminum riser bar 202
17. shes and brush holder in place Tighten the nuts to 20 25 in lbs Over tightening can break the brush holder Flip the comm end back over Reinstall the Philips head screws and washers the way you found them Torque the screws to 20 25 in lbs It is very important that the wires be routed correctly Where the two long brush wires cross they are retained by the washer under one of the Philips head screws Make sure that the white plastic insulating sleeves are correctly placed to prevent the copper wires from contacting the aluminum end cap Make sure that the bushes can freely slide in the holder If a brush cannot move freely the motor will fail after a small amount of use Service Manual Section 2 ESR750 amp ESR750Ex gt gt As the motor spins the commutator gradually wears down the brushes The brush springs insure that the brushes stay in constant contact with the commutator If a brush becomes stuck it will gradually lose contact with the face and electricity will begin arcing to the commutator This will gradually degrade the commutator It will also cause overheating which could damage the brushes the wires or the brush holder When a stuck brush occurs the rider will feel his power diminish to about 50 of normal as the motor begins to malfunction When you are ready to reassemble the motor you can reinstall the brush springs It can be difficult to hold the brushes in place while you assemble the motor Using the drawing below
18. the plastic shim between the motor and the inside of the frame tube to keep the motor from vibrating in the frame Install the M6x35 socket head bolt which both mounts the chain tensioner AND retains the motor in the frame Torque to 8 ft lbs The original bolt has a locking nylon patch which is only good for one or two installations If the patch is worn out use a new bolt or Blue Loctite Reinstall the sprocket and chain You might need to clean up the end of the motor shaft to allow the sprocket to easily reinstall Sandpaper or a file can quickly accomplish this Hook the small plastic 2 wire thermostat connector back together Hook the motor wires back up Make sure the terminal rings are not left close to the aluminum end cap or a short could occur Torque the two outer 4 20 nuts to 20 25 in lbs Overtightening could break the brush holder Those nuts have a nylon locking insert which can only be reused a couple of times If the nuts are not locking properly replace them with new ones With the rear wheel OFF THE GROUND turn on the scooter and apply the throttle Make sure the rear wheel is spinning the correct direction If it is spinning backwards reverse the two motor wires Reinstall the rubber boots over the terminals Reinstall the fender Motor Testing You can test the motor in the following way With the motor installed in a scooter remove the chain Either hook up a Go prammer to the scooter or place a cla
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