Gas Electric 36V Service Manual 15312R1
Contents
1. 36V 300A Electric Output Power Torque 9 9 hp 7500rpm 13ft lbs 5500rpm Starting tain Ena eene Keyed Electric Transmission Double Belt Drive TOP SPCC Geese 20mph CAPACITIES Maximum Load Driver Passenger amp Gear 650lbs 20 25 Batteries 12V Golf Car 155Ah 3 eC IGN 12V 35W 2 Tail Light 220 n nono nn nnn nn ccnnncnne 12V 21W SW CHASSIS Brakes Front and Rear Hydraulic disc Left foot control Tires Front Rear 20 x 7 0 8 15psi 22x11 10 15psi Page 1 200 Series 36V 15312 Suspension Front Dual A arm with 1 8 45mm of travel Suspension Rear Spring over shock with 2 4 60 of travel WEIGHT Dry Weight 408Kg 975lbs WARRANTY The specifications are subject to change without notice Section 2 MAINTENANCE PERIODIC CHECKS AND SERVICES The maintenance intervals in the following table are based upon average riding conditions Riding in unusually dusty or muddy areas reguire more freguent servicing Initial service Tire Pressure Wear p 2 Brake Fluid and Performance p 32. 5 Belt 5 Primary Belt Replacement 6 Secondary Belt Replacement 6 SECTION 5 TOUS 7 Throttle Installation and Adjustment 7 Throttle Assembly Removal 7 Throttle Sensor Removal 7 Throttle Safety Switch Removal 7 Throttle Safety Switch 7 200 Series 36V 15312 Throttle Sensor Installation 7 Throttle Assembly 8 Section 6 Electrical SYStem ssssinsusa nananana nananana nananana annan 9 SCHIEIMIAUCS 9 DOS ISS ee ee 11 Testing and Water 11 11 Nal GING 13 13 Section 7 CHASSIS 14 Steering AlGMMEN cccsccecsccecsecnerecnenrcncarsucarsuecuseeceneesenersesuess 14 SECUON S Brake 15 Brake System Replacement 15 Section 9 Troubleshooting aa aa aan
3. r Q 4 n p lt a 72 HEADLIGHT II 25W BR W WORK UOHT B G BR RUNNING LIGHT twits O N IONIDOAN V WTO J p 57 A ON VOLIMETER A 2 p lt JA FUSE ISA a 17 POWER RAN OUTLET x RADO XLT Ora Y 519 J HEADLIGHT 12 7 25W n JA She 3 WORK LIGHT BATTERY R BRAKE UGH SWITCH BR G R BR 4 GIy w 314 3 5 16 3 B BRAKE TALLICHT VIV G 133573 9 2 G yX 4 lassa o N R x 52 gt 34V FROM MAIN p CONTACTOR PAN N RECOMMENDED BATIERY CABLE GAUGE 4A WG MINIMUM RECOMMENDED MOTOR CABLE GALGE 4AWG RECOMMENDED FIELD CABLE GAUGE J0AWC RECOMMENDED CONTROL WIRING GAUGE ISAWG ULIO07 UL 1549 CC00 7 3 MOTOR A LEFT SPEAKER _ T Page 9 15312 200 Series 36V wano voi 394 W 4 VINOD 134205 050 10 66 SX 0015 10 68 2 ZXZ 0705 10 66 3 570 1062 11109 SP VYLJIIIA 114 IN 18110654 200 Series 36V BATTERIES Batteries contain acid that can be harmful Therefore special care must be taken when handling Testing and Water Level Each battery should measure at least 12 8V fully charged Before charging ensure the water level for each cell of the batteries is at least slightly above the
4. 2 Connect the two motor Field connections F and F 3 Install the three bolts that hold the controller to the mounting plate Section 4 DRIVE SYSTEM Before servicing the belt or other drive components ensure the vehicle power is OFF and the wheels are chocked Fingers or other body parts can get severely injured by moving drive components BELT TENSIONING AND REPLACEMENT Belt Tensioning Adjust both the primary and secondary belts to 1 2 flex Do NOT over tighten as this will cause premature belt wear and excessive drive noise 1 Unlock the tensioner by loosening the smaller 3 8 tensioner bolt 2 Insert a 3 8 socket wrench into the tensioner set to loosen counter clockwise 3 Apply a small amount of pressure to the socket wrench until there is approximately 1 2 flex in the belt 4 Tighten the smaller 3 8 tensioner bolt to lock the tensioner in place It is not necessary to tighten the center nut on the tensioner but it may be tightened if desired or if tensioner slip is occurring Primary Belt Replacement Primary belt replacement requires disassembly of the jackshaft components When attempting to loosen or tighten jackshaft nuts stay clear of all belt driven components as they may rotate during this process Before servicing chock the rear wheels of the vehicle Remove the guard above the pulleys Loosen the primary belt tensioner by loosening the smaller 3 8 bolt Remove the n
5. Chassis Nuts and Bolts p 3 Belt Tension p 4 Motor p 4 Batteries p 4 C ve A adjust C clean I inspect clean or replace if necessary L lubricate R replace MAINTENANCE AND TUNE UP PROCEDURES This section describes the servicing procedures for each item in the Periodic Maintenance requirements Tire Pressure Wear Check the tire pressure every time the kart is ridden The tire pressure is very important for the stability of the ride 15312 200 Series 36V For proper tire pressure ratings see Section 1 Specifications Brake Fluid and Performance Always check that there is plenty of brake fluid in the brake fluid reservoir Ensure brake fluid looks clean and brake hoses are in good condition Check that the front 7150 only and rear brake pads are in good condition Check the brake rotors for abnormal wear lt lt lt lt Chassis Nuts and Bolts Always pay attention to the karts nuts and bolts Some loosening after use is normal and should not be left unchecked for an extended period of time TIGHTENING TORQUE CHART Bolt Conventional marked bolt 8 8 marked bolt Diameter mm Nm Kom Nm 0 2 0 4 1 5 3 0 3 6 0 3 0 6 2 0 4 5 0 4 0 7 3 0 5 0 0 8 1 2 6 0 8 5 Chassis Lubrication Clean and Grease chassis bushings and bearings quarterly to assure smooth operation and extended life of the bushings and the components If used in extreme
6. options 4 Pin Connector with 2 power feeds purple wires probe placement and meter result Action If the proper voltage is not present check all connections and splices in the 36 volt harness and repair as necessary Wiring must be traced to locate the item that is disrupting the circuit Relay e Make sure it makes a faint click when the key is powered ON and again when key is OFF e If the click is not present check the wiring to the relay With the Key ON verify 12V exists between at the black connection e If 12V exists and Relay does not click replace the relay Page 23 200 Series 36V 15312 Relay Blue or Black Power Checks 36 V 15312 If there is no 36 volt power check the main 350 amp fuse and the 36 volt harness fuse Check fuses first by looking at the piece of metal that runs through the glass If it is broken replace the fuse If it appears to be intact confirm with the meter by setting on the meter to and placing a probe on each end of the fuse The meter should give a value close to Zero Ohms 0Q OL displayed will represent a blown fuse If still no power check all connections pins wires locations same as you would for the models with gas engines o Relay plug Blue or Black automotive relay o ALL pins at ALL connectors of ALL harnesses are properly installed and in the correct positions o Check all splices in the harness All connectors are ful
7. probe placement B Terminal Controller Meter Result Approximately 30V Action If the required voltage is not present wiring must be traced to locate the item that is disrupting the circuit Additionally check for a hot resistor across the Contactor This indicates a failed controller 15312 200 Series 36V Resistor e Remove the resistor from one post of the contactor The side that is powered from the battery is recommended Use setting on the meter Place one probe on the free end of the resistor and one on the other post The reading should be approximately 680 ohms e If this does not happen replace the resistor Probe Placement Resistor Removed Probe Placement from this Post and Resistance Note Additionally a hot resistor across the Contactor indicates a failed controller Controller Evaluation If it is Suspected that the motor controller is bad perform these checks before replacing Page 27 200 Series 36V 15312 Measuring from M to B will be around 18 25KQ From M to B will start around 18 25 and charge up as the meter is connected Measuring from F to F will be around 15312 200 Series 36V
8. wet and muddy conditions or dusty conditions it is recommended more often Page 3 200 Series 36V 15312 Inspect components for cracks or abnormal or excessive wear Belt Tension Inspect and adjust belt tension Refer to Section 4 Drive System for details Motor Inspect electrical connections to the motor Tighten loose connections as specified in Section 3 Motor removal and Installation Inspect motor mounting bolt tension and condition of insulating washers Clean motor with soapy water to allow proper cooling Batteries Clean surfaces of batteries with a solution of water and baking soda Inspect for damage or excessive leaking Inspect nut tension and the condition of the cables If any signs of arching or wear exist adjust or replace the affected component Loose connections in the battery system can cause serious damage to the vehicle s electrical system Inspect water level of each cell of each battery See Section 6 15312 200 Series 36V Batteries Section 3 MOTOR AND CONTROLLER Before servicing the Motor or Motor Controller be sure to disconnect the Main Fuse A charge is stored in the Motor Controller and if its terminals are shorted out even though disconnected from the battery it may spark This will not cause damage to the controller MOTOR REMOVAL AND INSTALLATION The motor is isolated from the chassis to ensure arching will not damage the motor controller Ensure isola
9. Service MEET 200 Series 36V Table of Contents Section 1 General Information 1 1G SHUT CATON sisisi Naran 1 Frame NUMDER 1 85916 deinen ection aN 1 Section 2 2 Periodic Checks and Services 2 Maintenance and Tune Up Procedures 2 Tike Pressure WV Cal 2 Brake Fluid and Performance 3 Chassis NOUS and BOWS a a 3 Chassis 5 1 3 TENSION 4 J I STEN SIE SJ N Ne SEITE e PIN I 4 Batteries 4 Section 3 Motor and 4 Motor removal and Installation 4 4 Osassa 5 Controller Removal and 5 Controler REMOVAL 5 Controller 5 Section 4 Drive System 5 Belt Tensioning and Replacement
10. a nananana 16 16 ROCCO UE 17 Throttle Harness Throttle Sensor Potentiometer Signal 17 Throttle Harness Throttle Switch 17 Throttle Position Sensor Potentiometer 18 SWIC 19 TZ POWO 20 P wer CHECKS 12V cesusidvcmistimuesatnnndueandevevantensdenaiemusatasuivans 20 Battery Checks Individual Battery 21 Battery Checks Battery System 21 Power to Throttle Switch 22 Controller Power from 36V Harness 22 ROE 23 POWer CHECKS 24 Power to Small Posts of Contactor 25 Controller Power Through Contactor 26 A 27 Controller EVAN ON 27 15312 200 Series 36V Section 1 GENERAL INFORMATION MODEL IDENTIFICATION Frame Number The frame number or VIN can be found on a plate which is located on the crossbar behind the seats SPECIFICATIONS DIMENSIONS IVU LENGU 2502mm 98 5inch OVEra 1245 49inch Over 9 sisi sas 1765mm 69 5inch PERFORMANCE Motor 5
11. e which of the 7 charging steps are most appropriate A red light indicates the battery is being charged Green indicates the charger is in the final stage of charge and is at least 90 charged Over the next 2 hours or so the battery is topped off It is okay to use the vehicle once the chargers indicators are all green Overall this process can take up to 12 hours The charger is able to detect a battery is connected all the way down to 2V If the battery voltage is below 2V the charger will flash Red Green In this case another source can be used to jump the battery so charging can begin With the charger plugged in connect another external source such as a 12V dumb charger or a separate 12V battery to the terminals of the low voltage battery for a moment until the charge indicator changes from flashing Red Green to solid Red Remove the external source as soon as the light is solid Red Flashing Red Green lights also indicates an open battery circuit between the charger and respective battery Check for a broken connection wire Lastly flashing Red Green can indicate charging cannot be completed on the respective battery If at any point during the charge cycle a problem is detected with the battery charging will stop and the lights will flash Red Green This includes if charging cannot complete in a 1 hour period If left plugged in as a maintenance charger the charger will check the state of charge on the batterie
12. es is not there If the discharge meter is not resetting to full the charger should also be indicating a problem on the respective battery Section 7 CHASSIS STEERING ALIGNMENT For best off road performance the steering alignment should be set toed in as shown here The front wheel should be toed in 1 8 to 1 4 To check alignment measure distance from A to B to the centerline CL of the tires with the wheels point straight ahead For the proper toe in dimension A should be 1 8 1 4 greater than dimension B Loosen the locknuts on both sides of Front Tie Rods To Make Dimension B smaller screw the rod left If B needs to be longer screw the rod right Tighten the jam nut tightly against the rod end Recheck the distance and repeat the above steps until the Dimensions are per paragraph 1 above Lock nut FR Wheel tle rod N VI Left rotate a TZ lt Right rotate e m wk IE lt y Right rotate Left rotate TR Wheel rod 15312 200 Series 36V Section 8 BRAKES BRAKE SYSTEM REPLACEMENT Page 15 200 Series 36V 15312 Section 9 TROUBLESHOOTING FLOWCHART Follow the steps below to quickly diagnose common issues For detailed testing information see Procedures below Vehicle does not move when throttle depressed Having the throttle depressed while shifting from F to or visa versa will generate a fault Reset Key S
13. ety Switch Signal Throttle Position Sensor Potentiometer Use setting on the meter Unplug the throttle position sensor from the harness Place one probe on the end of each wire With plunger extended throttle returned the resistance should be less than 160 Ohms e Depress plunger by pressing down on the throttle pedal With the throttle fully depressed the resistance should be at least 4 300 Ohms Q or 4 3KQ e If this does not happen replace the sensor 15312 200 Series 36V Throttle Position Sensor gt 4 3 with throttle depressed 44 lt 160 Q with throttle returned Throttle Switch The throttle switch 1s an ON OFF switch Use setting on the meter Remove the throttle harness connectors Place one probe on each spade terminal on the Switch With the button pushed in throttle fully returned the meter should say With the button extended throttle pressed there should be a value shown close to Zero Ohms 0Q e If this does not happen replace the switch Page 19 200 Series 36V 15312 Complete circuit with throttle pressed Open circuit with throttle returned 12V Power e With ignition key ON check to make certain that the battery indicator and headlights are functional Power Checks 12V e If there is no 12 volt power check the main 350 amp fuse and chassis harness fuse e Check fuse first by looking at the piece of
14. he preferred side or removal Disconnect Main Fuse Disconnect battery wiring to all batteries Remove battery hold down nuts located underneath the battery rack Remove battery hold down Slide end battery out and remove from system NOTE the orientation of the battery as it is removed Repeat for all others to be replaced To install or more batteries 8 Slide battery into place keeping its orientation correct as shown here 9 Install battery hold down 10 Install battery hold down nuts 11 Install wiring to batteries and Main Fuse as shown here e 12 Torque battery nuts to 8 10 ft lbs 96 120 in lbs 13 Double check all wiring nuts and battery orientation 15312 200 Series 36V 14 Connect Main Fuse 15 Turn ON the key and check that throttle functions properly 16 Reinstall wheel assembly 17 Raise vehicle slightly and remove jack stands and lower vehicle Charging The included onboard NOCO Genius charger is a complete charger and maintainer package It charges and maintains each battery individually Charging starts soon after the charger is plugged in A slight spark when first plugged in is normal For the first minute after the charger is plugged in a series of checks is performed to ensure it is safe to charge the batteries After a minute or so charging begins at up to 10A per battery From this point on the charger constantly monitors the battery state of charge to determin
15. ly inserted into the controller Check continuity of all wires and cables Confirm with the meter by setting on the meter to Q and placing a probe on each end of the wire cable The meter should give a value close to Zero Ohms 00 OL displayed will represent a broken wire 36V Fuse 12V Fuse 200 Series 36V Power to Small Posts of Contactor e Use V setting on the meter e Place the RED probe on the small stud of the contactor with the orange wire and the BLACK probe to a good chassis ground such as the negative post at the 350 amp fuse e Turn the ignition key to the position e The meter should read at least 36 volts One probe placement shown probe placement to either small post with the orange wire either small post with an orange wire 1s acceptable Meter Result gt 36V Page 25 200 Series 36V 15312 Controller Power Through Contactor e Use setting on the meter e Make certain that the resistor has been re installed if it was disconnected in a previous test e Place the black probe to a good chassis ground such as the negative post at the 350 amp fuse or where the ground cable attaches to the frame e Place the other at the controller s B position on the cable coming from the contactor It should read approximately 30 volts B terminal Farthest rearward and only terminal with both a red and black cable attached
16. metal that runs through the glass If itis broken replace the fuse If it appears to be intact confirm with the meter by setting on the meter to and placing a probe on each end of the fuse The meter should give a value close to Zero Ohms 042 OL displayed will represent a blown fuse e If still no power check all connections pins wires locations same as you would for the models with gas engines o Chassis harness yellow plug inserted fully o Relay plug Blue or Black automotive relay o The dash panel harness especially the bullet connectors make sure they are tight and the spade connectors make sure they are properly installed o ALL pins at ALL connectors of ALL harnesses are properly installed and in the correct positions o Checkall splices in the harness e All connectors are fully inserted into the controller e Confirm that batteries are wired correctly e Check continuity of all wires and cables Confirm with the meter by setting on the meter to Q and placing a probe on each end of the wire cable The meter should give a value close to Zero Ohms 042 OL displayed will represent a broken wire 15312 200 Series 36V 12V Fuse Chassis Harness Battery Checks Individual Battery e Use V setting on the meter e Place one probe on the positive post and one on the negative post of a given battery It should read greater than 12 volts on each battery Probe Placeme
17. ng pliers carefully remove the throttle sensor clip Throttle Safety Switch Removal 7 Remove the two nuts holding the switch in place Throttle Safety Switch Installation 8 Align the two holes on the safety switch with the holes in the throttle bracket 9 Install both mounting bolts and locking nuts Throttle Sensor Installation 10 Align sensor and clip with holes in throttle bracket Outward force may be applied to the clip to align with the holes 11 Carefully apply even pressure on the clip to insert it into the holes The sensor can get damaged if care is not taken here The sensor may have some play between the bracket and clip This is normal Throttle Assembly Installation 12 Install the throttle pedal bolt through the throttle components as shown 13 Verify the throttle pedal is free to move and is not bound 14 Tighten the nut for the throttle pedal bolt 15 Again verify the throttle pedal is free to move 16 Connect the throttle spring starting with the throttle pedal then the throttle bracket 17 Connect the wires and connector to the sensor and switch 18 Follow the test procedures in section Section 9 Procedures to verify the correct signals are at the motor controller 19 With the seatbelt properly fastened attempt to drive the vehicle slowly to ensure proper functionality of the throttle circuit 15312 200 Series 36V LEJ al lt Q ja 4 Q mel O
18. nt gt 12 volts for an individual battery Battery Checks Battery System e Use setting on the meter e Place one probe on the negative post at the 350 amp fuse Place the other on the positive cable going to the contactor e Itshouldread greater than 36 volts Page 21 200 Series 36V 15312 e fit does not check to be certain that the 36 volt circuit is wired properly Probe Placement Probe Placement Main Fuse Power to Throttle Switch e Use setting on the meter e Place one probe on the white wire of the Throttle switch and one probe to a good chassis ground such as the negative post at the 350 amp fuse e Turn the ignition key to the ON position e The meter should read 12 14 volts Safety Switch probe placement shown probe placement to any good chassis ground Meter Result 12 14 Controller Power from 36V Harness e Use setting on the meter 15312 200 Series 36V e Place one probe of the three purple wires and one probe to a good chassis ground e Turn the ignition key to the ON position The meter should read in excess of 36 volts e Repeat for the other purple wires All purple wires are tied together If one is not getting power and the others are a bad crimp or broken wire may be the problem 10 Pin Connector with 1 power feed purple wire iL Controller S probe placement
19. plates as shown below If any battery cannot be charged to this level ensure the water level is where it should be per the instructions below If the water level is good and the battery ies still will not hold 12 8V or higher check the specific gravity for each cell 1 Open the vent caps and look inside the fill wells 2 Check electrolyte level the minimum level is at the top of the plates Water level above this point before charging 3 If necessary add just enough water to cover the plates at this time and replace the vent caps Put batteries on a complete charge before adding any additional water refer to Raise vehicle slightly and remove jack stands and lower vehicle Charging below Once charging is completed open the vent caps and look inside the fill wells Add water until the electrolyte level is 1 8 below the bottom of the fill well A piece of rubber can be used safely as a dipstick to help determine this level 9 Clean replace and tighten all vent caps gt Replacement Each battery in the system should be the same make and model Replacing a battery with one of a different rating may hinder vehicle performance and fail prematurely To remove one or more batteries Page 11 200 Series 36V 15312 1 Jack the vehicle s swingarm and place on jack stands to keep the rear wheels off the ground Do NOT use the Axle as a jack point Remove one of the rear wheel assemblies to give access to t
20. s every 24 hours If detected that the battery voltage has dropped around 20 or more charging will start over at the finishing stages of charge It is recommended that the charger remain plugged in as long as the vehicle is not in use including winter months or in storage Battery Indicator Located in the dash is a battery discharge meter This is driven by the 12V battery which drives the entire 12V electrical system If a problem is suspected with the batteries not attached to this meter the charger should indicate this during the charge cycle by flashing Red Green at any point along the charge Page 13 200 Series 36V 15312 cycle The indicator is meant to provide the condition of the typically lowest charged battery in the group Typically the indicator will show empty alternating red lights well before the vehicle cannot fully operate It is okay to operate the vehicle until it slows due to low voltage but is recommended to be charged whenever the gauge shows empty This will provide the best life of the batteries It is normal for the discharge meter to not show an increase in voltage level until charging has completed Battery voltage must be greater than 14 1V for a minimum of 7 minutes for the gauge to reset All digital battery indicators have this characteristic to prevent the gauge from indicating a voltage that is not relevant As batteries sit unused the voltage may creep up but the useable potential of the batteri
21. sor signal is making it to the controller e Remove the 5 pin connector from the controller There will be three wires in it e Use setting on the meter e Place one probe on the end of the gray wire and one on the end of the gray wire with the black stripe e With plunger extended throttle returned the resistance should be less than 160 Ohms O e Depress plunger by pressing down on the throttle pedal With the throttle fully depressed the resistance should be at least 4 300 Ohms or 4 3KQ e If this test result is good the throttle position sensor is also good and does not need tested as an individual component Throttle Harness Throttle Harness Throttle Harness Throttle Switch Signal Confirm that the throttle switch signal is making it to the controller Page 17 200 Series 36V 15312 Remove the 5 pin connector from the controller There will be three wires in it The throttle switch is an ON OFF switch Use setting on the meter Place one probe on the white wire and one on the chassis ground With the button pushed in throttle fully returned the meter should say With the button extended throttle pressed there should be a value shown close to Zero Ohms 0Q e If this test result is good the throttle switch is also good and does not need tested as an individual component Throttle Harness Nearest Chassis Ground Probe Placement for Throttle Harness Testing of Saf
22. then off the axle 9 Install the new belt by sliding it over the axle through the slot of the Swingarm axle bracket and placing it over the axle pulley 10 Place loose pulley inside the belt 11 Line up pulley with keyway on the jackshaft and slide the jackshaft right through the spacer and bearing 12 Install and tighten jackshaft nut until there is no horizontal play in the pulleys approx 90 110 ft Ibs 13 Replace guard removed in step 3 14 Tension the belt following the instructions found in Section 4 Belt Tensioning 15 Reinstall the left rear tire wheel 16 Raise vehicle slightly and remove jack stands and lower vehicle 20055 Section 5 THROTTLE Proper installation and adjustment of the throttle assembly will ensure safe and reliable control Improper adjustment could result in undesirable results such as a sticking throttle pedal or lack of functionality Follow the instructions below THROTTLE INSTALLATION AND ADJUSTMENT Before working on the throttle assembly ensure the key switch is in the OFF position Page 7 200 Series 36V 15312 The following instructions include replacement of the sensor switch and bracket Throttle Assembly Removal 1 Disconnect throttle sensor and safety switch 2 Unhook the throttle spring from the throttle bracket 3 Loosen the throttle bracket adjustment screw 4 Remove the throttle pedal bolt 5 Remove throttle assembly Throttle Sensor Removal 6 Usi
23. ting washers are put back in place after removal Motor Removal To remove the motor 1 Disconnect the Main Fuse 2 Using a 2 5mm Allen Wrench loosen the drive pulley set screw 3 4 Remove bottom bolts from motor attaching it to the mounting plate then Loosen the Drive Belt Tensioner to allow excess play in the belt remove the upper bolts Notice the order of washers as the bolts are removed Carefully pull the motor away from the mounting plate allowing the drive pulley to slide off the motor shaft Motor Installation To install the motor oe First install the isolating washers and bolts into the motor mounting plate Align motor and install bolts Place key in keyway of motor shaft Fit drive pulley into belt and install onto motor shaft Center the drive pulley with the secondary pulley Apply removable thread lock to the threads of the drive pulley set screw Using 2 5mm Allen Wrench tighten the set screw CONTROLLER REMOVAL AND INSTALLATION Controller Removal 1 Disconnect the Main Fuse 2 Remove the three bolts holding the controller to the mounting plate 3 4 Using a 6mm Allen Wrench remove the three motor Armature and Ground Disconnect the two motor Field connections F and F connections M M and B Page 5 200 Series 36V 15312 Controller Installation 1 Using a 6mm Allen Wrench connect the three motor Armature and Ground connections M M and B
24. ut from the left side of jackshaft Slide jackshaft toward right side until the tall pulley is free to be removed Remove pulley and replace with new belt attached starting with the belt around the smaller drive pulley on the motor shaft Line up pulley with keyway on the jackshaft and slide the jackshaft left through the spacer and bearing Ju 15312 200 Series 36V 7 Install and tighten jackshaft nut until there is no horizontal play in the pulleys approx 90 110 ft lbs 8 Tension the belt following the instructions found in Section 4 Belt Tensioning 9 Replace guard removed in step 1 Secondary Belt Replacement Secondary belt replacement requires disassembly of the jackshaft components When attempting to loosen or tighten jackshaft nuts stay clear of all belt driven components as they may rotate during this process 1 Jack the vehicle s swingarm and place on jack stands to keep the rear wheels off the ground Do NOT use the Axle as a jack point Remove left rear tire wheel Remove the guard above the pulleys Loosen the secondary belt tensioner s smaller 3 8 bolt Loosen left rear axle bearing flange and slide bearing assembly to the left Remove the right jackshaft nut Slide the jackshaft to the left until the wide pulley is free to be removed Remove secondary drive belt by sliding it off of its pulley down the axle shaft to the left through the slot of the swingarm axle bracket and
25. witch to resolve the fault 15312 Turn Key Switch ON Battery Gauge turns ON Relay clicks once gt 36V at Orange Contactor wires Turn Key Switch OFF Throttle Switch continuity to Ground with Throttle depressed white wire at controller Throttle Sensor resistance normally below 1209 Gray to Gray Black wires at controller Throttle Sensor resistance above 43000 when Throttle depressed Gray to Gray Black wires at controller Check Main Fuse Check 12V circuit Fuse Check Yellow Body connector Check for gt 12V at Key Switch Red and Black on harness side Check connections at Relay Ensure 12V at Black wire when key ON Touch Pre charge Resistor If hot controller is bad Disconnect Main Fuse Check 36V circuit Fuse Check for gt 36V at Purple wires at Motor Controller Check condition or all other connections at controller Check connections at Throttle Switch Check that Throttle Pedal has fully returned Inspect Throttle sensor closely for cracks Check condition of connections at Throttle Sensor Check connection to harness 200 Series 36V Vehicle will not go Turn Key Switch OFF NN in Reverse Connections at F R Switch are good F R Switch continuity while O Check connections at controller is selected Blue to Blue Yellow wires at controller PROCEDURES Throttle Harness Throttle Sensor Potentiometer Signal Confirm that the throttle position sen
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