Chinese Jl50qt 4t Scooter Digital Workshop Repair Manual by www.heydownloads.com

SERVICE AND REPAIR MANUAL

4 STROKE ENGINE

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A. Electric Scooter Assembly

A. Electric Scooter Assembly Topic Important points Torque Settings Scheduled Maintenance Speciﬁcations Troubleshooting Rear Wheel Dismantling

Page A-2 A-2 A-3 A-4 A-4 A-5

Topic Rear Wheel Removal Electric Motor Removal Motor Dissasembly Motor Inspection Battery Access and Power Recharging Batteries

Page A-5 A-8 A-10 A-12 A-13 A-16

Important Points The electrolyte (diluted sulfuric acid) is very toxic. DO NOT allow acid to splash onto clothes, the skin or eyes to protect them from burning. Eye contact with acid may cause blindness. In case of contact with the acid, use a large amount of clean water to flush and rinse the areas in which the acid came into contact. See a Physician immediately. If the electrolyte acid gets into clothes, it will permeate to the skin. Remove tainted clothes immediately and then put them in water to rinse. •The batteries can withstand numerous cycles of charging and discharging as long as it is not left in a discharged condition for a long period of time. •If one of the batteries are overcharged, it can be detected by close inspection of the battery itself. If the battery is exposed to an extreme overcharged condition, it can break down and short circuit internally. In this condition, the battery will produce zero voltage under all load and charge conditions. An overcharged battery can “boil off” the electrolyte solution. This problem can be due to excessive time on a battery charger or a failed voltage regulator. •If the scooter is left to sit for a long time or is stored, the battery will slowly discharge. It is advisable to recharge the battery before attempting to start the scooter after a period of storage. •When filling a new battery with acid, allow it to sit and “breath” for fifteen minutes before installing it into the scooter or charging it. It is advisable to charge a new battery after filling with acid even though it may appear to have sufficient charge. •When working on the scooter’s electrical system, make sure that the main switch is turned off and/or the battery is disconnected. Disconnecting and reconnecting of live circuits can cause high instantaneous currents that can damage the battery and cause injury. •Any short-circuiting of the wiring can cause damage to the battery. Torque The nut of the rear wheel axle The top of the rear buffer The bottom bolt of the rear buffer The connection nut of the silencer The fix bolt of the silencer

10.0kg•m 4.5kg•m 3.0kg•m 1.2kg•m 3.5kg•m

75ft lbs 30ft lbs 20ft lbs 10ft lbs 25ft lbs

A. Electric Scooter Assembly Scheduled Maintenance ďż˝

Perform regular maintenance on the following parts as the chart indicates. C = Clean L = Lubricate I = Inspect, check, fix, replace when necessary Frequency Item Controller Charger Front/rear detent Wheel bearing Front/rear suspension Front fork bearing T ire Major side kickstand A ll other body parts A ll screws & nuts Motor bearing

Mileage (km) 124 (200)

621 (1000)

1864 (3000)

3107 (5000)

C I I

4972 (8000)

6215 (10000)

7458 (12000)

L L

C I I I I I I I I

L I

I I I L L I I

I I

I f riding the vehicle in dusty or rainy areas, perform maintenance more frequently.

A. Electric Scooter Assembly Specifications ďż˝

No. 1 2 3

Description Product Si ze T read

Description Speedchanging Motor type R ated power

Specifi cations Automatic

1180 mm 110 mm

No. 13 14 15

4 5 6 7

N. W L oad weight Maximum speed Mileage per charge

90 kg <80 kg >40 kg <40 kg

16 17 18 19

R ated current R ated voltage

22A 48V >72%

B attery

S ealed, free protective, leadacid battery

8 9 10 11

B rake distance B rake ways Climbing ability Max torque

<4.5 m M/M >8Â° 20 N. M

20 21 22 23

B attery capacity Charger T ire

12V 17Ahx4 A merican 3.0-10-4PR 175/225 (kpa)

Max noise

64dB(A )

M inimum clearance from ground

Specifi cations 1700x760x1180mm

W orking efficiency

W heel Pr essure (FR /R R )

B lushless mo tor

750W

Troubleshooting Problem Scooter does not start.

Cause No power B attery connection poor

Scooter runs weak.

Weak battery

Scooter starts but does not move.

Motor inoperative

Solution Charge or replace battery/batteries. R econnect battery terminals. R echarge or replace batteries. R eplace 750W motor.

A. Electric Scooter Assembly Dismantling and Removing Rear Wheel Assembly

ďż˝

1. Loosen and remove brake cable mount from Brake Arm.

Attention:

Exercise caution when loosening and removing cable tension spring

2. Loosen and remove brake cable tension spring from Brake Arm. 3. Loosen and remove fasteners securing anti-rotational bracket onto frame and rear wheel axle.

A. Electric Scooter Assembly

ďż˝

Dismantling the Rear Brake 4. Remove the adjusting nut of the rear brake. 5. Remove the ďŹ x bolt of the brake arm. 6. Remove the brake arm. 7. Remove the brake cam. 8. Remove anti-rotational brackets. 9. Remove smaller restraining bracket 10. Remove restraining bolt. When Assembling the Rear Brake A. Spread grease on the moving parts of the lining and of the ďŹ x pin (locating pin). B. Spread grease on the moving part of the brake cam shaft and then assemble it. C. Install the brake lining.

A. Electric Scooter Assembly 11. Assemble the wear indication board and the brake arm. 12. Assemble the brake arm and the brake cam.

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Attention: Point the “gullet” mark of the brake arm to the “dot” mark of the brake cam, and then assemble them. 13. Install and tighten the bolt of the brake arm.

14. Install and tighten the ﬁx bolt of the set arm. 15. Install the return spring of the brake arm. 16. Install the pin of the brake arm.

17. Install the adjusting nut of the brake cable. 18. Assemble the rear wheel (refer to 13-2). 19. Adjust the clearance of the brake lever (refer to 13-8).

A. Electric Scooter Assembly 20. Slide rear wheel away from frame mounting slots.

ďż˝

21. Slowly remove rear wheel from cam. 22.Carefully loosen all four mounting bolts securing electric motor to rear wheel.

Electric Motor Removal 1. Loosen and remove four mounting bolts securing 750 watt motor to rear wheel.

Attention:

The 750 watt electric motor is very heavy. Exercise caution while removing motor mounting bolts.

Attention:

Give particular attention to the power cable, when removing rear wheel.

A. Electric Scooter Assembly 2. Carefully place rear wheel onto ground with electric motor facing upwards.

ďż˝

3. Using a flat-head screwdriver, cautiously pry the electric motor from the rear wheel rim. 4. Lift and remove electric motor from wheel assembly.

5. Loosen set screw securing collar to motor spindle. 6. Remove and place collar set screw in secure place for reuse.

A. Electric Scooter Assembly Motor Disassembly ďż˝

1. Using the proper screwdriver or bit type and size, carefully loosen each screw that is securing the motor cover, . 2. Remove each screw and set aside for reuse.

Attention:

Removing the screws in a diagonal pattern is recommended to avoid stripping and damaging the screws and the threads.

3. Gently lift and remove the collar from the motor spindle.

Attention:

Exercise caution with the power cable when removing set collar.

A. Electric Scooter Assembly Attention:

Always exercise caution when using any tool to pry one surface from another.

ďż˝

4. Once again, using a flat-head screwdriver, carefully pry motor cover from the motor assembly.

Attention:

Use very mild and steady force when prying, to avoid damaging motor housing and coils.

5.Gently lift and remove the motor cover from the motor assembly.

A. Electric Scooter Assembly Motor Inspection ďż˝

1. Carefully lift and remove motor coil sub-assembly from motor housing.

Attention:

Once again, exercise caution when removing motor sub-assembly to avoid damaging motor coils.

2. Thoroughly inspect coils and coil wires for damage.

A. Electric Scooter Assembly Battery Access and Power Attention:

Exercise caution when removing body panels and fasteners to avoid damage.

1. Loosen and remove fasteners securing left and right side panels. 2. Loosen and remove fasteners securing floor panels and panel beneath scooter seat. 3. Carefully remove body panels (as shown).

A. Electric Scooter Assembly

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4. Access battery power switch located in rear storage compartment of scooter. 5. Remove power to motor by flipping the power switch to the ‘OFF’ position.

Attention:

Confirm that power is removed from motor before beginning work on vehicle

6. Once power has been removed, disconnect power connection to motor by carefully unclipping and seperating the wire connectors

Attention:

Be sure not to sperate the ground wire connections that are seperate for the connector.

A. Electric Scooter Assembly Battery Access and Removal Attention:

Confirm that power is removed from motor before disconnecting and removing batteries

7. Loosen and remove fasteners securing battery restraining bracket. 8. Remove bracket. 9 Disconnect battery terminals.

Attention:

Disconnect and reconnect positive terminal first, followed by the negative battery terminal.

A. Electric Scooter Assembly 10. Use a volt meter to check battery voltage (as shown).

Recharging Batteries 1. Access charging input recepticle, located inside scooter rear storage compartment. 3. Allow batteries to continue charging until indicator shows that batteries are fully charged.

2. Plug charger into charging recepticle as well as into wall outlet (standard AC).

B. Retro Model Scooter Panels

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C. Scooter Panels