Welcome to Electric-Bikes.com
Fixing Electric Scooters and Bikes
If the problem is electrical, your repair options include:
Diagnose the problem yourself. Start with our diagnostics page. After isolating your problem, you'll know whether you can fix it yourself or want a service company to repair it.
Fix the problem yourself. If you need parts before you fix it yourself, get them from a parts retailer. Your local LEV retailer may have what you need. If not, check our list of on-line parts retailers.
Have someone repair it for you. If you want someone else to solve the problem, your local LEV retailer may do repairs. Many local retailers service the brands they carry - and others. If not, check our list of quality repair shops. Other shops that understand and work on electric-powered devices include sew/vacuum shops, automobile electric shops and electric wheelchairs shops.
Most people - with a few tools and the right replacement parts - can fix their LEV power system. If you need parts, check first with your local LEV retailer. Or check our list of on-line parts retailers. Here are the common procedures:
replacing batteries
- replacing belts or chains
- replacing throttle
- fixing flats
- replace the fuse
- replacing the motor
- replacing the controller
- Learn to properly care for your rechargeable batteries at http://www.ingenuityinc.com/ttssla.htm
Until we complete this page, you'll likely find useful information in the archives section of these online user groups:
http://yahoogroups.com/group/zappy/ (electric scooters)
http://yahoogroups.com/group/power-assist/ (electric bikes)
If the fuse is blown, there's a problem that must be repaired or your new fuse will likely blow also. Many LEV fuses are difficult to find. Besides checking with your local LEV retailer, you can order fuses online.
With a few fuses in hand, start diagnosing the problem. First, disconnect the battery pack from the controller and motor. Switch the ON/OFF switch to OFF, insert the fuse, and switch to ON. If the fuse popped, you've got a short in the wiring; look for blackened spots which may still be hot.
If the fuse is OK, switch the ON/OFF switch to OFF, connect to the controller, and switch to ON. If the fuse popped, you've got a bad controller. On some scooters (e.g. Currie Flyer), the controller is imbedded in the motor housing - and both must be replaced.
If the fuse is OK, switch the ON/OFF switch to OFF, connect to the motor, and switch to ON. If the fuse popped, you've got a bad motor or wiring. On some scooters (e.g. Currie Flyer), the controller is imbedded in the motor housing - and both must be replaced. Look for blackened spots which may still be hot.
Your sense of smell is also a good detector of problems. If the controller or motor smell like something's wrong, it probably is.
Never replace fuses with a higher amp fuse than stock.
EVdeals offers various parts/kits for improving performance of Currie scooters (Flyer, Tsunami, F-18). Find their on-line list of kit instructions at:
http://www.evdeals.com/KitInstructIndex.htm
36 Volt/long range battery pan (2002 Flyer and later models)
- Long Range Hawker Upgrade (prior to 2002 Flyer)
- USPD Pinion Gear Exchange (15 thru 23 tooth)
- F-18/GT Shockwave Motor Brace (prevents chain derailment)
- Zappy-Dual Hawker Battery Pan (long range version)
- Airless Tire Installation Tips
- Installing the EVdeals Basket Kit
- Delrin Chain Block Installation
- F-18/GT Shockwave Pinion Gear Installation
- Flyer Pinion Gear Installation
- Installing the 90 Degree Valve Stem Tube
- Installing the EVdeals V-Brake on Early Model Curries
- Hot Scoot Motor Mount Upgrade Installation
- Speedometer Installation
- Chains and How to Modify Them
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Subject: Removing frozen roller bearing/pinion assemblies from Currie motor shafts
> I just discovered that on both of my MAC motors the roller bearing
> mechanism has frozen, preventing freewheeling and seemingly the
> removal of the pinion gear as well. Has anyone else had this problem
> and found a way to unfreeze the bearings?If the roller clutch bearings have become dry due to water, dirt, etc., getting into the mechanism, you're likely to have a tough time getting them off the motor shaft. Remove the "C" retaining clip on the motor shaft and gently pry under the sprocket with a screwdriver as you turn the shaft. The rollers in the bearing are most likely broken and jammed, so this will probably cause them to release. Do your best to avoid damaging the shaft, since it provides the bearing surface for the new clutch bearing you'll be installing.
I forgot to mention that the adapter shaft (the shaft held onto the motor shaft with a roll pin) can be replaced as well. I've made them in both .500" and 12mm, so I can provide the complete assembly if needed. (clutch bearing/pinion/adapter)
Regards, www.EVdeals.com, Scott MacGregor, 9 South St, Plainville, MA 02762, Voice 508-695-3717, Fax 508-643-0233,smacgregor@aasp.net, Scott@EVdeals.com
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Manuals, User Guides, Assembly Instructions, and Notes for Electric Scooters and Bicycles (click here)