eGO Electric Scooter: Service
Note: these are .pdf files that require Adobe Acrobat®. To download Acrobat Reader, click here.
Online Service Manual
This service manual is designed to help diagnose and solve problems with the eGO Cycle 2 and eGO Helio Cycle. This page includes a useful combination of tools to diagnose problems and detailed procedures to perform required service to the cycle.
Service procedures are to be performed only by persons with the training and experience to safely work on electrical appliances and mechanical systems. eGO Vehicles DOES NOT warranty any service that is not performed at the eGO Vehicles Factory Service Center or at an Authorized Service Center.
CAUTION: Service procedures performed incorrectly can cause serious injury or even death. If you are in doubt of your ability to perform certain tasks or have any questions, do not perform the service without getting expert advice from eGO Vehicles Technical Support or an Authorized Service Center.
For each symptom there are two main steps for service:
1. Diagnose the problem: "Fishbone" diagrams are designed to assist in diagnosing the root cause of a symptom. They allow the service technician to pinpoint the problem though a series of logical steps. To identify the root cause of the symptom using the fishbone diagram, follow the four steps below.
- First choose the fishbone diagram that is titled with the general symptom you are experiencing.
- Then choose the most appropriate description at the end of the main branches (in bold)
- Then choose the most appropriate sub description of the sub-branch.
- Repeat this process until you have found the root cause.
- Once the root cause is found, scroll down and select the Service Procedure(s) that are noted in the root cause description.
2. Perform Service: "Procedures" are detailed, step-by-step instructions for performing a task on the eGO. Some procedures require the use of multiple sub-procedures.
Diagnosis
Service Procedures
Reference Materials
Diagnosis
- Dead - will not turn on or move.
- Short Range - noticeable decrease in range
- Slow or Sluggish - noticeable decrease in speed or power
- Making Strange Noise
Service Procedures
- Diagnosing a charger failure
- Battery Removal/Installation
- Charger Replacement
- Controller Replacement
- Contactor Replacement
- Controller Fuse Inspection
- Front Brake Adjustment
- Key Switch Replacement
- Motor Mount Removal
- Motor Replacement
- Primary Belt Installation
- Rear Wheel Removal
- Secondary Belt Installation
- Secondary Drive Pulley Removal/Installation
- Throttle Replacement
- Sevcon/SC Compatibility Procedure
Reference Materials
- EC200 Wiring Diagrams (Note: The colors of the wires in the diagrams do not necessarily match the colors of the wires in the eGO):
- WHU-01 - bikes manufactured before 12/21/03
- WHU-02 - bikes manufactured between 1/1/04 and 3/1/04 with a Sevcon Controller (identified by a blue case)
- WHU-03 - bikes manufactured between 1/1/04 and 3/1/04 with an SC Controller (identified by a silver case with a black face)
- WHU-04 - bikes manufactured after 3/1/04
- WHU-04-01 - bikes manufactured after 3/1/04 with circuit breakers
- WHU-05 - eGO Classic manufactured in 2006 or later
- WHU-06 - LX bikes manufactured in 2006 or Later
- EC200-EU (Helio) Wiring Diagrams:
- Sevcon Controller Diagnostic Code Chart
- A Sevcon controller is identified by a blue case.
- SC Controller Diagnostic Code Chart
- An SC controller is identified by a silver case and black face.
- SC Controller Schematics
- LAN Power Onboard Charger Schematics
- Detailed information about the eGO Cycle onboard charger.
- Other Dealer Materials
- Use the Retail Delivery Form to report the sale or re-sale of an eGO Cycle to an end user.
