X-TREME XB-502, Owner'S Manual

Page 1: ...1 XB 502 Electric Moped Bicycle Owner s Manual Read this manual completely before riding your electric bicycle X Treme TM Electric Moped ...

Page 2: ...tion 13 Operation 14 Riding Tip Checklist 14 Battery Charging Safety 15 Basic Maintenance Schedule 15 16 How To Guide 17 24 How To Assemble Rear Wheel 17 18 How To Remove Front Wheel 18 How To Install Front Wheel 19 How To Remove Hub Motor 19 How To Replace Controller 19 How To Replace Rear Inner Tube 19 20 How To Replace Dash 20 How To Center Handle Bars 20 How To Check Brake Safety Switch 20 21 ...

Page 3: ...4 25 Throttle Voltage Test 25 Intermitted Power Loss 25 26 No Power 26 After Fully Charging Powers Only For Short Distance Use 27 Scooter On Won t Run 27 Scooter Will Not Move 28 Charger 28 Hub Motor Tests 29 30 Diagrams 31 35 Controller Connector Placement Wiring Diagram 31 Voltmeter Wiring Diagram 32 Rear Motor Diagrams 33 Complete Wiring Diagram 34 Battery Wiring Diagrams 35 Support 36 ...

Page 4: ...ll stay on the floorboard o Wear bright visible clothing that is not so loose that it can catch on moving parts of the XB 502 or objects at the side of the road or trail o Think about your speed and keep your speed consistent with safe operating conditions The Don ts o Never ride with headphones They mask traffic sounds distract you from concentrating on your surroundings and their wires can tangl...

Page 5: ... comfortable stopping distance from all other riders vehicles and objects Safe braking distance and forces are subject to the prevailing weather and road conditions Wet Weather Riding Wet weather impairs traction braking and visibility both for the rider and for other vehicles sharing the road The risk of accident is dramatically increased in wet conditions In wet weather you need to take extra ca...

Page 6: ...essary Slow down and use familiar roads with street lighting if possible Other Important Reminders The battery does NOT require deep discharging If your XB 502 is put into storage re charge its battery at least once every 90 days Do not store your XB 502 in direct sunlight for an extended time Store your XB 502 in a dry place Exposing your XB 502 to rain snow or other precipitation may result in d...

Page 7: ...7 Product features ...

Page 8: ... all protective packaging foam Remove axle from front fork shipping crate and set aside do not discard There are 8 installation steps that must be done prior to using your XB 502 Be sure to do them in order and do not skip a step 1 INSTALLATION OF FRONT WHEELAND BRAKE 1 Insert brake hub onto wheel as shown above 2 Slide wheel into front forks being sure to align brake hub bracket with right side f...

Page 9: ... 1 Locate and remove the handlebar bolt washer nut as shown above 2 Slide handlebars over post in the correct position then insert the bolt concave washer into the front speedometer side of the handlebars and secure with nut on the back riders side Concave washer should be partially inserted into the handlebar and make contact with internal post to be tightened properly and securely ...

Page 10: ...ire clips as shown 3 Line up headlight fairing to front of scooter being careful not to break the plastic clips underneath 4 Slide the headlight fairing into place and snap 5 Finally secure to front of scooter using the 4 enclosed screws 1 Attach trunk to back cargo rack using the 4 enclosed bolts nuts washers Secure to rack with the washers nuts on the underside ...

Page 11: ...luding ones not mentioned in the set up for tightness and fit before riding 1 Attach left right foot pedals according to correct side by lining up pedal with bearing on pedal shaft and snap into place 4 Screw left right mirrors into place and adjust to appropriate riding need 1 Remove battery pack and locate plug 2 Plug battery wire into battery pack and reinstall pack into foot plate 3 IMPORTANT ...

Page 12: ...y Voltage 48Volt Dc 12Ah Motor Wattage 500W Wheel Size 16 inch Top Speed 20 MPH Charging Time 6 8h Distance of full charge 20 25 miles Battery charging cycles Around 350 times Max rider weight 300 Lbs Two rider Yes Left and Right Indicators Yes Rear View mirrors Yes ...

Page 13: ... PSI for bikes Remember performance of the bike is directly related to weight of the rider and any baggage load together with the charge in the batteries Ensure batteries are fully charged prior to riding Charge overnight prior to riding the next day Never let the batteries go fully flat This will reduce battery and bike performance Apply chain oil periodically and clean if dirty or gummed up usin...

Page 14: ...ally you can also remove the battery pack and charge outside of the bike if preferred 2 Insert the power plug on the battery charger into power outlet 3 While charging the light on the battery charger will illuminate Red 4 When fully charged the light will illuminate Green 5 NEVER CHARGE FOR OVER 8 HOURS DAMAGE MAY OCCUR TO BATTERY 6 Always charge the bike in an enclosed area outdoors away from we...

Page 15: ...ll require a short time to re charge and a long ride will require a longer time A complete 90 discharge may require 6 hours to recharge To prevent electrolysis battery fluid loss by hydrogen generation do not charge for longer than eight hours WARNING Do not place the battery near heat or fire Do not expose the chargers to water Maintenance Basic 1 Your bike comes with a 30amp fuse pre installed a...

Page 16: ...ll Brake Pad Change over Yes Check condition and torque settings of wheel nuts and suspension forks Yes Yes Other Helpful Instructions Pedals 1 Use a pedal wrench of 16mm spanner to tighten pedals 2 Check and tighten pedal crank bolts with 14mm socket Tires 1 Inflate tire using a pump to 35 45psi Remember lower tire pressures will negatively impact performance by causing too much resistance but ov...

Page 17: ...that hold the plastic plates on both sides of rear wheel See figure 1 5 figure 1 5 2 Remove the screw from the end of Brake Cable and then pull the cable out See figure 1 6 figure 1 6 3 Remove the tightening screw See figure 1 7 figure 1 8 figure 1 7 figure 1 8 ...

Page 18: ...he rear flywheel and remove the wheel from the bicycle How To Remove Front Wheel 1 Remove the two nuts from both sides of the front wheel See figure 1 10 figure 1 10 2 Remove the screw from the end of Brake Cable and then pull the cable out Then remove the axle and spacer as shown below in figure 1 12 1 13 figure 1 11 figure1 12 figure1 13 3 Remove the front wheel ...

Page 19: ... sprocket Use the pedals to turn until the chain is totally off of the sprocket Then remove the sprocket off of wheel sprocket 7 Remove wheel motor from scooter How To Replace Controller 1 Remove the Battery Pack from the scooter and set aside until new controller is installed 2 Open the seat and remove the four 4 seat barrel screws two 2 near the Latch and two 2 in Front 3 Remove entire Seat and ...

Page 20: ...erclockwise 7 Now the handle bar faring is ready to be removed Start on the left side by where you removed the mirror Gently pull the front and back of the handle bar fairing apart It should snap apart fairly easily Work your way across until the top is completely apart 8 Remove and replace 9 Reverse the order to reassemble How To Center Handle Bars 1 First remove the dash You should not have to r...

Page 21: ...while holding the cable tight until the brake just starts to drag when the tire is turned off the ground Tighten the lock nut back down onto the cable 3 Next fine tune the adjustment by screwing the cable tension screw outward to pull on brake line until proper braking is achieved 4 Lock this position down by tightening the nuts 5 Avoid adjusting brakes on handlebars because there is a safety swit...

Page 22: ...dc per battery min 50vdc to turn on the controller 1 Across the large Red Black wires coming out of the controller is main power leads Should have 50vdc here Throttle measurement Leave connector connected while measuring 2 Locate the throttle connector on the controller it will be a red connector with 3 wires coming out of it of RED BLACK GREEN Put you Black meter probe in on the black wire Insert...

Page 23: ... dead and that s your only problem you ll see that disconnecting one or the other of the good sensors prevents the motor from turning altogether while disconnecting the bad one has no effect at all it still sputters If that didn t work try this second method It is more complex but useful to identify a bad controller vs the motor and more nuanced issues or problems stemming from multiple failures R...

Page 24: ...ind a wire that is not connected a connector that is not pushed together properly or a fuse holder that is not letting the fuse connect properly Troubleshooting Is It My Throttle Or My Controller These tests require a digital VOM Most E scooter throttles use Hall effect devices not potentiometers rheostats A Hall effect device is a chip that responds to a movable magnet If you have a digital VOM I...

Page 25: ...not take off Turn the scooter on Place the red meter test lead on the Red wire and the black meter lead on the Black wire The meter should measure 5 volts Now place the meter red lead on the Green wire With out turning the throttle you should read around 0 8 volts Now turn the throttle wide open You should now read around 4 volts If everything else powers up on the scooter and you do not have 5 vo...

Page 26: ...d and plug in to turn it back on Troubleshooting No Power In this situation we will assume that the battery has been charged or allowed to stand for several hours a battery will normally self charge up to a point and make the scooter power up for a fair distance There are generally two main suspects 1 First suspect is a loose or broken connection Take the top or deck off to see the wiring and insp...

Page 27: ...s can be performed using a 24 volt battery cell too WARNING Batteries contain acid that can explode or the vapors ignite from an arc Batteries produce current and voltage that can burn you when a shorted circuit occurs Be absolutely sure you know what you are doing before trying any tests to eliminate a component from consideration of being defective 3 You can take the battery to a shop capable of...

Page 28: ...es that are in the back of the fuse holder You must open up scooter and reattach these wires to back of fuse assembly or to battery and control box If this is the problem the lights WILL work when you have the charger plugged in Troubleshooting Charger The charger is a handy tester to check the wiring connections on the battery pack all the way thru the fuse holder into the controller Some charger...

Page 29: ...wire Infinite 3 Place the red meter lead on the green sensor wire Infinite 4 Place the red meter lead on the blue sensor wire Infinite Place the red meter lead on the black sensor lead for the next three tests 5 Place the black meter lead on the yellow sensor wire Around 4 meg 6 Place the black meter lead on the green sensor wire Around 4 meg 7 Place the black meter lead on the blue sensor wire Ar...

Page 30: ... the leads If you get a lot of difference between readings of the motor leads the controller is be bad Common Causes To Complaints Any customer complaints of jerky motor or motor not running have the customer check the sensor and motor connections at the controller and at the connectors at the rear of the moped If this doesn t help go to steps one or two below 1 If the customer complains that the ...

Page 31: ...31 Controller Connector Placement Wiring Diagram ...

Page 32: ...32 Voltmeter Connection Diagram ...

Page 33: ...33 Rear Motor Diagrams ...

Page 34: ...34 ...

Page 35: ...35 Battery Wiring Diagrams ...

Page 36: ...36 DO NOT RETURN TO STORE IF YOU NEED HELP CALL OR GO ONLINE 1 253 777 0690 www x tremescooters com support For General Information or Parts Visit www x tremescooters com Revised 2 28 12 ...