Troubleshooting - Drive System
3A4637A Operation, Repair, Parts
53
Troubleshooting - Drive System
Does not Drive
Step 1:
Drive System turned ON?
Step 2:
Speed knob turned
fully clockwise?
NO
NO
NO
NO
NO
NO
NO
Step 3:
Handlebar switch in
Drive (D) or Cruise ( ) position?
Step 4:
Battery installed and
connected correctly?
YES
Step 5:
Fuse present and
NOT blown?
Step 6:
Does the battery
have at least 12v?
Step 7:
All 7 wires connected
to motor control board and two
wires to wire harness?
YES
YES
YES
Step 8:
Is red LED on motor
control board illuminated?
Step 9:
Does the Drive Switch
have continuity across the two
white leads, and across the
two blue leads when in ( )
or in ‘D’?
Turn Drive System switch to ON (down position).
Green LED should illuminate indicating drive is powered.
Green LED on motor control board also indicates board is powered.
With switch set to cruise ( ), slowly turn Speed Control knob
clockwise until unit begins to move.
Press ‘D’ or cruise ( ) to test if unit will move.
Install battery and /or ensure it is connected with the red wire to
positive (+) and the black wire to negative (—).
Install or replace with 30A automotive fuse.
Run engine at full RPM to
charge battery to at least 13v.
Charging voltage is approx. 14.2V
Connect and/or double check for proper wire connections
to motor control board. See wiring diagram on page 68 or 69.
Check for seized or locked drive components preventing
motor from spinning. Red LED indicates the control has hit its
current limit settings; approx. 20-21A.
Step 10:
Dissconnect the speed control from control board. Does it have 0
:
across the orange and red wires when turned fully counterclockwise, or approximately
5 k
:
when turned fully clockwise, or approximately 5 k
:
across the red and white
wires when turned fully counterclockwise and 0
:
when turned fully clockwise?
NO
13.0
V
-
ti30518a
NO
YES
Step 11:
Does the motor have continuity
across the yellow and blue leads?
NO
NO
YES
YES
Replace the switch and wire
harness.
Replace motor brushes.
Replace the motor control board.
Replace the speed
control potentiometer.
YES
YES
YES
YES
NOTICE
DO NOT reverse the positive and negative battery wires.
This will damage the motor control board.