E. The system turns on, but the headlight
does not operate.
1. Remove the battery, and turn the power
knob to ON to discharge the capacitor in the
controller.
2. Remove the lens from the headlight and
visually inspect the bulb. Replace the bulb if it
is blown.
3. Perform the headlight bulb resistance test.
4. Perform the headlight resistance test.
5. Perform the headlight switch test.
6. If all of the above components work proper-
ly, replace the controller.
F. The system turns on, but the horn does
not operate.
1. Remove the battery, and turn the power
knob to ON to discharge the capacitor in the
controller.
2. Perform the horn switch test.
3. Perform the horn resistance test.
4. If all of the above components work proper-
ly, replace the controller.
G. The system turns on, but the taillight
does not operate.
1. Remove the battery, and turn the power
knob to ON to discharge the capacitor in the
controller.
2. Perform the brake sensor operation test.
a. If only one brake sensor fails the test,
perform the brake sensor continuity test
on that sensor.
b. If both brake sensors fail the test, per-
form the taillight test.
3. If all of the above components work proper-
ly, replace the controller.
H. The charger LED turns red and the fan
operates, but the charger does not turn off
within four hours.
1. Unplug the charger immediately.
2. Perform the charger test described in
Chapter Three.
a. If the charger is faulty, replace it.
b. If the charger works properly, replace
the battery.
Test Procedures
Battery contact test
1. Remove the battery pack and visually
inspect the terminals in the battery pack and
on the terminal block. If they are dirty, clean
them with contact cleaner.
2. Reinstall the battery pack into the E-Bike
®
.
Push the bottom of the battery pack into the
battery compartment with your hand, and turn
the power knob ON. The problem is solved if
the E-Bike
®
beeps GO and the LEDs flash.
3. Measure the voltage between the controller
fuse and the brake sensor #2 terminal by per-
forming the following:
a. Disconnect a brake sensor connector (D
or E, Figure 1) from its terminals on the
controller.
b. Connect a digital volt ohmmeter positive
(+) probe to a terminal on the controller
fuse. Connect the meter negative (-)
probe to the brake sensor’s #2 terminal
on the controller board.
c. Turn the power knob ON, and check the
voltmeter.
4A. The contacts are good if the voltage is 31-
39 volts.
4B. If the voltage is less than 31 volts, the bat-
tery to terminal block contact is poor. Shim the
terminal block by performing the following:
a. Loosen the two mounting screws (A
Figure 6) and lift the terminal block (B,
Figure 6) from the frame.
b. With the mounting screws still installed
through the terminal block, place a
washer (1 mm thick) over the end of
each mounting screw.
c. Reinstall the terminal block so the wash-
ers are between the frame and the back
of the terminal block.
Battery fuse test
1. Remove the cover from the charger and
visually inspect the battery fuse. If the fuse is
blown, replace the fuse and replace the con-
troller. See the CAUTION below.
2. Check the continuity across the battery
fuse terminals. There should be continuity. The
fuse is blown if there is no continuity. Replace
the battery fuse and replace the controller. See
the CAUTION below.
CAUTION
A safety system is built into the controller. You
must replace both the battery fuse and the
controller whenever the battery fuse is blown. If
you do not replace the controller, it will blow the
new battery fuse and cause further damage in
the system.
ELECTRICAL
8-9