E-TON EV3 E-MO Service Manual Download Page 38

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4-4

MOTOR

CONT

Dowel pin

Regulator

MOTOR INSTALLATION

WARNING

• Reverse the removal procedure for installation.

• It is necessary to confirm whether the regular

and dowel pin are fastened tightly during brake
cable installation.

clearance to maintain at 5~10mm.

• It is necessary to check and adjust the brake

It is necessary to confirm whether brake indicator
can light on and function regularly after adjusting

brake.

NOTICE

Summary of Contents for EV3 E-MO

Page 1: ...SERVICE MANUAL EV3 E MO E TON POWER...

Page 2: ...9 by E TON POWER TECH CO LTD First edition April 2009 All rights reserved Any reproduction or unauthorized use without the written permission of E TON POWER TECH CO LTD is expressly prohibited SERVICE...

Page 3: ...ions or procedures will be forwarded to all authorized E TON dealers and will appear in future editions of this manual where applicabe NOTE Designs and specifications are subject to change without not...

Page 4: ...CONTENTS SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CONTROLLER SYSTEM BATTERY CHARGER TROUBLESHOOTING GENERAL INFORMATION CHASSIS CHK ADJ GEN INFO CHAS ELECTRICAL SYSTEM ELEC TRBL SHTG CONT SPEC...

Page 5: ...AL INFORMATION GENERAL INFORMATION 1 1 FRAME SERIAL NUMBER 1 1 MOTOR SERIAL NUMBER 1 1 IMPORTANT INFORMATION 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 CHECKING THE CONNECTIONS 1 3 SP...

Page 6: ...s MOTOR SERIAL NUMBER The serial number of the motor is stamped on the portion of the left section of the motor box TIP The fourth to the sixth digits of these numbers are for identifying the model th...

Page 7: ...ps LOCK WASHERS PLATES AND COTTER PINS 1 Replace all lock washers plates and cot ter pins after removal Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specifica...

Page 8: ...nnect and disconnect sev eral times 3 Check all connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector TIP Make sure al...

Page 9: ...32 35 40 42 45 47 48 52 58 wheel and oil seal 64 mm Tool name Tire valve driver Function To disassemble and assemble an air Double head 6 2mm 5 4mm needle in the inner tube of a tire Tool name Tire l...

Page 10: ...Tool name Function GEN INFO Tool NO Tool name Function Picture Motor checking tool Testing the Hall data of motor Testing interface software Testing interface connector Only for testing driver Only fo...

Page 11: ...SPECIFICATIONS 2 1 MAINTENENCE SPECIFICATIONS 2 2 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 4 CONVERSION TABLE 2 4 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 4 TIGHTENING TORQUES 2...

Page 12: ...sis Frame type Steel tube FRAME Caster angle 24 00 Trail 73 5 mm 2 9 in Tire Size front 2 25 14 27B Size rear Manufacturer front Manufacturer rear 2 25 14 27B Type front C 109R X Type rear C 109R X MA...

Page 13: ...eading trailing 86 0mm 1 5mm 3 39 in 0 06 in Type 85 0 mm 3 35 in Brake drum inside diameter 3 0 mm 0 12 in Lining thickness 46 3 mm 1 82 in Shoe spring free length Rear drum brake Leading trailing 86...

Page 14: ...l brake light Fuse Fuse main Fuse turn signal 12V 21 5W X1 Turn signal light 12V 10W X4 30A 10A Controller system Charger Power input DC transformer output 48V 10V 0A 30A SPEC Item Standard Limit volt...

Page 15: ...Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm x 0 03937 in 2 mm x 0 03937 0 08 in METRIC TO IMPERIAL Torque Metric unit...

Page 16: ...9 2 9 25 3 18 1 7 2 2 9 25 3 32 5 2 9 4 3 6 5 M6 2 Part to be tightened Part name Thread Q ty size Tightening torque Remarks Chassis Rear fork Front fork Rear shock absorber up Bar footrest Controlle...

Page 17: ...arness Cable brake rear Main switch lead Horn lead wire clamp Turn signal lead 12 pin connector EMI coil Starter controller lead DC 12V connecter 6 pin connecter Positive battery lead Negative battery...

Page 18: ...3 4 5 6 8 9 3 2 1 7 8 9 10 10 10 2 7 CABLE ROUTING SPEC Right turn light lead Right brake lead Cable brake front Throttle lead Headlight lead Meter connector Horn lead Left brake lead Cable brake rear...

Page 19: ...N 3 8 CHECKING THE FROENT FORK 3 9 CHECKING THE REAR SHOCK ABSORBER 3 10 CHECKING THE TIRES 3 10 CHECKING THE WHEELS 3 11 REPLACING THE HEADLIGHT BULB 3 12 REPLACING THE FRONT REAR TURN LIGHT BULB 3 1...

Page 20: ...ooseness or damage Replace Front fork Replace if necessary Check operation and correct if necessary Steering bearings Replace if necessary Check bearing play and steering for roughness Lubricate with...

Page 21: ...0 4 m kg 2 9 ft Ib SIDE COVER BODY COVER HEADLIGHT METER REMOVE AND INSTALL Removing the side cover and the body Remove the parts in the order listed cover REMOVING THE SIDE COVER AND THE BODY COVER...

Page 22: ...m 0 4 m kg 2 9 ft Ib 7 1 SIDE COVER BODY COVER HEADLIGHT METER REMOVE AND INSTALL CHK ADJ Removing seat battery seat driver assy REMOVING SEAT BATTERY SEAT DRIVER ASSY BAR FOOTREST Remove the parts in...

Page 23: ...t Ib SIDE COVER BODY COVER HEADLIGHT METER REMOVE AND INSTALL CHK ADJ REMOVING HEADLIGHT METER METER SIDE COVER Removing headlight meter meter side cover Remove the parts in the order listed For insta...

Page 24: ...g 2 9 ft Ib 6 1 6 REMOVING AND INSTALLING REAR BOTTOM COVER REAR FENDER CHK ADJ REMOVING REAR BOTTOM COVER REAR FENDER Remove the parts in the order listed For installation reverse the removal pro ced...

Page 25: ...r free play Out of specification Adjust a front and rear brake linings should be checked TIP NOTICE Must confirm adjusting nut and dowel pin clench the teeth Proper lever free play is essential to avo...

Page 26: ...indicators reaches the wear limit line Replace the brake shoes as a set Refer to REAR BRAKE in chapter 7 Wear limit line Wear indicator Wear limit line Wear indicator 3 Adjust the front and rear brake...

Page 27: ...ort the scooter so that there is no danger of it falling over T R 3 Check steering shaft bushings and bearings Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness...

Page 28: ...ower ring nuts with a ring nut wrench and tighten the upper ring nut with a steering nut wrench 6 Install e Check the steering head for looseness or bind ing by turning the front fork all the way in b...

Page 29: ...ck absorber assembly 5Hfer to 5 5 6 2 625 5 in chapter 7 Bolts Loosen WLJKWHQ Upper lower Bolts The rear shock absorbers can t disassemble improper one overhaul can cause performa nce reduce 1 Stand t...

Page 30: ...7LUH SUHVVXUH 2YHU VSHFLILHG YDOXH GMXVW TRWDO weighW Rf rider anG DFFHVVRULHV HDU OLPLW OLQH 1 Check ZKHHO DPDJH RXW RI URXQG 5HSODFH Never attempt to make any repairs to the wheel IWer a Wire RU ZKH...

Page 31: ...CHK ADJ REPLACING THE HEADLIGHT BULB 1 Remove Headlight Refer to REMOVING AND INSTALLING THE COVER Opening the headlight bulb holder cover Remove headlight coupler Loosen the screw of bulb fixer and t...

Page 32: ...the bulb until it has cooled down 2 Change Headlight bulb burned 3 Install Bulb fixer Headlight coupler Bulb holder cover Headlight New Avoid touching the glass part of the headlight bulb to keep it f...

Page 33: ...REPLACING THE TAIL LIGHT BULB Press the bulb in and counterclockwise revolving will take it out TIP Lens Bulb TIP Press the bulb in and clockwise revloving will insert into the holder site REPLACING T...

Page 34: ...ESHOOTING 4 1 REMOVING THE MOTOR 4 2 MOTOR INSTALLATION 4 4 DRIVER 4 5 SPECIFICATION 4 5 CHECK AND TROUBLESHOOTING 4 5 LEV INTERFACE TESTING INTERFACE 4 7 STATUS 4 10 INSTRUMENT PANEL 4 11 HOW TO READ...

Page 35: ...n on light on or light off and every indictor remains on regularly flashing the Hall signal can function normally b How to confirm Hall Sensor signal function Turn the rear wheel by hand If any of Hal...

Page 36: ...bottom bolt 1 2 1 2 2 2 1 2 1 1 cover R Remove the bolts and rear bottom 2 1 Remove the rear fender bolt Remove the band and rear fender 2 1 and rear fender Remove the rear fender bracket bolt 1 4 2 M...

Page 37: ...sen set nuts on left and right motor and frame as illustrated Remove motor three phase circuit and Hall connector as illustrated Pull the three phase circuit and Hall connector across frame gap Remove...

Page 38: ...It is necessary to confirm whether the regular and dowel pin are fastened tightly during brake cable installation clearance to maintain at 5 10mm It is necessary to check and adjust the brake It is n...

Page 39: ...nfirm each circuit system can function regularly If the fuse blows out quickly again please check each circuit system WARNING Never use the fuse of a different specification or other metal to replace...

Page 40: ...below LQGLFDWHG E WKH VLJQ I WKHUH LV QRW DQ RU D PHDVXUHPHQW YDOXH RI OHVV WKDQ LW FDQ EH MXGJHG DV IDLOHG tester to conduct ohmmeter measurement driver according to the illustration and list below...

Page 41: ...Inert the key to switch on the power Remove the connector between instrument connect the 4 pin connector of the testing interface panel and driver as illustrated in the left and with the driver connec...

Page 42: ...ntents FOLFN KDUGZDUH GHYLFH NHHSHU DIWHU LQVWDOO WKH WHVWLQJ LQWHUIDFH VRIWZDUH DQG FRQQHFW GULYHU and computer 7KH VRIWZDUH RI LQGRZV 3 9LVWD are suitable for use the steps I RQ OLQH FRQQHFWLRQ IDLO...

Page 43: ...as If it is necessary to leave interface testing software after completing testing please click on the selected frame COM Release and click on COM Release and the switch off the software and pull off...

Page 44: ...city shuts down the driver shall be replaced Status Operate the throttle switch after the booting but the vehicle doesn t respond Operate according the testing interface operation steps After the syst...

Page 45: ...4 testing steps are described in the following to to judge irregular function and to make trouble Testing steps 1 After switching on the power of electric vehicle the instrument panel beeper shall sou...

Page 46: ...ction wire or connector is installed properly Make sure the installation is completed properly b When poor contact is confirmed but beeper still sound irregularly the beeper shall be replaced Failure...

Page 47: ...turn signal and main wiring can function regularly Please refer to Chapter 6 wiring diagram Failure Status 2 Switch on the turn signal in riding screen and the turn signal LED flashes but the icon Ey...

Page 48: ...Status 1 Switch on the headlight in the riding screen but the headlight indicator LCD isn t on a Check 3 pin connector is installed properly Make sure the connector is installed properly b Connect the...

Page 49: ...ITY 5 1 CHARGER 5 4 INSTALLATION STEPS 5 4 TROUBLESHOOTING 5 6 MAINTENANCE AND TESTING STEPS 5 5 REFERENCE VALUE FOR BATTERY RESIDUAL CAPACITY 5 2 CHARGING ELECTRICITY CURRENT AND OPERATION ENVIRONMEN...

Page 50: ...pacity will be displayed then How to read the battery residual capacity indicator light from the battery box 1 Remove the battery a Turn the main switch to OFF b Lift the seat Pull the buckle on the s...

Page 51: ...ery residual capacity shall be conducted immediately capacity Riding shall be stopped and charging the battery means nearly no battery residual flash on the instrument panel or red light on Only 4 sec...

Page 52: ...minal for 10 seconds and observe whether electricity vol tage is over 36V If the electricity voltage is less than 36V please replace the battery immediately 2 Use an ammeter to measure charging signal...

Page 53: ...default is preset to be 115V Taiwan 3 After the electricity power is connected turn the power switch 0 to ON Check whether the LED light illuminates in red in charging status Green light indicates it...

Page 54: ...40 30 Adjustment electricity Voltage button under the warn sticker have already set up the voltage of charging suitable when dispatched from the factory it will cause the damage of battery and charger...

Page 55: ...switch is not turned to ON Incorrect connection of electric pole output fuse burned out Replace the fuse 115 230VAC Incorrect selection on switch Maintenance and repair is needed Excessively low outp...

Page 56: ...HES 6 4 CHECKING THE CONDITION OF THE BULBS 6 5 CHECKING THE CONDITION OF THE BULB SOCKETS 6 6 WIRING DIAGRAM 6 2 CHECKING SWITCH CONTINUITY 6 3 CIRCUIT DIAGRAM 6 7 TROUBLESHOOTING 6 8 CHECKING THE LI...

Page 57: ...COMPONENTS 6 1 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Main switch Controller Battery Fuse Throttle Handle Switch Horn Meter 8 9 10 Turn signal relay 11 Charge 5 1 6 5 7 2 2 3 4 Motor 6 7 ELEC 9 10 1...

Page 58: ...SW TURN HORN SW HEADLIGHT SW Controller Meter Motor Fuse Battery connection Battery box Main switch Throttle handle Turn signal switch Horn switch Headlight switch Turn signal relay Front brake light...

Page 59: ...and to the x1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g trun signal switch horn switch are shown in an...

Page 60: ...replace Improperly connected Properly connect Incorrect continuity reading Replace the switch G Y B Y Turn signal switch Headlight switch Horn switch Front brake switch Rear brake switch Main switch M...

Page 61: ...lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bulbs d and e are used for meter and indicator lights and can be removed from their respective socket by care...

Page 62: ...inuity c If either of the readings indicate no conti nuity replace the bulb CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets 1 Check bulb socket fo...

Page 63: ...W R W R W G Y G Y R W B W B W Y B Br W B W Br W G B Y B G B Y W G W L W Y W G W L W Br W B W Br W B W Y W W Pu G W L W Br W B W B W B W Y W G W G B Br W Y B B W G B L W Br W R W R W R W R W R W R W 1...

Page 64: ...lighting system s wiring Refer to CIRCUIT DIAGRAM Is the lighting system s wiring properly con nected and without defects The headlight switch is faulty Replace the left handlebar switch Properly conn...

Page 65: ...o the headlight light coupler is faulty and must be repaired This circuit is OK YES NO 3 The tail brake light fails to come on 1 Tail brake light bulb and socket Check the tail brake light bulb and so...

Page 66: ...G W L W Br W B W B W B W Y W G W G B Br W Y B B W G B L W Br W R W R W R W R W R W R W 12V 10W 12V 10W 14 13 12V 10W 12V 10W 16 15 R W 12V 21 5W 10 11 12 18 17 20 1 2 3 4 5 6 9 SIGNAL SW TURN HORN SW...

Page 67: ...Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 5 Minimum open circuit voltage 40 0 V or more at 20 C Is the battery OK 3 Main switch Check the main s...

Page 68: ...at the horn terminal Connect a jumper lead to the horn terminal and ground the jumper lead Set the main switch to ON Does the horn sound 4 Voltage Connect the pocket tester DC 20 V to the horn connec...

Page 69: ...tail brake light coupler ess side Is the voltage within specification 3 The turn signal light turn signal indicator light or both fail to blink 1 Turn signal indicator light bulb and socket Check the...

Page 70: ...5 Voltage Connect the pocket tester DC 20 V to the turn signal light connector or meter coupler wire harness side as shown Right turn signal light Positive tester probe Negative tester probe light gre...

Page 71: ...THE REAR SHOCK ABSORBER 7 13 CHECKING THE SWINGARM 7 11 REMOVING THE FRONT REAR WHEEL 7 3 REMOVING THE FRONT REAR BRAKE 7 7 REMOVING THE FRONT REAR BRAKE 7 8 CHECKING THE BRAKE DISK 7 7 CHECKING THE B...

Page 72: ...LOWER BRACKET 7 18 FRONT FORK 7 21 FRONT FORK 7 21 REMOVING THE FRONT FORK 7 22 DISASSEMBLE THE FRONT FORK 7 22 CHECKING THE FRONT FORK 7 23 ASSEMBLING THE FRONT FORK 7 23 INSTALLING THE FRONT FORK 7...

Page 73: ...e bolt 5 2 Front wheel 6 2 Front brake shoe plate 2 1 Collar B 7 1 Collar A Oil seal Bearing 1 3 4 5 6 2 5 6 7 1 CHAS Remove the parts in the order listed TIP Place the scooter on a suitable stand so...

Page 74: ...AR WHEEL REAR WHEEL CHAS Remove the parts in the order listed For installation reverse the removal pro cedure Remarks Q ty Job Part Order Removing the rear wheel TIP Place the scooter on a suitable st...

Page 75: ...CKING THE FRONT REAR WHEEL AXLE 1 Checking Front wheel axle Rear wheel axle DPDJH ZHDU 5HSODFH Roll the wheel axle on a flat surface and check Do not attempt to straighten a bent wheel axle WARNING Fr...

Page 76: ...eel 2 Install 3 Tighten Rear wheel axle Front wheel axle Front wheel axle nut Rear wheel axle nut For installation reverse the removal procedure and following procedure applies to all the front rear I...

Page 77: ...BRAKE CHAS Remarks Q ty Job Part Order Removing the front brake Remove the parts in the order listed Please refer to LOWER BRACKET in cheaper 7 For installation reverse the removal pro cedure Front f...

Page 78: ...E REAR BRAKE CHAS Remarks Q ty Job Part Order Removing the rear brake Remove the parts in the order listed Please refer to MOVING AND STALLING THE COVER in cheaper 3 For installation reverse the remov...

Page 79: ...H Felt seal HDU GDPDJH UHSODFH The following procedure applies to each brake CHECKING THE BRAKE SHOES 1 Checking Brake shoes Brake shoe spring UDFNV GDPDJH UHSODFH TIP When removing the brake arm mark...

Page 80: ...h brake brake drum inside diameter 2XW RI VSHFLILFDWLRQ UHSODFH Brake drum inside diameter 85 0 mm 3 35 in Limit 86 0 mm 3 39 in a a Brake lining thickness 3 0 mm 0 12 in Limit 1 5 mm 0 06 in 1 Check...

Page 81: ...the brake arm cam with the mark on the brake arm a TIP Rear brake cable Brake disk brake arm operation 8QVPRRWK RSHUDWLRQ UHSDLU When installing the brake disk align the groove of the brake disk with...

Page 82: ...4 Nm 0 4 m kg 2 9 ft Ib SWINGARM SWINGARM CHAS Remove the parts in the order listed Remarks Q ty Job Part Order Removing the swingarm Cap A Cap B Rear bottom cover L R Rear fender bracket Rear fender...

Page 83: ...rque of the pivot shaft nut c Check the swingarm vertical movement by moving it up and down If vertical movement is tight or rough or if there is binding check the spacer bearings and frame pivot 2 Re...

Page 84: ...25 3 ft Ib REAR SHOCK ABSORBER REAR SHOCK ABSORBER CHAS Remove the parts in the order listed Remarks Q ty Job Part Order Removing the rear shock absorber For installation reverse the removal pro cedur...

Page 85: ...rod Bends damage replace the rear absorber assembly Spring Fatigue replace the rear shock absorber assembly INSTALL THE REAR SHOCK ABSORBER 1 Install Shock absorber Rear shock absorber upper bolt and...

Page 86: ...he parts in the order listed Remarks Q ty Job Part Order For installation reverse the removal pro cedure Front brake cable Front cap Meter side L R Headlight Meter Handle lever assembly L Handlebar gr...

Page 87: ...off the handlebar Removing step 1 Check Handlebar HQGV GDPDJH UHSODFH CHECKING THE HANDLEBAR Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar WARNING INSTALL...

Page 88: ...Securely support the scooter so that there is no danger of it falling over Install all cables should refer to CABLE Flange bolt ROUTING in cheaper 2 Align the lower handlebar holder with the upper gro...

Page 89: ...BRACKET CHAS LOWER BRACKET Remove the parts in the order listed Remarks Q ty Job Part Order For installation reverse the removal procedure Remove the lower bracket Front wheel Refer to FRONT WHEEL RE...

Page 90: ...the front fork safety and firmly avoid topple and fall Do not lose the bearing ball inside of the bearing 2 Remove Front fender Please refer to FRONT FROK in cheaper 7 CHECKING THE LOWER BRACKET 1 Wa...

Page 91: ...fender assembly Ball race outer Bearing ball Ball race upper Ball race cover Ring nut Holding the front fender assembly until tighten 4 Tighten Ring nut Tighten steps Install a ring nut wrench on the...

Page 92: ...3 2 7 20 LOWER BRACKET CHAS Tighten the ring nut please refer to CHECKING STEERING HEAD in cheaper 3...

Page 93: ...1 T R 30 Nm 3 0 m kg 21 7 ft Ib FRONT FORK CHAS FRONT FORK Remove the parts in the order listed Remarks Q ty Job Part Order For installation reverse the removal procedure Remove the front fork Cap L R...

Page 94: ...support the scooter so that there Bolt Nut fork WARNING Front fork L R The fork spring would spring should pay attention when remove the bolt DISASSEMBLE THE FRONT FORK 1 Remove Inner tube Dust seal O...

Page 95: ...rk spring free length 99 0 mm 3 90 in limit 94 0 mm 3 70 in ASSEMBLING THE FRONT FORK 5HYHUVH WKH GLVDVVHPEO SURFHGXUH HDU LQ PLQG WKH IROORZLQJ SRLQWV QVWDOO Inner tube RUN VSULQJ 0LQL VSULQJ Washer...

Page 96: ...irclip Couple the circlip correctly on the groove of the outer tube 4 Check Operation of inner tube 8QVPRRWK RSHUDWLRQ UHSODFH INSTALLING THE FRONT FORK Reverse the disassembly procedure The following...

Page 97: ...d no response 8 2 Light bulb burnt out 8 2 Headlight does not light 8 2 Turn signal remains lit 8 2 Turn signal does not light 8 2 Turn signal blinks quickly 8 2 Turn signal blinks slowly STARTING FAI...

Page 98: ...and no response Have not put the battery Faulty battery Faulty main switch Faulty meter Faulty meter Faulty driver Faulty driver Battery contact bad connection Blown damaged or incorrect fuse Wiring c...

Page 99: ...sity Incorrect oil level HORN DOES NOT SOUND Headlight does not light Wrong light bulb Faulty battery Improperly grounded circuit Poor contacts main or light switch Light bulb life expired Light bulb...

Page 100: ...ears when the battery user to recharge the battery is completely exhausted to remind the Remind that the battery is charging Remind that the battery charging has already completed 1 Release the accele...

Page 101: ...up in system or already enter the correct password During standby mode this message will dis play to remind the user to press confirmation button to enter into riding page After starting This message...

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