Merits S331 series Service Manual Download

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2.5.6. To replace the throttle lever assembly

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When should you replace the throttle lever assembly?

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If your throttle lever assembly is deformation.

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If the throttle lever assembly out of shape due to an accident.

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If your throttle lever assembly cause error code happen continuously.

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How to replace the throttle lever assembly?

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Please proceeding steps as follows if it has to remove.

1. Loosen the screw (5.82)*3pcs by screw driver and take out the

throttle lever assembly (5.3) from frame.

2. Loosen the set screw (5.64)*2pcs by hex. tools then take out the

throttle lever set (5.62) with steel pin (5.65)*2pcs from the
potentiometer (5.80).

3. Loosen the nut (5.63)*2pcs by wrench and screw driver can take out

the steel pin from throttle lever set (5.62).

4. Take out the spring (5.78) by hand and loosen the screw (5.74) and

nut (5.77) by screw driver and wrench to take out the setting plate
(5.75) and spacer (5.76).

5. Use the wrench to loosen the nut (attached to potentiometer) then

separate potentiometer (5.80) and base plate (5.79).

Summary of Contents for S331 series

Page 1: ...Merits S331 S341 series Service Manual Nov 1 2006 V1 ...

Page 2: ...2 2 6 To replace the transaxle assembly P9 2 2 7 To remove the rear bumper and anti tipper assembly P10 2 3 How to replace or repair the Front section Assembly S331 Series P11 2 3 1 To replace the tiller assembly P11 2 3 2 To replace the caster wheel with fork assembly P12 2 3 3 To replace the Front bumper assembly P12 2 3 4 To replace the front wheel P12 2 3 5 To replace the suspension spring set...

Page 3: ...he front shroud of tiller P19 2 5 4 To replace the regulation cylinder P20 2 5 5 To replace the dashed board assembly P20 2 5 6 To replace the throttle lever assembly P21 2 5 7 To replace the electric components from dashed board assembly P22 The numbers shown in this service manual is just for reference The part numbers should be in accordance with current exploded drawing ...

Page 4: ... body seat base plate slide and left right armrests 2 1 1 To remove seat body assembly Pull the end 3 02 of the swivel lever 3 03 under the seat till unlock it and rotate the seat a little bit to the position where you can feel the seat rotate freely then lift up the seat body assembly 2 1 2 To replace the seat base plate When should you replace the seat base plate If the seat base plate is deform...

Page 5: ...lide 3 12 2 1 4 To disassemble seat body When should you replace the seat body If the seat body is worn out If the seat body is pierced or scratched by something If the scooter crashed cause the seat body out of shape How to replace the seat body Please proceeding steps as follows if it has to replace Follow the following step to disassemble seat body a Remove seat body assembly see section 2 1 1 ...

Page 6: ...arm pad is worn out If the arm pad is pierced or scratched by something If the scooter crashed cause the arm pad out of shape How to replace the arm pad Please proceeding steps as follows if it has to replace Revolve the knob 3 35 and pull the armrest assembly outside If the ...

Page 7: ...formation If the seat post out of shape due to an accident How to replace the seat post Please proceeding steps as follows if it has to replace Use two open end wrenches to loosen hexagon fixed bolt 1 63 and screw 1 65 Adjust the seat height based 1 62 to the demanded position there are 5 holes on the tube for adjusting the seat height Then insert and tighten the bolt Illus 06 ...

Page 8: ...1 then pull up rear shroud assembly 4 2 from chassis and unplug the connector of cable loom indicator rear light 4 21 which connect with main cable loom 5 83 2 Untie the battery strap and unplug the connector of battery harness from controller panel 2 56 then remove the battery 2 2 2 To remove the driven wheel assembly When should you replace the driven wheel assembly If your driven wheel assembly...

Page 9: ...embly 1 Loosen the screw 2 57 4 pcs by screw driver then pull up the controller panel 2 56 2 Unplug 4 connectors from controller 2 2 4 To remove the controller mounting plate and controller 1 Loosen the screw 2 51 and nylon nut 2 52 by hex tools and wrench 2 Take away the controller mounting plate and controller from the frame 3 Loosen the screw 2 54 and nylon nut 2 55 by hex tools and wrench then...

Page 10: ...sk brake 2 27 directly 5 Take the C clip A out from input shaft of transmission by pliers 6 Loosen the screw 2 25 by hex tools 7 Along the output shaft axial take out the disk brake 2 27 with brake disk 2 38 2 2 6 To replace the transaxle assembly When you should replace the transaxle assembly and the suspension frame If the transaxle assembly has noise If the transaxle assembly can t drive the sc...

Page 11: ... Take off the transaxle assembly 5 5 from suspension frame 2 2 7 To remove the rear bumper and anti tipper assembly When should you replace the rear bumper rear anti tipper assembly If the rear bumper rear anti tipper assembly out of shape due to an accident If rear bumper the rear anti tipper assembly is deformation How to replace rear bumper the rear anti tipper assembly Please proceeding steps ...

Page 12: ...hroud 4 02 by hand directly then loosen the screw 4 06 4pcs by screwdriver to make shroud come off the chassis 3 Pull out the connectors from tiller main cable loom 5 83 which connect to controller panel 2 56 head light 5 69 and half speed sensor 4 Loosen the screw 5 71 and nylon nut 5 73 by hex tools and wrench 5 Pull out the tiller assembly from fork stem and you can take out the shroud assembly...

Page 13: ... the front bumper assembly When should you replace the front bumper assembly If the front bumper assembly out of shape due to an accident If front bumper assembly is deformation How to replace front bumper assembly Please proceeding steps as follows if it has to replace Loosen the screw 1 05 and nylon nut 1 06 both side by hex tools and wrench Then you can take out the front bumper 2 3 4 To replac...

Page 14: ...an t make a smooth movement How to replace the front wheel Please proceeding steps as follows if it has to replace 1 Loosen the nylon nut 1 21 by wrench total 4pcs 2 Pull out the spring support shaft 1 12 by hand 3 Take out the related parts 1 22 1 26 in according with sequence 2 3 6 To replace the front fork assembly When should you replace the front fork assembly If your front fork assembly is d...

Page 15: ...me front shroud front wheel assembly and mat 2 4 1 To remove the tiller assembly 1 Repeat the item 2 3 1 step 1 5 Note Separate the mat from the shroud 4 02 by hand directly then loosen the screw 4 07 4pcs by screwdriver to make shroud come off the chassis the same as item 2 3 1 step 2 ...

Page 16: ...out 3 Along the shaft axial to take out the driven wheel assembly the parts 1 55 1 59 will come out with wheel assembly 4 The other side follow the step above 1 3 2 4 3 To replace the tire of wheel assembly When should you replace the front wheel with fork assembly If your front wheel is deformation If the front wheel out of shape due to an accident If the front wheel is worn out If the front whee...

Page 17: ... out the front bumper 1 03 from front frame 2 4 5 To replace the half speed sensor bracket and sensor When should you replace the half speed sensor If the half speed sensor is deformation If the half speed sensor is not functioning well or can t not work How to replace rear bumper the rear anti tipper assembly Please proceeding steps as follows if it has to replace 1 Loosen the screw 1 38 by screw...

Page 18: ...ist of 1 28 1 29 1 30 1 31 1 32 if necessary loosen the nut 1 29 and related parts like a joint 1 28 1 32 then can wholly separate Rod A and Rod B 3 Loosen the headset bearing 1 02 by wrench total 3 sets then can take out the steering tube 1 25 front axle set LH 1 33 and front axle set RH 1 34 from front frame 2 4 7 To replace front suspension arm assembly When should you replace the suspension ar...

Page 19: ...ler assembly includes tiller frame control units main harness shroud adjustable component 2 5 1 To replace the tiller assembly To remove the tiller assembly from vehicle please refer to the item 2 3 1 step 1 5 2 5 2 To replace the rear shroud of tiller 1 Loosen the screw 5 20 6pcs by screw driver 2 Press the lever 5 05 down then take out the rear shroud 5 19 When should you replace the rear shroud...

Page 20: ... 5 68 by hand directly 2 Loosen the screw 5 30 4pcs by hex tools and take out the basket bracket 5 28 2pcs 3 Loosen the screw 5 11 4pcs by screw driver 4 Remove the grip then loosen the screw mounted on the lever 5 03 and pull it out from tiller s hand bar 5 Unplug the connector of the indicator L R 5 25 then take out the front shroud of tiller Note Regarding to step 4 above Remove the grip becaus...

Page 21: ...ut 5 10 by hex tools and wrench then loosen the screw 5 16 5 17 by hex tools only 4 Take out the regulation cylinder 5 07 cable wire 5 06 and lever 5 05 from the tiller frame together 2 5 5 To replace the dashed board assembly When should you replace the dashed board assembly If your dashed board assembly is deformation If the dashed board assembly out of shape due to an accident If your control u...

Page 22: ...5 82 3pcs by screw driver and take out the throttle lever assembly 5 3 from frame 2 Loosen the set screw 5 64 2pcs by hex tools then take out the throttle lever set 5 62 with steel pin 5 65 2pcs from the potentiometer 5 80 3 Loosen the nut 5 63 2pcs by wrench and screw driver can take out the steel pin from throttle lever set 5 62 4 Take out the spring 5 78 by hand and loosen the screw 5 74 and nu...

Page 23: ...ch wire 5 53 key switch wire 5 45 speed pot Wire 5 39 power cord 5 42 and power indicator 5 41 2 Loosen the brass stud 5 36 4pcs and take out the PCB from upper cover 5 32 3 Each button switch and electric component which mounted on upper cover all coating the polyester to avoid loosing so if you want to take out the component which you want you must clean away it by knife and alcohol to assist 4 ...

Page 24: ...23 ...

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