Sunrise Medical ELITE XS 3 wheel Workshop Manual Download Page 4

Page: 4 / 89

IMPORTANT

It is potentially hazardous to fit or use any parts other than genuine

Sunrise Medical parts.

The company disclaims all liability for the consequences of such use,

which in addition voids the machine warranty.

This scooter is for the carriage of

ONE PERSON

And must not be used for any other purpose.

ELITE XS, ONYX

WORKSHOP MANUAL

TITLE

CONTENTS

PAGES

Tiller Fascia Panel

Tiller Fascia Panel & Tiller Back Panel

53 to 54

Hand Brake & Tiller Front Panel

Tiller Front & Top Panel

Tiller Horn & Reflector

Tiller-Indicators-Bulbs

Tiller Charging Socket

Tiller Loom

Tiller Adjustment & Weld Assy.

61 to 62

Tiller Bracket

H’lamps, Fnt Body Panel & Main Loom

Gaiter & Front Bumper

Headlamp & Bulb (4-Wheel)

65 to 66

Headlamp (3-Wheel)

Fnt. Body Panel (4-Wheel)

Fnt. Body Panel (3-Wheel)

Main Loom

70 to 72

Front Suspension & Steering

Stub Axles

73 to 75

Steering Rods

76 to 77

Front Suspension Struts

Swinging Arm

Steering Head (4-Wheel)

80 to 81

Steering Head & Forks

82 to 83

Summary of Contents for ELITE XS 3 wheel

Page 1: ...Workshop Manual ELITE XS 3 4 WHEEL ONYX EN G LISH Scooters ...

Page 2: ......

Page 3: ...ty 1 to 2 Recommended Tools 3 Service Inspection 4 Technical Specifications 5 to 7 Programme 8 Bumper Brakes Wheels Front Bumper 3W 9 Front Wheel Brake 3W 10 to 12 Rear Wheel Elite XS 13 to 14 Front Wheel Onyx XL8 15 Rear Wheel Onyx XL8 16 Tyres Tube Onyx XL8 17 to 19 Tyres Tube Elite 20 Front Brake Elite 4W Onyx XL8 21 to 22 Seat Batteries Rear Panel Seat Removal All 23 Seat Post Removal All 24 S...

Page 4: ...cia Panel Tiller Back Panel 53 to 54 Hand Brake Tiller Front Panel 55 Tiller Front Top Panel 56 Tiller Horn Reflector 57 Tiller Indicators Bulbs 58 Tiller Charging Socket 59 Tiller Loom 60 Tiller Adjustment Weld Assy 61 to 62 Tiller Bracket 63 H lamps Fnt Body Panel Main Loom Gaiter Front Bumper 64 Headlamp Bulb 4 Wheel 65 to 66 Headlamp 3 Wheel 67 Fnt Body Panel 4 Wheel 68 Fnt Body Panel 3 Wheel ...

Page 5: ......

Page 6: ...s are disconnected from the vehicle before commencing work Always check that the battery charger is disconnected from the vehicle batteries before commencing work Do not smoke Keep batteries away from all sources of ignition Do not place objects on the battery tops Always try to keep someone within earshot of your work area so that they may come to your assistance if needed Always wear personnel p...

Page 7: ...ial that correct lifting techniques be employed when moving batteries around It is also recommended that safety footwear be worn When disposing of old batteries please ensure that correct disposal procedures are followed Contact your local authority for their recommendations Battery Chargers Remember battery chargers are Mains Driven Units Always observe all guidelines and laws relating to mains c...

Page 8: ...le Spanner 13 Combination pliers 14 Ciclip pliers 15 Hammer small large 16 Soft hammer rubber hide or nylon 17 Feeler gauges metric imperial 18 Stanley knife 19 Pin punches 20 Electric drill mains battery 21 Drill bits metric imperial 22 Hacksaw standard junior 23 Toque wrench 24 Steel engineering rule 25 Tape measure 26 Tyre pump 27 Tyre pressure gauge 28 Personal safety gear 29 Wire strippers cu...

Page 9: ...e PhysicalInspection EmergencyStop Connections LeftTurn DischargeTest RightTurn Up Down Slope Over Obstacles ParkingBrake Wheels Tyres Wear Pressure PneumaticOnly Bearings Where appropriate WheelNuts Castors Where appropriate StubAxles Motors Wiring Noise Connections Brake Brushes Chassis Condition Welded Joints etc Steering Twists etc Upholstery Seat Seat Back Arm pads SeatSlideMechanism wherefit...

Page 10: ... user weight 150 kg total weight excl batteries 82 kg total length 138 cm total width 67 cm weight heaviest part 64 kg batteries 74 AH weight batteries each 74 AH 26 5 kg adjustable seat height 48 55 cm backrest height 52 cm seat depth 43 cm seat width 51 cm Elite XS 3 Wheel Range is calculated under test conditions Weight terrain and weather conditions can affect range and speed 5 ...

Page 11: ... weight excl batteries 87 kg total length 138 cm total width 67 cm weight heaviest part 69 kg batteries 74 AH weight batteries each 74 AH 26 5 kg adjustable seatheight 48 55 cm backrest height 52 cm seat depth 43 cm seat width 51 cm Elite XS 4 Wheel Range is calculated under test conditions Weight terrain and weather conditions can affect range and speed TECHNICAL SPECIFICATIONS 6 ...

Page 12: ...4 138 cm Overall Width 26 67 cm Max user weight 330 lbs 150 kg 23 5 st Max Gradient 1 14 degrees 115 kg user weight Max Gradient 2 11 degrees 150 kg user weight Range 24 m 37 km Speed 8 mph 12 kph Turning Radius 63 162 cm Weight excluding batteries 190 lbs 87 kg Battery Capacity 50 AH Adjustable seat height 19 23 48 cm 58 cm Front wheel diameter 12 31 cm Rear wheel diameter 12 31 cm 7 ...

Page 13: ...2 Current limit 110A 110A Motor compensation 60m 60m Hold factor hold comp 180 180 Mid current 0s mid time 0 Brake time 15 ISO tests on Bridge hold time 20 Throttle gain 100 Pulse reverse alarm yes Wig wag throttle yes Low battery flash inhibit yes Soft stop yes Throttle deadband 10 Output voltage 25V Trucharge cable resistance 40m Trucharge cal 100 Max charge amps 30 Min charge amps Accessible on...

Page 14: ... The nuts are between the outer chassis member and the edge of the foot board 3 Use a 10 00mm open spanner and a 5 00mm hex key to undo the bolts 4 Remove all four bolts 5 Finally remove the bumper 6 Note that the bumper has a smooth curved profile on the top surface and an angled profile underneath 9 ...

Page 15: ...ess the front brake 2 Use a 4 00mm hex driver to release the brake anchor stud 3 The BrakeAnchor Stud Washers 4 Turn the brake adjuster and locking wheel to align their slots with the slot in the bracket 5 Pull the brake cable cap out of the adjuster 6 Drop the cable through the slots 10 ...

Page 16: ...e cable with the slot in the actuator lever 9 Pull the brake cable nipple out of the actuator lever 10 Use a 10 00mm cranked hex key to loosen the front axle 11 Use a 19 00mm socket to secure the other end of the front axle 12 Once the axle is loosened jack the front wheel up until it clears the floor ...

Page 17: ...t clockwise and pull the axle slowly out 15 Be careful not to lose the two shim washers as the axle retreats through the wheel 16 Remove the large spacer as the axle withdraws from the wheel and fork 17 With the axle removed lift the front wheel clear of the forks 18 Lift the brake assembly out from the centre of the wheel ...

Page 18: ... Carefully prize the hub cap off 3 Use a 19 00mm socket to loosen the hub nut 4 Use a jack or blocks to lift the rear wheel Note that the jack should only be placed under the chassis box sections not the flat panels 5 Use the socket with hand pressure to undo the hub nut fully 6 Remove the hub nut 13 ...

Page 19: ...unt of force may be carefully applied to loosen the wheel 9 Remove the wheel 10 Remove the drive key 11 Remove the spacer Note that there is a rebate cut into the end of the inside face of the spacer 12 The locating circlip that the spacer rebate encloses This circlip correctly positions the rear wheel on the drive shaft 14 ...

Page 20: ...the wheel on the ground use a 19 00mm socket to loosen the centre self locking nut 3 Once the centre nut is loosened raise the wheel using a jack or axle stands blocks 4 Remove the centre nut using finger pressure only 5 Remove the washer 6 Carefully remove the wheel ...

Page 21: ...hile it is still on the ground 2 Use a jack or axle stands blocks to elevate the wheel 3 Use finger pressure to remove the centre nut 4 Remove the nut and washer 5 Note that there is a key way cut in the centre of the rear wheel 6 Remove the corresponding key from the drive shaft ...

Page 22: ...ossible squeeze the tyre 3 Using a soft face hammer carefully tap around the circumference of the back of the tyre 4 Then tap around the front This action helps to break the seal on the rims to aid removal 5 The front face of the wheel has 4 dome nuts securing the hub 6 The rear face of the wheel has 4 corre sponding captured studs ...

Page 23: ...our hub nuts using the opposites sequence but don t take them off 8 Once the hub nuts are loosened use the socket shaft and finger pres sure to fully remove them 9 Remove the hub nuts 10 Remove the washers 11 Turn the wheel over 12 Lift the hub away from the rims ...

Page 24: ...14 Turn the wheel over and repeat for the outer rim Note Be careful if using metal tyre levers as excessive force on the rim edge may cause fracture 15 With the rims removed reach into the tyre and gently pull the tube out 16 The Hub Hub Nuts Washers and Centre Wheel nut 17 The Outer Inner Rims 18 The Tyre Tube ...

Page 25: ...move the valve dust cap and de flate the tyre as previously described 3 Squeeze as much of the air out of the tyre as is possible At this stage use a non corrosive releasing agent between the tyre rim 4 Remove the five recessed rim studs using a 4 00 mm hex key driver 5 Remove the inner rim from the tyre 6 Lift the outer rim from the tyre pro ceed as before to remove the tube Note that the outer r...

Page 26: ...ate the brake actuator lever 3 Push the brake actuator lever so that it releases the tension on the cable 4 Push the Nipple on the end of the brake cable out of the actuator lever 5 Carefully turn the brake adjuster until the slots line up with the slot in the bracket 6 Release the end of the brake cable ...

Page 27: ...the front 8 The bolt heads are accessed from behind the brake assembly 9 Use a 13 00mm open spanner on the nuts 10 Use a 13 00mm ring spanner on the bolt heads 11 Access is easier if the fingers are used when the nuts are loose enough to remove Repeat for the other side 12 Finally remove the brake assembly from the stub axle ...

Page 28: ...al process is the same for the Onyx and the Elite XS seats 1 Lift the armrests up 2 Pull the backrest lever up 3 Fold the backrest forward 4 Stand behind the seat lift the seat swivel lever up and lift the seat off the seat post 5 The complete seat assembly removed ...

Page 29: ...ous and next page 1 The seat post in situ 3 Use two 17 00 mm spanners to loosen the seat post bolt 4 Take the nut and washer off using finger pressure 5 Hold the top of the seat stem to prevent it from falling when the bolt is withdrawn 6 Lift the seat stem out Note the height positioning holes in the seat stem 24 ...

Page 30: ...access the two armrest width adjuster knobs 2 Loosen both knobs 3 Withdraw the armrests 4 There are four nuts securing the seat plate assembly 5 Use a 13 00 mm socket to undo the four seat plate securing nuts 6 Lift the seat plate assembly off the four seat rail studs ...

Page 31: ...wo seat rails top and bottom 9 Slide the seat rails forward to expose the bottom bolts and use a 5 00 mm hex key to undo them 10 Depress the seat slide and slide the rail back to expose the top two bolts Note that the other rail slides freely 11 Undo the top two bolts 12 Lift the seat rails off the seat assembly 26 ...

Page 32: ...3 The seat swivel lever showing the position of the spring 14 For safety use a strong tie wrap to secure the spring as shown above 15 Use a second tie wrap adjusted slightly looser to catch the spring if it flies up 16 Use a 5 00 mm hex key and a 13 00 mm socket to undo the fulcrum nut 17 Carefully remove the fulcrum bolt 18 With the fulcrum bolt removed cut the first tie wrap ...

Page 33: ... lever ful crum 21 The lever spring assembly 22 The lever can be fitted to either side of the seat plate providing left or right hand operation 23 The lever spring showing the correct orientation of the spring ready for refitting 24 Squeeze the two ends of the spring into the two holes whilst holding the lever vertically The angled end of the lever should face away from the seat post 28 ...

Page 34: ...ever steady and insert the fulcrum bolt 27 Drive the bolt through the fulcrum using a hex driver 28 Tighten the nut bolt but do not over tighten 29 The angle on the lever head should be facing downwards towards the seat plate 30 Operate the lever several times to ensure it does not stick If it is stiff loosen the fulcrum nut and bolt slightly until a smooth action is obtained 29 ...

Page 35: ...g the ignition key 2 Lift out the battery charger and cords 3 Lift up the two plastic battery cover clips 4 Carefully lift the rear panel tags out of the two location slots in the floor panel 5 Pull the panel forwards 6 Finally lift the panel away from the scooter 30 ...

Page 36: ...t the battery size is 50A h on the Onyx 74A h on the Elite 8 Disconnect the twoAnderson battery connectors 9 Undo each of the velcro retaining straps 10 Use the correct lifting technique to remove the batteries 11 Remove the batteries one at a time 12 The battery compartment ...

Page 37: ... 1 Unscrew the Parking Brake knob 2 The rear panel is held in place by two screws 3 Remove the two screws 4 Lift the front of the panel up to access the rear lighting loom plugs 5 Unplug the rear lighting loom 6 Lift the panel clear of the scooter ...

Page 38: ...arlier 2 Flip the pane up to expose the underside and loom 3 Cut the small tie wrap located on the bottom of the storage compart ment 4 Cut the next tie wrap situated just below the first 5 Cut the tie wrap next to the right hand light cluster 6 Cut the tie wrap next to the left hand cluster ...

Page 39: ... the light cluster 8 Twist and turn the holder to remove it from the back of the light cluster 9 Carefully pull the bulb out of the holder All rear bulbs are 24V 5W Capless type 10 Both bulb holders removed 11 The rear lighting loom removed 12 View of the flexi clip on the light ing cluster body ...

Page 40: ...DICATORS ELITE XS ONYX 13 Use a flat blade screwdriver to gently prise the flexi clip through the panel 14 Lift the light cluster part way out 15 Withdraw the light cluster taking care not to break the straight locating tab 35 ...

Page 41: ...motor brake handle 2 Use an 8 00mm socket X head screw driver to undo the nut and bolt 3 Lift the brake lever out of the bottom mount 4 Slide the top of the brake lever out the P clip 5 Unplug the small white molex plug 6 Unplug the main motor loom plug from main control box 36 ...

Page 42: ...n the rear splash panel 2 Remove the splash panel 3 Repeat for the other side Note that the upper screws are larger than the lower screws 4 Remove the rear wheel as previously described 5 This exposes the rear wheel back panel 6 Undo the screws 37 ELITE ONYX ...

Page 43: ... place the screws back into the frame for safe keeping 9 There are two bolts found at each side of the rear frame 10 Use a 17 00mm socket spanner to remove the nuts 11 Note that the bolt will not normally come out of the frame using the socket 12 Use a soft faced hammer to care fully tap the bolts through the frame 38 ...

Page 44: ...struts 14 The top chassis bolt 15 Use a 10 00mm hex key 19 00mm spanner to undo and remove the top bolt 16 Carefully pull the drive assembly away from the main chassis 17 Retrieve the washers don t forget to fit them back when reassem bling the scooter 18 Place the drive assembly on a work bench for easier access 39 ...

Page 45: ...Remove the two self tapping screws from the rear valance 21 Remove the rear valance by carefully feeding the brake release lever through the slot in the valence 22 It s a good idea to put the screws back in the frame for safe keeping 23 There are four transaxle mounting bolts Two on the left hand side 24 Two on the right hand side 40 ...

Page 46: ...transaxle securing studs located under the assembly 3 For easy access to the nuts studs turn the drive assembly so that it rests on the stabiliser wheels 4 Use a 13 00mm socket 6 00mm hex key to loosen the studs but do not remove them yet 5 Repeat for the lower stud 6 Turn the drive assembly around to access the other set of studs 41 ...

Page 47: ...Don t forget to remove the wash ers also 11 Some studs may drop out of the frame quite easily 12 Some studs may require tapping out with a soft face hammer Caution The transaxle may suddenly move when the studs are re moved Ensure that the drive assembly is in a stable work area and that your fingers are clear of the frame work top 42 ...

Page 48: ...techniques When resting the transaxle on the bench be sure that fingers thumbs are clear of the assembly 15 Remove the spacers 16 Note that two of the transaxle mounting studs cannot be removed at this stage due to a clash with the suspension struts 17 The transaxle removed from the drive assembly frame 18 It is a good idea to put the studs brackets back onto the frame for safe keeping 43 ...

Page 49: ...grips Both struts must be evenly tensioned 3 The struts are secured by two concentric studs Use two 5 00mm hex keys drivers to undo them 4 Repeat the process for the top studs 5 Note the use of thread lock on the inner concentric studs 6 Withdraw the outer concentric stud This process can be carried out with the transxle still in place if required 44 ...

Page 50: ...op mounting 8 Remove the lower concentric stud 9 Lift the suspension strut out of the frame the transaxle stud described previously can now be removed 10 The stabiliser wheels are secured by a nylok nut 11 Use 8 00mm hex key 12 and a 17 00mm socket to undo the axle studs 45 ...

Page 51: ...stud 15 Slide the spacer off the axle stud 16 Withdraw the axle stud from the frame Repeat the process for the other stabiliser 17 The rear bumper is secured by the stabiliser axle studs that have just been removed and a further two studs 18 Use the 8 00mm hex key and 17 00mm socket to undo these studs 46 ...

Page 52: ...Lift the bumper off 21 Use a 17 00mm socket and a 13 00mm spanner to undo the rear frame pivot bolts 22 Take extra care when loosening removing the pivot bolts as the frame can drop down suddenly 23 Lift the two halves of the frame apart 24 The two halves of the rear frame 47 ...

Page 53: ...fuse holder 2 Be careful when removing the plastic fuse cover as it is easy to break the four locating lugs 3 Use an 8 00mm socket spanner to undo the fuse ring tag connectors 4 Remove the ring tags 5 The main fuse is held on the two studs 6 Use fingers to remove the main fuse 48 ...

Page 54: ...ip the cover and remove it to access the fuses 10 There are six blade fuses in total each have the rating in amps marked on the body 11 To remove the fuse carefully pull the body using finger force only not pliers always replace fuses with the correct value and type 12 The programming socket is located next to the fuse panel on the Elite only The Onyx is programmed directly into the Egis main cont...

Page 55: ...sconnect the main loom plug 3 Remember to squeeze the locking tab to release the plug Be careful not to pull the wires 4 Release the square molex pro gramming plug next 5 Use the locking tag to release the programming plug 6 Finally squeeze the end tabs to release the power motor looms 50 ...

Page 56: ...nd may cover the ends of the thread 10 Carefully pull the main control box away from the rear of the fuse panel plate 11 The rear of the main control box is coated with sticky white heatsink compound Avoid contact with the skin and clothing It is important that more heatsink compound is applied when fitting a new main control box The heatsink compound is available from electronics stockists RS Com...

Page 57: ...rewdriver It is a push fit 2 Lift the fascia up to expose the plugs on the underside 3 Locate the large white molex plug 4 Press the plastic catch on the plug to remove it from the PCB 5 Next locate the smaller white and orange plugs 6 Press the catch down on these two plugs to remove them from the PCB 52 ...

Page 58: ... same procedure to re move the blue plug 9 When the plugs are disconnected remove the fascia and store it in a safe place for reuse or fit new one 10 Location of tiller back panel screws 11 Unscrew the TillerAdjust Handle remove it 12 Undo the six screws in the tiller back panel 53 ...

Page 59: ...NEL 13 Lift away the tiller back panel to expose the looms behind it 14 Unclip and disconnect the orange plug 15 Do the same with the green plug 16 Finally unclip and disconnect the white plug 17 Remove the tiller back panel 54 ...

Page 60: ...handle go and at the same time pull firmly on the cable 3 The brake cable should pop out of the location groove 4 It may be easier to rotate the hand brake to gain access to the cable retaining rebate 5 Release the brake nipple from the handle 6 Feed the brake cable back through the hole in the tiller front panel Re move the Handbrake if required 55 ...

Page 61: ...two Basket Bracket screws 2 Remove the Basket Bracket 3 Undo the two Tiller Top Panel screws 4 Withdraw the Tiller Top Panel 5 Make sure all of the remaining plugs are disconnected remove the Tiller Front Panel 6 The three tiller panels removed 56 ...

Page 62: ...ocated on the Tiller Front Panel 2 The horn AWD is secured by one of the Reflector fixing screws 3 Undo the screw to remove the Horn AWD 4 Undo the remaining three screws 5 Lift the Reflector off the mounting posts 6 TheAWD Reflector Note that the longer screw secures the horn 57 ...

Page 63: ... acting as a bayonet fixing 3 To release the Indicator unit twist the indicator body untill the clips align with the square cut out section 4 Feed the whole assembly through the cut out in the panel 5 The bulb holder is a push fit simply pull it out from the lense 6 The bulb is also a push fit to re lease it carefully pull on the glass bulb 24V 5W Capless 58 ...

Page 64: ... cover over to the side to expose the two mounting screws for removal 3 The sprung cover screw is located at the back of the socket unscrew this with care as it could pop out suddenly 4 Carefully remove the Charging Socket from the front of the panel 5 Be careful not to lose the tiny spring 6 The Charging Socket and screw 59 ...

Page 65: ... up the Tiller stem 2 Undo the Rubber Gaiter securing screw 3 Carefully roll the rubber gaiter back to expose the tiller bracket 4 Note that the lower cable tag holds the loom clear of the mobile joint 5 Release the cable tag 6 Check the cables for chaffing or splits 60 ...

Page 66: ...ogether but screwed almost out gently tap the standard stud to push through the sleeved stud 3 Remove the standard stud and carefully lower the cylinder Remove the sleeved stud 4 The lower cylinder bracket 5 The lower cylinder bracket requires a 12 0mm and a 10 0mm spanner socket to undo it 6 Lift the Cylinder TillerAdjuster away 61 ...

Page 67: ... loom ties 8 Unplug any remaining connectors 9 Move the cables clear of the Tiller Bracket 10 Use a 12 0mm socket 10 0mm spanner to undo the Tiller Bracket bolts 11 Carefully lift the Tiller WeldAssem bly out of the Tiller Bracket 12 Remove the Tiller WeldAssy 62 ...

Page 68: ... out of the way to expose the Tiller Bracket Fixing Stud 4 Use a 13 0mm socket to undo the stud but be aware that the steering may turn onto the steering stop 5 Lift the Tiller Bracket out from the Steering Head 6 Note the serrations at the bottom of the bracket assy When refitting the bracket ensure the steering is aligned parallel and straight ahead 63 ...

Page 69: ...gaiter over the remaining looms and brake cables to remove it 2 Cut the last remaining plastic tie wrap 3 The two Front Bumper fixing studs are located directly beneath the bumper mounting bracket 4 Use a 5 0mm hex key to undo the two studs 5 Remove the Front Bumper 64 ...

Page 70: ...y or driver to undo the two studs 4 Carefully remove the Headlamp unit taking care not to damage the rubber beading attached to the panel 5 When refitting slide the headlamp unit tight up against the rubber bead ing Note the mounting bracket has elongations to facilitate this 6 The headlamp bulb is accessed through the back plastic cover at the rear of the headlamp unit 65 ...

Page 71: ... pull the black rubber cover back to expose the lamp holder 8 There may be two redundant wires inside the rubber cover these are not used but check that they are insu lated 9 The bulb holder is a bayonet type Twist and pull to release it 10 Withdraw the bulb 24V 15W 11 The Headlamp unit components 66 ...

Page 72: ...amp 2 The Headlamp can then be with drawn from the cowling as a complete unit Don t forget to disconnect the headlight loom from the main loom 3 Unclip the reusable tie wrap 4 Pull the rubber cover back 5 Twist and turn the bayonet fit termi nal cover 6 Remove the 24V 15W bulb 67 ...

Page 73: ...ront of the body panel 2 There are four further screws located in the foot mat 3 Unscrew all four self tapping screws 4 Lift the body panel up from the front 5 Note that there is a velcro pad under each wheel arch and corre sponding chassis member 6 The 4 wheel Front Body Panel 68 ...

Page 74: ... Please note that the photographs below do not show the foot mat The screws can be accessed without removing the foot mat exactly the same as the 4 wheel version 1 Unscrew the left hand front self tapping screw 2 and the right hand screw 3 Undo the two self tapping screws at the rear of the foot board 4 Lift the Footboard clear of the frame 69 ...

Page 75: ...M 1 Start at the back of the scooter 2 Unclip the two square molex plugs 3 Unclip the small molex plug 4 Cut the plastic tie wrap 5 Unclip any remaining plugs 6 Make sure the loom is free of cable ties and connections 70 ...

Page 76: ...sh guard has to be removed 9 Undo the two screws located di rectly below the splash guard 10 Remove the splash guard 11 It is a good idea to screw the screws back into the frame for safe keeping 12 Release the cable clip at the base of the flat form loom 71 ELITE ONYX ...

Page 77: ...Start by undoing the wire clip at the rear end of the loom 15 The loom runs inside a metal channel There are a further three clips to undo along this channel 16 The final clip is located at the front of the channel 17 Gently feed the loom out of the channel 18 The Main Loom 72 ...

Page 78: ...al with the steering still in place 2 Use a 6 0mm hex key on the secur ing stud 3 Use a 13 0mm socket on the nut below the securing stud 4 With the nut removed unscrew the securing stud as it is threaded inside the bracket 5 Use a 19 0mm spanner on the top stub axle bolt 6 Use a 19 0mm socket on the lower stub axle nut 73 ELITE ONYX ...

Page 79: ...is refitted first fol lowed by the self locking nut 9 Use care when lifting the pivot bolt out as there are bushes and spacers which can fall out of the assembly 10 Remove the StubAxle again taking care not to lose the spacers and bushes 11 The top and bottom brass spacer bushes 12 The top sleeved bush 74 ELITE ONYX ...

Page 80: ...nal spacer 15 The StubAxle assembly 16 View of the bushing order Brass Bush Sleeved Bush Spacer Sleeved Bush and Brass Bush 17 The stub axle component parts 18 The remaining stub axle is a mirror image of the previous one and is removed using the same process 75 ELITE ONYX ...

Page 81: ...ot the stud 3 Lift the steering rod up until the stud is clear of the stub axle 4 The second nut is permanently attached to the stud and acts as a spacer 5 The other end of the steering rod is connected to the Steering Head 6 Use an 8 0mm hex key and a 17mm spanner to release the steer ing rod inner stud in exactly the same way 76 ELITE ONYX ...

Page 82: ...ing rod 9 If the stub axle has been removed before the steering rod the stub axle pivot bracket will have to be removed from the steering rod 10 Note that the two Steering Rods are identical 11 Each end of the steering rods have grease nipples to aid the application of lubricant 77 ELITE ONYX ...

Page 83: ... end hex key 3 The studs are concentric and thread into each other The blue colour is thread lock 4 The upper studs are removed in the same way as the lower studs 5 Remove the front suspension strut and repeat the process for the other strut if required 6 One of the Front Suspension Struts showing the concentric studs Note that the strut can be adjusted using the tension ring at the bottom 78 ELIT...

Page 84: ... a 13 0mm socket and a 13 0mm open spanner to release the pivot bolt 3 Withdraw the long pivot bolt 5 There is a bush in each end of the swinging arm pivot 4 There is an inner sleeve within the swinging arm Use long nose pliers to pull this out 6 The SwingingArm assembly 79 ELITE ONYX ...

Page 85: ...eering head to stop it turning here a screw driver is used 3 The steering head securing nut should loosen quite easily 4 As the steering head has a fine thread it is quicker to remove the securing nut using the fingers 5 Next remove the spacer ring 6 Again use an adjustable spanner to release the Steering bearing retaining nut 80 ELITE ONYX ...

Page 86: ... the top steering bearing race 9 Use thin nose pliers to lift the top bearings out 10 With the top bearings removed lower the steering head to expose the bottom bearing race 11 Feed the lower bearing race up and over the top of the steering head 12 The 4 Wheel Steering Head Assy 81 ELITE ONYX ...

Page 87: ...nut 2 As this nut has a fine thread it is better to use fingers to undo it all the way 3 Remove the nut and the washer 4 The steering bearing nut 5 Use the adjustable spanner to loosen the steering bearing nut also 6 Undo the nut the rest of the way using finger pressure 82 ELITE ONYX ...

Page 88: ... away with the nut 8 Steering top bearing and retaining nut 9 Withdraw the front fork assembly from the steering head 10 The lower steering bearing will come away with the fork assembly 11 View of the Steering bearings retaining nut and Front Fork assembly 83 ELITE ONYX ...

Page 89: ...NOTES ...

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Sunrise Medical ELITE XS 3 wheel, Workshop Manual

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