X-TREME XB-502, Owner'S Manual

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+50vdc when the ignition key switch is in the ON position.
4. DC/DC controller check. This is the smaller silver box under the headlight assembly and has 3
wires coming out of it. Red & Black wire should have 48vdc with the key on, and Yellow and
Black should have 12vdc before and after the Glass Fuse. The DC/DC Controller powers
accessories like the lights, horn etc.
How To Test Motor Sensors
Sort out the motor's wiring. There is eight wires total, or leads, running from the motor to the
controller. Three larger wires power the motor and are larger (16 AWG): Green, Blue, and Yellow.
Two wires power the sensors and are smaller: Red and Black. And three wires connect the sensors
to the controller: Green, Blue, and Yellow. All 5 small wires are connected to one white quick
disconnect. For this project, we are concerned only with the smaller wires of Green, Yellow and
Blue.
Now, there are two methods used to determine a bad connection or which of the three sensors have
failed. Both require the motor to be fully assembled.
The first is to simply run the motor while one sensor lead is disconnected, “refer to section-A
below on how to do this”, then again for the second lead, and a third time for the last lead. If one
sensor is dead (and that's your only problem), you'll see that disconnecting one or the other of the
good sensors prevents the motor from turning altogether, while disconnecting the bad one has no
effect at all--it still sputters.
If that didn't work, try this second method. It is more complex, but useful to identify a bad
controller vs. the motor, and more nuanced issues or problems stemming from multiple failures.
Remove the 3 small wires from the 5 wire connector leaving the red and black wire attached.
While the motor is connected to the controller, powered, and at rest--or, alternatively, powered
with +5 volts from a workbench power supply--set up a multi-meter to monitor the sensor's output
on one of the 3 wires. Connect the Black Voltmeter Lead to the small black wire by inserting the
probe in where the wire goes into the connector. Attach the Red Voltmeter to one of the 3 wires to
be tested. IMPORTANT: DO NOT let any of the small wires touch each other or will blow the
sensor . Turn the motor by hand very slowly while watch the voltmeter. It should pulse to 5vdc
when active and 0vdc when not. Repeat this step for other 2 wires. If all three wires Green, Blue
and Yellow pulses 5vdc then the motor is good and controller is bad.
Section-A: Do not have scooter powered up. Locate the white quick 5 wire connecter leading from
the controller to the motor and unplug connector. With a small ice pick or large needle inserted to