E-Bike 36V Service Manual - Chapter Eight
Battery voltage test
1. Remove the battery pack from the E-Bike
®
.
2. Use a digital volt ohmmeter to measure the
voltage across the terminals at the bottom of
the battery pack.
a. The battery is good if the voltage is 31-
39 voltage.
b. If battery voltage is 0 volts, perform the
battery fuse test.
c. If the battery voltage is less than 31
volts, perform the battery pack test
described in Chapter Three.
Brake sensor continuity test
1. Disconnect the brake sensor connector (D
or E, Figure 1) from the controller.
2. Check the continuity between the two pins
in the sensor connector. The sensor should
have continuity when the brake lever is applied.
It should have no continuity when the brake
lever is released.
3. If a brake sensor fails either check, adjust
the sensor by performing the following:
a. Press the sensor with your thumb and
reposition it on the brake lever housing.
b. Check the operation of the taillight while
you operate the brake. The taillight
should turn on when you apply the
brake, and it should turn off when you
release the brake.
c. If the taillight works properly, remove the
sensor mounting screw. Apply Loctite
242 to the threads of the mounting screw
and install the screw. Reposition the sen-
sor until it works, and tighten the mount
ing screw securely.
4. If adjusting the sensor does not correct the
problem, replace the brake lever assembly.
Brake sensor operation test
1. Operate the front brake, and watch the tail-
light.
2. The taillight should turn on when you apply
the brake, and it should turn off when you
release the brake.
3. Repeat step 1 for the rear brake.
Controller fuse test
NOTE
The controller fuse blows whenever there is a
failure in either the headlight, horn, or taillight
circuit. Do not simply replace a controller fuse
without solving the problem. The new fuse will
also be blown.
1. Remove the battery pack from the E-Bike
®
and turn the power knob to ON.
2. Visually inspect the fuse on the controller.
Replace the fuse and perform troubleshooting
procedure B if the fuse appears blown.
3. Check the continuity of the fuse with a digi-
tal volt ohmmeter. It should have continuity.
Replace the fuse and perform troubleshooting
procedure B if the fuse does not have conti-
nuity.
Headlight bulb resistance test
1. Be sure the bulb is cold.
2. Remove the bulb from the headlight.
3. Connect one probe of a digital volt ohmme-
ter to the spade connector at the end of the
blue wire. Connect the meter’s other probe to a
metal part of the bulb housing.
3. Replace the bulb if the resistance is outside
the specified range.
Headlight bulb resistance:
Approximately 0.5 ohms (cold).
Headlight resistance test
1. Disconnect the headlight connector (H,
Figure 1) from the controller.
2. Connect the positive (+) probe of a digital
volt ohmmeter to pin 1 on the connector and
connect the ohmmeter’s negative (-) probe to
pin 3.
3. Note the reading on the ohmmeter.
Headlight resistance:
Approximately 0.5 ohms (cold).
4. Replace the headlight assembly if the read-
ing is outside the specified range.
Headlight switch test
1. Disconnect the accessory control connector
(B, Figure 1) from the controller.
2. Connect the probes of a digital volt ohm-
meter to pins 1 and 2 on the connector.
3. Turn the headlight switch on and off and
watch the meter. The circuit should have conti-
nuity when the switch is ON. It should have no
continuity when the switch is OFF. Replace the
accessory control if the headlight switch fails
either test.
Chapter Eight
8-10