E-Bike 36V Service Manual - Electrical
Horn resistance test.
1. Disconnect the horn connector (G, Figure
1) from the controller.
2. Connect the positive (+) probe of a digital
volt ohmmeter to pin 1 on the connector and
connect the meter’s negative (-) probe to pin 2.
3. Note the reading on the ohmmeter.
Horn resistance:
Approximately 11 ohms.
4. Replace the horn if the reading is outside
the specified range.
Horn switch test
1. Disconnect the accessory control connec-
tor (B, Figure 1) from the controller.
2. Connect the probes of a digital volt ohm-
meter to pins 1 and 6 on the connector.
3. Press and release the horn switch, and
watch the meter. The circuit should have conti-
nuity (close to zero ohms) when the switch is
pressed. It should have no continuity (infinity
ohms) when the switch is OFF.
4. If the switch fails either test, replace the
accessory control.
Motor test
1. Remove the battery pack from the E-Bike
®
,
and turn the power knob ON to discharge the
capacitor on the controller.
2. Disconnect the QR connector.
3. Connect the negative (-) probe of a digital
voltmeter to the red terminal on the motor side
of the connector. Connect the meter’s positive
(+) probe to the blue terminal.
4. Spin the wheel backwards, and watch the
meter. If any voltage is present when you spin
the wheel backwards, the motor is good. If no
voltage is present when you spin the wheel,
replace the motor.
Power knob test
1. Remove the battery pack from the E-Bike
®
and turn the power knob to ON to discharge
the capacitor in the connector.
2. Disconnect the throttle control connector
(C, Figure 1) from the controller.
3. Use a digital volt ohmmeter to check the
continuity across pins 3 and 4 in the connector.
The throttle control should have continuity
when power knob is ON. It should not have
continuity when power knob OFF. The throttle
control is faulty if it does not pass both tests;
replace it.
QR connector test
1. Inspect the cable on both sides of the con-
nector. Be sure the cable does not rub against
the wheel.
2. Disconnect the QR connector.
3. Plug the connector securely into its mate,
and turn the power knob ON.
4. The problem is corrected if the motor oper-
ates.
Taillight test
1. Check the continuity in the taillight cable by
performing the following:
a. Disconnect the taillight connector (F,
Figure 1) from the controller.
b. Disconnect the taillight connector
(Figure 20) under the seat.
c. Check the continuity on each wire (red,
black and white) in the taillight cable.
d. Each wire should have continuity.
Replace the taillight cable if any wire in
the cable does not have continuity.
2. Reconnect the taillight connector (F, Figure
1) to the controller.
3. Connect a known-good taillight assembly to
the taillight end of the taillight cable.
4. Check the operation of the taillight/brake
light by turning on the headlight switch and by
operating the brake levers. The original taillight
assembly is faulty if this known good taillight
assembly operates properly.
Throttle resistance test
1. Remove the throttle control connector (C,
Figure 1) from the controller.
2. Connect the probes of digital volt ohmmeter
to pin1 and pin 2 in the connector.
3. Check the resistance when the throttle is
completely off and when the throttle is fully on.
Throttle resistance:
No throttle:
Less than 1100 ohms
Full throttle:
More than 3800 ohms
4. Replace the throttle control if either reading
is outside the specified range.
ELECTRICAL
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