Currier Tech 650CD Series Technical information

Currie Technologies®
Currie Technologies®
Table of Contents
Section
Section
Section
Section
Section
Section
PLEASE DO NOT RETURN
THIS ITEM TO THE STORE.
For questions or assistance on assembly contact
Currie Technologies® Customer Service toll free
(800) 377-4532
Monday - Friday
8:00 am - 4:00 pm (PST)
1 . . . . . Technical Information . . . . . . . . . . . . . . . . page
2 . . . . . Safety Guidelines . . . . . . . . . . . . . . . . . . . page
3 . . . . . Basic Assembly . . . . . . . . . . . . . . . . . . . . page
4 . . . . . Repair and Maintenance . . . . . . . . . . . . . page
5 . . . . . Frequently Asked Questions (FAQs) . . . . . page
6 . . . . . Pre-Ride Checklist . . . . . . . . . . . . . . . . . . page
Section 1 - TECHNICAL INFORMATION
300 Series
Scooter
4.0 Series
Scooter
400 Series
Scooter
Minimum Rider
Age
13 years old
13 years old
13 years old
Maximum Rider
Weight
180 lbs
(82 kg)
180 lbs
(82 kg)
240 lbs
(109 kg)
Up to 12 mph
(19 km/h)
Up to 12 mph
(19 km/h)
Up to 15 mph
(24 km/h)
7 miles
(11 km)
7 miles
(11 km)
8 miles
(13 km)
Battery
24V 10Ah
SLA
24V 10Ah
SLA
24V 10Ah
SLA
Charging time**
6-8 hours
6-8 hours
6-8 hours
500CD Series
Scooter
650CD Series
Scooter
750CD Series
Scooter
900CD Series
Scooter
Minimum Rider
Age
13 years old
13 years old
13 years old
13 years old
Maximum Rider
Weight
240 lbs
(109 kg)
260 lbs
(118 kg)
260 lbs
(118 kg)
260 lbs
(118 kg)
Up to 15 mph
(24 km/h)
Up to 15 mph
(24 km/h)
Up to 15 mph
(24 km/h)
Up to 15 mph
(24 km/h)
8 miles
(13 km)
12 miles
(19 km)
12 miles
(19 km)
12 miles
(19 km)
Battery
24V 10Ah
SLA
24V 12Ah
SLA
24V 12Ah
SLA
24V 12Ah
SLA
Charging time**
6-8 hours
8-10 hours
8-10 hours
8-10 hours
Maximum
speed*
Max Range*
OR
Consult the trouble shooting guide of the owner’s manual or
visit our website at www.CurrieTech.com
IMPORTANT - Activate your warranty by registering your new Currie
Technologies® product within 10 days of purchase by visiting our website at
www.CurrieTech.com.
Retain this manual along with the original sales receipt. Record the
product serial number (S/N), place of purchase and date of purchase
below.
Model Name : __________________________________________
S/N : __________________________________________________
Place of Purchase : ______________________________________
3
4-7
8-9
10-33
34-35
36-37
Maximum
speed*
Max Range*
*Maximum range and speed varies based on rider weight and terrain.
**Charge time is based on new batteries charged with a standard charger.
Date of Purchase : _______________________________________
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Section 2 - SAFETY GUIDELINES
Limitations of Safety and Warning Notices
!
WARNING
This owner’s manual includes important safety
guidelines and maintenance instructions. Failure to
read, understand and follow the instructions in this
manual may lead to serious injury or even death.
INSURANCE NOTICE
Your insurance policies may not provide coverage for accidents
involving the use of this electric scooter. To determine if coverage
is provided, you should contact your insurance company or agent.
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This product is intended for use under adult supervision only. Even
under adult supervision serious injuries or even death can occur.
Always ride within your capabilities and use common sense, do
not ride at night. You are using this product at your own risk. Never
operate this product at a speed which is too fast for your skills.
Always drive at low speed on dusty surfaces.
This product is not intended, designed or licensed for roadway
use. This product is intended for use outdoors and on a private,
closed course only. Ride only on dry, smooth, solid paved surfaces
without motor vehicle traffic. Never use this product on roadways
(paved, gravel or dirt), sidewalks, driveways, parking lots near motor
vehicles, on or near steep inclines or steps, swimming pools or other
bodies of water.
Currie Technologies®
!
WARNING
Never operate this product without proper training
or instructions.
WARNING Children under 13 years old should never operate these
scooters. Rider age does not necessarily mean that they are qualified to
operate this product. A parent should never allow this product to be used by
an individual not having the ability, coordination, maturity, skills and strength
to operate it safely and in a controlled manner.
!
!
WARNING
Maximum rider weight is 180 lbs, (82 kg) for the 300 and
4.0 series scooters, 240 lbs. (109 kg) for the 400 and 500CD series scooters
and 260 lbs. (118 kg) for the 650CD, 750CD and 900CD series scooters;
never exceed it. Rider weight does not necessarily mean that they are
qualified to operate this product.
WARNING Never modify this product through improper installation,
modification of existing parts or use of non-authorized accessories. Doing so
may result in denied warranty claims.
!
Adults must assist children in the initial adjustment procedures to unfold
scooter, adjust handlebar and steering to height, and finally to fold scooter.
Check and secure all fasteners before every ride. Before every ride, make
sure the “Easy Fold Handlebar Hinge” is in the fully upright position. Be sure
the locking pin is fully engaged and the quick release lever is in the “closed”
position.
Check and secure all fasteners before every ride.
This product is not regulated by transportation regulations (that is,
Department of Transportation (DOT) or state law).
This product is designed to be used by only one person at a time. Never
carry passengers or allow more than one person to use this product at a
time.
Obey all local traffic and scooter riding laws and regulations. The
laws and ordinances vary greatly from municipality to municipality.
It is your responsibility to know and abide by your local restrictions.
We recommend you contact your local police or Department of
Motor Vehicles to find out about any special laws or rules governing
the use of this product where you live.
Always wear an approved helmet that fits and is worn properly with the
chinstrap securely buckled when using this product. Wear shoes when
using this product, never operate this product barefoot or in sandals as this
increases the risk of injury. Also wear knee pads, elbow pads, eye protection
(goggles or face shield), gloves, boots, long sleeved shirt or jacket and long
pants.
Do not ride at night.
Always keep both hands on the handlebars (hand grips) and both feet on the
footboard during operation.
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Currie Technologies®
Currie Technologies®
Avoid excessive speed associated with downhill riding. Always drive slowly
and pay extra attention when operating on unfamiliar terrain. Always be alert
to changing terrain conditions when operating this product. Never operate on
excessively rough, slippery or loose terrain.
BATTERY CHARGER
The charger and charger port should be regularly inspected for damage
(cord, plug, enclosure, etc.). If damage is found stop using the charger until it
can repaired or replaced.
Avoid sharp bumps, drainage grates, and sudden surface changes. Scooter
may suddenly stop. Always check for obstacles before operating in a new
area. Never attempt to operate over large obstacles, such as large rocks or
fallen trees.
The charger is not a toy and should be kept out of reach children at all times.
Watch out for pedestrians
Do not charge your battery for more than 24 hours at one time.
Replace worn or broken parts immediately. Do not use this product until worn
or broken parts have been replaced by a qualified mechanic.
Do not allow hands, feet, hair, body parts, clothing, or similar articles to
come in contact with moving parts, wheels or drivetrain, while the motor is
running.
Practice turning at low speeds before attempting to turn at faster speeds. Do
not turn at excessive speed as this could increase the risk of injury.
Do not ride with headphones. They mask traffic sounds and emergency
vehicle sirens, distract you from concentrating on what is going on around
you, and their wires can tangle in the moving parts of the scooter, causing
you to lose control.
Do not do stunts, wheelies, jumps or any other type of dangerous riding.
They can cause severe injury to you and damage your scooter.
Do not lean the scooter excessively as this may allow parts of the scooter to
contact the ground and may result in lose of control, damage to the scooter
or injury to rider.
Do not touch the motor or brakes as they can become hot from use.
WET WEATHER RIDING
This product is not meant for use in the water (damp roads, puddles, rain,
streams, etc.) or in wet weather. Never immerse this product in water as the
electrical and brake systems may be damaged. Avoid streets and surfaces
with water, sand gravel, dirt, leaves, and other debris. Wet weather impairs
traction, braking and visibility.
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Always disconnect the charger from the wall outlet and the charger port on
the scooter when not using it.
Make sure that the areas that the scooter is to be used in is safe and suitable
for safe operation.
Make sure that all safety labels are in place and understood by the rider. No
passengers are allowed on the scooter
Make sure that any and all axle guards, chain guards, or other covers or
guards supplied with the scooter are in place and in good working condition.
Make sure that tires are in good condition, inflated properly, and have
sufficient tread remaining.
Persons with following conditions are cautioned not to operate the scooter:
•Those with heart conditions
•Pregnant women
•Those with head, back, or neck ailments, or prior surgeries to those
areas of the body
•Those with any mental or physical conditions that may make them
susceptible to injury or impair their physical dexterity or mental capacities
to recognize, understand and perform all of the safety instructions and to
be able to assume the hazards inherent in operating the scooter.
Starting
1.
2.
3.
4.
Turn the power switch to the “ON” position
Place one foot on the deck with both hands on the handlebars.
Slowly twist the throttle to operate the motor.
Place the other foot on the deck once you have properly balanced yourself.
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Currie Technologies®
Currie Technologies®
2. Install the front wheel (certain models will have the front wheel
Stopping
1.
2.
already installed) being sure to properly install the safety washers.
Align the front wheel in the fork and tighten the axle nuts. Wait until
after you have installed the handlebars to connect the front brake (if
your scooter is so equipped).
3. Install the handlebars onto the stem, align and tighten.
4. Unfold the stem hinge. Be sure the locking pin is fully engaged and
close the quick release lever.
5. The brake(s) come pre-assembled from the factory (some scooters
have one brake while others have two brakes). However, you need
to check to make sure it is connected and operating properly. Test
the brake lever(s) by squeezing it. It should stop the wheel(s) easily
and NOT come in contact with the handlebar. If the brake lever(s)
needs adjusting, refer to pages 19-20 for instructions. If the brake(s)
does not work properly, DO NOT RIDE THE SCOOTER. Call
Customer Service at 1-800-377-4532 for further assistance.
6. Install the seat assembly, if so desired, by fully sliding the seat
tube into the frame and securing the pinch bolt. If the seat tube is
equipped with an indexing pin be sure to align this properly with the
frame.
7. Install the seat onto the seat tube if not already done and align
saddle angle and tilt and tighten accordingly.
8. Remove the battery charger from its box. Make sure the power
switch on the scooter is in the “OFF” position. Connect the charger
to the scooter first then plug the charger into the wall socket. Allow
the batteries to charge a full 6-10 hours (depending on the size of
batteries) before first use. Refer to page 17 for complete Battery
Care instructions
9. Before every ride, test the throttle with the power switch in
the “OFF” position. Twist the throttle, it should twist easily and
immediately spring back to the starting position when you release
it. If the throttle does not work properly, DO NOT RIDE THE
SCOOTER. Call Customer Service at 1-800-377-4532 for further
assistance.
10. Check tire pressure and inflate to the pressure recommended on the
tire sidewall as necessary.
To slow down or come to a stop, allow the throttle to completely return to its
“zero speed” position
Squeeze the brake lever(s) on the handlebar to come to a safe stop. (Note: It
is not necessary to skid the wheel in order to slow or stop the scooter)
!
WARNING
Skidding the wheel can damage the wheel and is not
covered by the warranty!
Storing your Scooter
1. When you are not using the scooter, turn the power switch to the
“OFF” position.
2. Always be sure to fully charge batteries (6-10 hours depending on
battery size) at least every 30 days.
3. Plug the charger into the scooter then plug the charger into the wall
outlet. Do not charge your battery for more than 24 hours at one
time.
5 minute sleep mode
Scooters are equipped with a 5 minute sleep mode. If no activity is detected
after 5 minutes the scooter will go into stasis mode to conserve the batteries.
To restart, cycle the power switch Off then On.
Never store your scooter in Sleep Mode as battery power will still be used by
the scooter. Always be sure to turn the power switch to the “OFF” position.
Section 3 - Basic assembly & set-up
IMPORTANT: Some adult assembly required. Before using your scooter
please be sure to read and follow the basic assembly, set-up and operating
instructions. Following these instructions will help insure safe riding.
Tools Required:
Listed below are the tools you may need to assemble and adjust your
•
•
•
•
10mm
13mm
15mm
17mm
box wrench
box wrench
box wrench
cone wrench
•
•
•
•
•
4mm hex key wrench
5mm hex key wrench
6mm hex key wrench
Phillips screwdriver
Bicycle tire pump
Electro-Drive™ scooter depending on model:
Steps for BASIC Assembly
1. Remove scooter from carton. Remove all of the packaging materials
from the scooter.
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!
WARNING
Adults must assist children in the initial adjustment
procedures to unfold scooter, adjust handlebar and steering to height, and
finally to fold scooter. Before you ride the scooter, make sure you have
tightened all parts. Riding with a loose handlebar, front wheel, brake, seat
assembly, etc. may cause a rider to fall, possibly damaging the scooter and
causing serious injury.
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Currie Technologies®
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3. Open the stem hinge to
Section 4 - repair & maintenance
access the steerer bolt
(6mm Allen Bolt or 13mm
Hex Bolt).
IMPORTANT: Some adult assembly required.
Handlebar Assembly and Adjustment
Electro-Drive™ scooters are equipped with an folding stem hinge. Take care
not to pinch your hands or fingers in the hinge when you are folding and
locking the handlebar in place. Additionally be careful not to pinch or crimp
the brake and throttle cables in the hinge whenever you fold the stem hinge.
1. Insert the stem into the
4. Loosely tighten the steerer
steerer tube. Be sure
to insert stem past the
“Minimum Insertion Mark”.
bolt. The stem is held in
position with the expander
bolt and wedge.
2. Open the stem quick release
(QR) lever (Ref Photo A)
and rotate it forward out
of the upper plate (Ref
Photo B, step 1). Slide the
QR retention pin (silver)
sideways (Ref Photo B, step
2) to disengage it from the
upper plate.
!
5. Slide the QR retention pin
(silver) sideways (Ref Photo
A). Close the stem hinge
(Ref Photo B).
WARNING
Photo A
If the
quick release lever is either
too tight (cannot be flipped to
its fully locked position) or is
too loose (can be too easily
flipped to its locked position)
refer to the “QR Lever Adjustment” on page 14.
Photo B
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1
Photo A
2
Photo B
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6. Rotate the stem QR lever
8. Align the handlebars to the
forward into of the upper
plate (Ref Photo A). Close
the stem QR lever (Ref
Photo B) being sure the QR
retention pin (silver) is fully
engaged with the upper
plate.
front wheel. The handlebars
must be perpendicular to the
front wheel.
Photo A
9. Repeat steps 2 and 3
to once again access the
steerer bolt (6mm Allen Bolt
or 13mm Hex Bolt). Fully
tighten the steerer bolt.
The stem is held in position
with the expander bolt and
wedge.
7. Install the handlebars onto
Photo B
10. Repeat steps 5 and 6
the stem, align and tighten.
to once again secure the
folding stem. Be sure the
QR retention pin (silver) is
fully engaged with the upper
plate.
!
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WARNING
If you are unable to lock the handlebar folding hinge
properly, or its Quick- Release lever, or properly secure
the two main handlebar parts to the scooter, DO NOT
RIDE THE SCOOTER. Contact Currie Technologies®
Customer Service at 1-800-377-4532 for further
instructions. Failure to do so may result in serious injury
or death to the rider or severe damage to the scooter.
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Currie Technologies®
QR Lever Adjustment:
Battery Pack, Charger Port and Charger
Electro-Drive™ SMART Charger: The Electro-Drive™ scooter comes
with its own Electro-Drive™ Smart Charger that connects with an easyaccess charger port for recharging the batteries. This charger unit has lights
that show the battery charge status. Refer to the instructions that appear on
the charger unit and its instructions.
If the quick release lever is either
too tight (cannot be flipped to its fully
locked position) or is too loose (can
be too easily flipped to its locked
position) you will need to adjust the
QR (Quick Release) Lever.
!
Open the QR lever (Ref Photo A) and
adjust the 10mm nut underneath the
center pin (Ref Photo B).
If the QR lever was too tight initially
you will need to loosen the nut a 1/4
turn at a time. Test the adjustment
you have made by closing the QR
lever (Ref Photo C). The lever should
be tight in its closed position and unable to vibrate loose.
If the QR lever was too loose initially
you will need to tighten the nut a 1/4
turn at a time. Test the adjustment
you have made by closing the QR
lever (Ref Photo C). The lever should
be tight in its closed position and unable to vibrate loose.
Photo A
Photo B
Repeat adjustment as necessary
until QR lever is properly tightened.
!
Currie Technologies®
WARNING
If you are unable
to properly adjust the QR lever DO
NOT RIDE THE SCOOTER. Contact
Currie Technologies® Customer
Service at 1-800-377-4532 for further
instructions. Failure to do so may
result in serious injury or death to the
Photo C
rider or severe damage to the scooter.
WARNING
Use only a Currie Authorized Smart Charger to charge
the batteries. Using any other charger may damage the
batteries and void your warranty.
How to Charge the Batteries
1. IMportant: Be sure the
power switch on the scooter
is in the “OFF” position. (Ref
Photo A)
2. Rotate open the charger port
cover (Ref Photo B).
3. Insert the Battery Charger’s
XLR (Male) plug into the CharPhoto A
ger Port (Ref Photo C).
4. Plug the Battery Charger’s AC
plug into a standard, grounded
110V AC outlet.
5. Let the batteries charge until
the charger lights indicate that
the batteries are fully charged,
then unplug the charger from
the scooter and the AC outlet.
Batteries like to have a full charge, so Photo B
always be sure to recharge them fully
after each ride. If you leave them in
a run-down condition, without quickly
recharging them, it will shorten their
life expectancy. The charger may get
warm to the touch, so make sure you
charge them in an open area and
do not lay anything on the charger
unit while charging. Although you
cannot over-charge the batteries
Photo C
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Currie Technologies®
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Battery care and Maintenance
using the Currie “Smart Charger”, we
recommend that you do not leave the
charger plugged in for more than 24
hours.
Changing the Battery Pack
1. Important: Be sure the
power switch on the scooter is
in the “OFF” position.
2. Remove the deck by unscrewing the “D” ring deck retention
screw then lifting the deck off.
(Ref Photo A)
Photo A
3. Remove the battery pack out of
the scooter’s battery tray. (Ref
Photo B)
4. Disconnect the battery power
pack connector (cut zip tie
holding the wire connector, if
necessary) (Ref Photo C)
5. Place the new or fully charged
battery pack into the battery
tray.
6. Reconnect the battery pack
connector and place all of the
cables into the tray.
7. Re-install the deck and secure Photo B
with the “D” ring deck retention
screw.
Not doing any and/or all of the following may lead to reduced performance
and/or permanent damage to the batteries. Batteries that have been damaged by not following the below steps will need to be replaced and are not
covered under warranty.
•
•
•
•
•
Always be sure to fully charge batteries before first use (6-10
hours depending on size).
Always be sure to fully charge batteries after each and every use
(6-10 hours depending on size).
Be sure to charge batteries at least every 30 days.
Do not store batteries below 50º Fahrenheit and never allow batteries to freeze (below 32º Fahrenheit).
Always be sure to turn the scooter “OFF” after each use via the
On/Off power switch.
SLA (Sealed Lead Acid) Battery Conditioning
SLA batteries should always be fully charged (charge time of 6-10 hours
depending on amperage of battery) before first use. This will help obtain
optimum performance.
SLA batteries have a “break-in” cycle consisting of ~ three discharge/charge
cycles before they will reach optimum performance. This involves three
complete discharges and three complete recharges (charge time of 6-10
hours depending on amperage of battery and strength of the charger). After
this initial “break-in” cycle the batteries will have increased performance and
less line voltage fluctuations under load, as indicated by the throttle LED’s.
FUSE
In the event of an overload the fuse will pop and need to be replaced. In this
instance replace only with approved part from Currie Technologies®.
!
WARNING
Risk of fire, Do not bypass fuse.
Photo C
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Currie Technologies®
Throttle and Brake Operation & Adjustment
Throttle Operation
The speed of the Electro-Drive™
scooter is controlled by a griptwist throttle, which is located on
the handlebar.
To check the throttle operation,
turn the power switch to the
“OFF” position. Fully twist the
throttle then quickly release it.
The throttle is spring loaded and
should immediately spring back to
its original (also know as “Zero Position) position.
To accelerate, twist the right hand throttle grip towards you as you stand
on the deck plate. The more you twist the throttle, the faster the motor will
propel the scooter until you reach the scooter’s top speed.
To go slower, or coast to a slower speed, allow the throttle to spring back to
its original position. To decelerate or come to a complete stop, release the
throttle and allow it to return automatically to its original position. Then squeeze
the brake lever(s) to activate the brake(s). Remember to release the throttle
whenever you apply the brake.
!
!
WARNING
WARNING
The throttle and its components are fully assembled and
tested at the factory. Do not attempt to adjust them at
any time. If you feel the throttle and/or components are in
need of service DO NOT RIDE THE SCOOTER! Contact Currie Technologies® Customer Service number at
1-800-377-4532.
If you do not fully understand how to operate your scooter
throttle properly, DO NOT RIDE YOUR SCOOTER. Contact Currie Technologies Customer Service for information
and instructions at 1-800-377-4532.
How to use the throttle LED’s
When the throttle is engaged (powering the motor) and the scooter is in motion, the LED’s on the throttle indicate instantaneous line voltage as measured at the battery terminals -- and not the available energy in the battery
pack.
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Currie Technologies®
The line voltage will fluctuate depending on the instantaneous load that the
motor is under. For example, when starting out from a dead stop, or going
up a steep hill, the motor will be under a high load and the “Yellow” or even
“Red” LED will illuminate. To a lesser degree, another factor that influences
the load on the motor (and therefore the LED readings) is the gearing of the
motor. Scooters with Direct Drive (DD) gearboxes are geared for slightly
higher top end speeds and therefore have a higher load when starting from
a dead stop versus scooters with belt or chain drive, which have a lower top
end speed. The higher gear ration of the DD scooters will cause the Red LED
to illuminate more often compared to other scooters.
When the throttle is disengaged (i.e. no power to the motor due to the
scooter being stationary or coasting) the LED’s on the throttle will indicate
the voltage of the battery pack. The voltage of the battery pack will rise
when no load is on the motor. The best indication of how much battery life is
remaining is to check the throttle LED’s, after reaching cruising speed, on a
flat straight road as this will allow the battery voltage to stabilize and give a
much more accurate reading.
5 minute sleep mode
Scooters are equipped with a 5 minute sleep mode. If no activity is detected
after 5 minutes the scooter will go into stasis mode to conserve the batteries.
To restart, cycle the power switch Off then On.
!
WARNING
Never store your scooter in Sleep Mode as battery power
will still be used by the scooter. Always be sure to turn the
power switch to the “OFF” position.
Heat shut-down mode
If the controller has over-heated and power to the motor has been shut down,
turn the main power switch “OFF” for at least 30 minutes to allow the controller
to cool down before riding any more. Turn the power switch “ON” and resume
riding.
!
WARNING
The scooter will shut down due to over-heating caused
by excessive stress on the motor (i.e. too steep a hill, too
heavy a rider, etc.).
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Currie Technologies®
Brake Operation
The Electro-Drive™ electric scooter
is equipped with front and/or rear
brakes. It is operated by using the
brake lever on the handlebars and is
designed to provide excellent stopping power for your scooter. Squeeze
the brake lever(s) firmly to bring your
scooter to a safe, controlled stop.
The brake lever itself should never
touch the handlebar or grip when
squeezed firmly. If it does, then immediately STOP RIDING and adjust the
brake cable.
!
WARNING
20
WARNING
Always test your brakes after making any adjustment to
be sure they are operating properly before riding.
If you reach the limit of the cable adjustments described
above and you are still experiencing poor braking
performance, do not continue to ride. Do not attempt
to adjust the cable any further or attempt to adjust
the brake. Take your scooter to a qualified scooter
or bicycle mechanic for proper service, or call Currie
Technologies® Customer Service at: 1-800-377-4532.
Proper brake performance and adjustment is vital to
safe scooter operation. Never ride your scooter unless
your brakes are adjusted and working correctly.
Drive Train Assembly
The Electro-Drive™ electric scooter is equipped with
the patented Currie Technologies® Electro-Drive™
propulsion system, the finest available in today’s
rapidly growing personal electric transportation
market.
Improper adjustment of your brake(s) can cause poor
braking and lead to an accident, serious rider injury or
death.
The Currie Electro-Drive™ features a DC motor with
direct chain drive to the rear wheel, a weather and
dust resistant motor controller, plus rechargeable and
recyclable sealed lead acid batteries that provide
many hours of trouble free riding.
Use the adjusting barrel on the brake
lever to adjust for this cable stretch.
Loosen the adjusting barrel lock nut.
Unscrew the adjusting barrel out of the lever 1 to 2 turns, then re-tighten the
lock nut to secure the adjusting barrel.
WARNING
!
All brakes need periodic adjustment. However, the brake
mechanism itself should be adjusted only by a qualified
service technician. If or when it needs service, take your
scooter to your local bicycle dealer or to the retailer who
sold you the scooter.
Brake Cable Adjustment
If your brake cable stretches (as is
common with new cables do during
the initial “breaking-in” period), your
brake lever will require a longer “pull”
to engage the brake and may even
touch the handlebar when squeezed.
!
Currie Technologies®
Do not allow the adjusting barrel to unscrew more than
5 full rotations out of the brake lever.
OM Chain Drive Scooters - 2012.indd
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The Electro-Drive™ motor and drive train system
comes fully assembled and “ready-to-ride” from the
factory.
Drive train on the 300,
4.0 and 400 series
scooters
IMPORTANT: All Electro-Drive™ motors, throttles and
the controllers are factory sealed units and are not
user serviceable. Do not open or tamper with any of
the factory sealed units; doing so may result in electric
shock or injury and will render them inoperable.
For answers to service questions regarding the
Drive train on the
Electro-Drive™ drive train, please contact your local
500CD, 650CD, 750CD
dealer, or call Currie Technologies® Customer Service
and 900CD series
at: 1-800-377-4532.
scooters
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21
Currie Technologies®
Currie Technologies®
chain adjustment
watching the chain. Be sure that the rear wheel is turning smoothly
and the chain does not try to run off the rear sprocket in either direction.
7. Test the brake adjustment to be sure it is operating properly and make
any necessary adjustments.
The chain can stretch during use or may occasionally come out of adjustment. Regular attention to proper chain tension and lubrication will minimize
the risk of the chain falling off the rear sprocket and help your scooter maintain optimum performance.
Properly adjusted, the chain should have 5-6mm (1/4”) of up-and-down travel
or slack.
WARNING
!
Currie
Technologies®
strongly recommends that any chain
tension adjustment be performed by a
trained scooter or bicycle mechanic.
500CD, 650CD, 750CD and 900CD
series scooters
Adjusting the chain tension is performed
by moving the motor back and forth within
the motor plate.
1. Loosen the three 5mm Allen bolts
that hold the motor and motor
guard to the motor plate. (Ref Photos A, B, C)
2. Twist the motor (counter-clockwise
to tighten the chain, clockwise to
Photo A
loosen the chain) to adjust the
chain. Please note that a slight rotation of the motor will dramatically
effect the chain tension.
3. When proper chain tension of
5-6mm (about 1/4”) of up and down
movement is achieved tighten the
three 5mm motor bolts.
300, 4.0 and 400
series scooters
Adjusting the chain tension is performed by moving the rear wheel back
Photo A
and forth in the frame.
1. Loosen the rear axle nuts us-
2.
3.
4.
5.
6.
22
ing a 15mm wrench but do not
remove. (Ref. Photo A)
Loosen the band brake arm
fixing bolt, using a 5mm hex
key wrench and an 8mm box
wrench, but do not remove.
(Ref Photo B).
Adjust the belt tensioners (Ref
Photo C) on both sides of the
Photo B
frame equally to keep the rear
wheel properly centered in the
frame and so that the chain has
5-6mm (about 1/4”) of up and
down movement.
Tighten the brake arm fixing
bolt.
Tighten both axle nuts.
Test the chain adjustment by
rotating the rear wheel forward
by hand a few revolutions while Photo C
OM Chain Drive Scooters - 2012.indd
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!
WARNING
Do not ride the
scooter in order to check the chain
adjustment. It is far easier and safer to
check the chain adjustment as described
above. If the chain does run off the rear
sprocket during the test, then further
adjustments are necessary.
Photo B
Note on chain Lubrication: To
help maintain both the performance and
longevity of the chain, be sure to lubricate it at least once a month using any
quality bicycle chain lube. While lubricating the chain take time to inspect it for
any damage and for proper chain tension. Photo C
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23
Currie Technologies®
Currie Technologies®
Wheel Removal
Rear Wheel & Drive Assembly
Removal
300, 4.0, 400, 500CD, 650CD, 750CD
and 900CD series scooters
1. Detach the V-Brake, if your
scooter was so equipped, (Ref
Photo A) by removing the brake
noodle (silver tube) from the
brake arm.
2. Loosen the axle nuts. (Ref
Photo B)
3. Remove the safety washers
Photo A
from the dropouts. (Ref Photo
C)
4. Remove the front wheel from
the forks.
300, 4.0 and 400
series scooters
1. Turn the power switch to the
“OFF” position.
2. Remove seat tube from the
frame.
3. Remove both the deck and rear Photo A
fender from the frame.
4. Remove chain guard. (Ref Photos A, B)
5. Disconnect the brake cable
from the band brake actuator
arm by removing the 10mm nut
and washer (Ref Photo C) from
the cable pinch bolt. The brake
cable has an end cap which will
keep the pinch bolt and spring Photo B
from coming completely off the
cable. Do not remove it.
6. Remove the band brake fixing
bolt using a 4mm hex key
wrench (or Phillips screwdriver)
and an 8mm wrench (Ref Photo
D). This bolt also holds the rear
cable hanger in place.
Front Wheel Removal
!
WARNING
Be sure the
scooter does
not fall over and
cause damage to
itself or to you!
Photo B
Photo C
Photo C
Photo D
24
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25
Currie Technologies®
Currie Technologies®
7. Loosen and remove both 15mm
6. Set the motor into the empty
axle nuts. (Ref Photo E)
8. Loosen and remove both 10mm
chain tensioners. (Ref Photo F)
9. Push the wheel all the way forward in the frame to allow you
to remove the chain from the
motor sprocket.
10. The rear wheel along with
sprocket, chain, band brake
Photo E
assembly and the rear half of
the chain guard can now be
removed from the rear of the
frame.
battery tray.
7. Loosen and remove both axle
nuts with a 15mm wrench (Ref
Photo B).
8. Loosen and remove the two
5mm motor plate fixing bolts.
(Ref Photo C, D)
9. The rear wheel with the sprocket, chain and motor plate can
now be removed from the rear
of the frame.
Photo B
Photo F
Rear Wheel & Drive Assembly
Removal
500CD, 650CD, 750CD and 900CD
series scooters
1. Turn the power switch to the
“OFF” position.
2. Remove seat tube from the
frame.
3. Remove both the deck and rear
fender from the frame.
4. Remove and disconnect the
battery pack.
5. Remove the motor from the
motor plate by remove the three
Photo A
5mm bolts (Ref Photo A). Set
the bolts and T-nuts aside for
now.
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Photo C
Photo D
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27
Currie Technologies®
Wheel Installation
Rear Wheel Installation
Front Wheel Installation:
300, 4.0 and 400 series scooters
300, 4.0, 400, 500CD, 650CD, 750CD
and 900CD series scooters
If your scooter is equipped with a
V-Brake you will need to disengage it
prior to installing the front wheel.
Currie Technologies®
The order of this installation is very important. Start with the chain pushed
over the frame so it can be placed on the large sprocket after the wheel is in
place.
1. If your scooter has a rear brake install it on the left side axle. Be sure
Photo A
Do so by squeezing both of the brake
arms together and unhooking the
brake noodle.
2.
3.
4.
1. Place the front wheel into the
5.
2.
3.
4.
5.
6.
forks being sure the axle is fully
seated into the dropouts.
Install the safety washers into
the dropouts. (Ref Photo A)
Photo B
Install the axle nuts. (Ref Photo
B)
Check to ensure the wheel is
centered in the fork. (Ref Photo
C)
Tighten the axle nuts. (Ref
Photo D)
Reattach the V-Brake if your
scooter was so equipped.
6.
7.
8.
Photo C
9.
Photo D
28
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the chain is mounted on the large sprocket on the right side of the hub.
Push the wheel with the larger chain guard all the way forward in the frame.
Work the chain onto the small drive sprocket on the motor.
When the chain is in place on both sprockets, pull the wheel back in
the frame until the chain slack is completely removed.
Install the left and right side chain tension adjusters and the axle
nuts, but do not tighten completely at this time. Chain tensioners are
mounted on the outside of the frame.
Adjust the chain tensioners for proper chain tension (5-6mm or about
1/4” slack), then install the smaller chain guard on the right side of the
frame, over the motor gear and chain with its fixing screw.
If your scooter has a rear band brake attach it and the brake cable
hanger by inserting the 4mm Allen bolt through the frame. Mount the
band brake arm on the bolt first, then the rear cable hanger. Hold the
nut using an 8mm wrench and tighten the bolt with a 4mm Allen key
(or Phillips screwdriver), and completely tighten both right and left axle
nuts at this time.
If your scooter has a rear band brake attach the brake cable by first
making sure the brake cable is inserted through the adjusting barrel
on the rear cable hanger. Then slide the spring over the brake wire.
Thread the brake cable through the hole in the cable pinch bolt. Next
insert the pinch bolt (with cable) through the brake actuator arm, starting from the back side of the arm so that the nut can be tightened from
the outside. Place the washer over the pinch bolt and install the nut.
Hand tighten the nut only at this point.
If your scooter has a rear band brake adjust the brake cable by pulling
and holding it taut with pliers through the pinch bolt, push the brake
actuator arm forward along the wire and then tighten the cable pinch
bolt using a 10mm wrench. Immediately test the brake cable adjustment by squeezing the brake lever. When the brake is fully applied it
should not touch the handlebar, and the wheel should spin freely when
you release the brake lever. It may take you 2 or 3 attempts to make
this adjustment.
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29
Currie Technologies®
WARNING
!
Proper braking performance is critical for safe riding.
®
Currie Technologies strongly recommends that brake(s) be adjusted only by
a trained scooter or bicycle technician.
WARNING
!
Do not ride the scooter in order to test the brake(s); it’s
easier and far safer to test the brake(s) as described above.
Rear Wheel Installation
500CD, 650CD, 750CD and 900CD series scooters
The order of this installation is very important. Start with the chain pushed
over the frame so it can be placed on the large sprocket after the wheel is in
place.
1. Be sure the chain is between the wheel and rear sprocket.
2. Install the rear wheel, large sprocket and motor plate assembly into
the dropouts.
3. Install the kickstand onto the left side axle.
4. Install retention washers both sides of the axle and loosely secure
with axle nuts.
5. Align the motor plate threaded holes to the frame tabs. Loosely secure with the 5mm motor plate bolts.
6. Fully tighten both axle nuts at this time.
7. Fully tighten both motor plate mounting bolts at this time.
8. Install the motor onto the motor plate. Start by loosely securing the
motor with the top motor mounting bolt.
9. Pivot the motor clockwise in order to install the chain onto both the
large and small sprockets.
10. Pivot the motor counter-clockwise and loosely secure the motor with
the lower two motor mounting bolts and T-nuts.
11. Adjust for proper chain and fully tighten all remaining bolts.
Currie Technologies®
Flat Tire Repair
Front Wheel
4.0 and 400 series scooters
1. To remove the front wheel refer
to page 24 then proceed to step
2.
2. With two 17mm wrenches loosen the lock nuts on both sides
of the axle. (Ref Photo A)
3. Remove one of the lock nuts
Photo A
and axle spacers. Remove the
axle from the wheel.
4. With a 5mm hex key wrench
remove all three bolts that hold
the two halves of the wheel
together. (Ref Photo B)
5. Separate the rim halves to
remove the tire and tube. (Ref
Photo C)
6. Remove tube from tire.
7. Slightly inflate the tube in order Photo B
to inspect for leaks or punctures. Patch or replace the tube
as necessary.
8. Carefully check the inside of
the tire and remove any sharp
objects or debris that caused
the puncture. If the tire is cut
through in any place replace it
9. To reassemble the front wheel,
Photo C
first slightly inflate the tube
to allow it to take shape, then
install into the tire.
10. Place the valve at the notch
(Ref Photo D) in one half of the
rim. Be sure to align the valve
and valve notches at the center
of the rim to insure proper assembly. Be sure to point the
valve away from the brake disc
Photo D
30
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31
Currie Technologies®
(if your scooter is equipped).
11. Slide the axle through one half of the rim, and place the center (longer) axle sleeve over the axle at the center of the two rim halves.
12. Bolt the two halves of the rim together with the 5mm Allen bolts.
13. Place the remaining axle sleeve and 17mm nut over the end of the
axle. Center the axle by hand, then tighten both 17mm nuts against
each other.
14. Inflate the tire slowly to the recommended tire pressure. Inspect the
tire during inflation to ensure it is seating onto the rim properly.
Currie Technologies®
7. To reassemble the front wheel, first slightly inflate the tube to allow it
to take shape then install into the tire.
8. Insert the valve thru the hole in the rim.
9. Push (by hand only) one side of the tire and tube all the way over and
onto the rim.
10. With a bicycle tire lever seat the other side of the tire onto the rim. Be
sure not the pinch (tube puncture caused by being caught between the
tire and rim) the tube.
11. Inflate the tire slowly to the recommended tire pressure. Inspect the
tire during inflation to ensure it is seating onto the rim properly.
Front and Rear Wheel
500CD, 650CD, 750CD and 900CD
series scooters
WARNING Do not use a flat
screwdriver or other sharp metal tool
to remove the tire from the rim as this
may cause damage to the rim, inner
tube and/or tire.
!
1. To remove the front wheel refer
2.
3.
4.
5.
6.
Photo A
to page 24 then proceed to step
3.
To remove the rear wheel refer
to pages 26-27 then proceed to
step 3.
With a bicycle tire lever unseat
one side of the tire from the rim.
(Ref Photo A, B, C)
Remove the tube from the tire.
Slightly inflate the tube in order Photo B
to inspect for leaks or punctures. Patch or replace the tube
as necessary.
Carefully check the inside of
the tire and remove any sharp
objects or debris that caused
the puncture. If the tire is cut
through in any place replace it
Photo C
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33
Currie Technologies®
Currie Technologies®
on the sidewall of the tire. Inflate to recommended pressure as necessary.
Section 5 - Faqs
• How far with the Electro-Drive™ scooter go on a full
charge?
Maximum range per charge for the 300 and 4.0 series scooters is 7
miles (11 km), 400 and 500CD series scooters is 8 miles (13 km) and the
650CD, 750CD and 900CD series scooters is 12 miles (19 km).
Note: Range per charge of the scooter depend on many variables, including but not limited to: riding conditions, rider weight, battery charge, etc.
Riding at full speed will dramatically reduce your range.
• What is the top speed of the scooter?
Your Electro-Drive™ scooter will accelerate up to 12 mph (20 km/h) for
the 300 and 4.0 series scooters and up to 15 mph (24 km/h) for the 400,
500CD, 650CD, 750CD and 900CD series scooters.
Note: Top speed of the scooter depend on many variables, including but
not limited to: riding conditions, rider weight, battery charge, etc.
• What is the weight limit of my scooter?
Maximum rider weight is 180 lbs, (82 kg) for the 300 and 4.0 series scooters, 240 lbs. (109 kg) for the 400 and 500CD series scooters and 260 lbs.
(118 kg) for the 650CD, 750CD and 900CD series scooters; never exceed
it.
• Can I ride my scooter in wet conditions or on wet pavement?
You might be surprised to hear that you can ride any Currie electric scooter
in pretty much the same conditions you would expect to ride a normal
bicycle or scooter. In fact as long as you don’t submerge the electrical
components you’ll be fine. This means avoiding deep puddles or streams,
that would cause the electrical components to be under water. All of our
electric scooters are designed to operate normally if they get wet. There
is no need to worry about electrocutions or shocks from riding in the rain.
Of course you must take special precautions when riding in wet weather
as braking distances will be greater and handling on slippery surfaces
compromised, as will visibility.
!
WARNING
Never inflate a tire beyond the maximum pressure imprinted on the sidewall
• How often should I recharge the batteries?
Recharge your batteries immediately after every ride. Your scooter will
perform best when the batteries are fully charged. To help prolong battery
life be sure they are fully charged before you store the scooter for any
extended period of time and that the batteries are charged at least every
90 days.
• How long should my batteries last?
With proper care, batteries can last up to 200 charges or approximately 6
months.
• How long should it take to charge a fully discharged
battery?
Up to 6-10 hours (depending on battery size) using the Currie charger supplied with the scooter.
Note: Charge time is based on new batteries charged with a standard
charger.
• Where can I purchase additional or replacement parts,
if needed, such as batteries, wheels or a faster charger?
Parts can be purchased directly from Currie Technologies® by calling
1-800-377-4532.
* Keep a copy of your purchase receipt on hand and available in case you
should need utilize the limited warranty. We recommend you attach a copy of
your receipt to this manual and store both in a safe and secure location.
• What is the correct air pressure for the tires?
For scooters equipped with a solid tire(s) inflating the tires is not necessary.
For scooters equipped with pneumatic tires check tire pressure imprinted
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35
Currie Technologies®
Section 6 - pre-ride checklist
It is recommended that you perform each of these checks before each and every ride.
TIRES
□□
□□
□□
□□
Check tires for any cuts or unusual wear.
Check tire pressure and inflate to the pressure recommended on the sidewall.
HANDLEBARS and FRAME
Inspect for bent, damaged or cracked welds and tubing caused by aggressive
riding.
Ensure the handlebars are properly aligned and secured tight enough so that you
cannot twist them out of alignment.
NUTS and BOLTS
□□
□□
Inspect and tighten all fasteners before each and every ride.
If unsure on how to inspect and tighten fasteners, seek advice from an authorized
and experienced mechanic.
BRAKES
□□
□□
□□
□□
□□
obvious wear.
Ensure brake control lever(s) are not binding and the clamps are tightly secured to
the handlebar.
Squeeze the brake lever(s) to make sure that it does not bottom out on the handlebar and the brake(s) holds the scooter from being pushed forward.
Squeeze the brake lever(s) to ensure the brake inhibitor(s) stop the motor.
NOTE: This equipment has been tested and found to comply with the
limits for a Class B digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against harmful
interference in a residential installation. This equipment generates, uses
and can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will
not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by
turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
* Reorient or relocate the receiving antenna.
* Increase the separation between the equipment and receiver.
* Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
* Consult the dealer or an experienced radio/TV technician for help.
Ensure brake shoe pads are not worn out and are correctly positioned.
Be sure the batteries are fully charged by using the battery gauge (colored LED’s)
on the throttle.
Ensure your battery pack is properly installed in your scooter with the deck plate
attached and secured.
Ensure the accelerator are secure, in good condition and working properly.
NOTES:_______________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
RIDING GEAR
□□
□□
□□
□□
FCC instructions
Warning: Changes or modifications to the charger not expressly approved
by the party responsible for compliance could void the user’s authority to
operate the equipment.
Ensure brake control cable(s) are lubricated, correctly adjusted and display no
ELECTRICAL SYSTEM
□□
□□
□□
Currie Technologies®
Always wear an approved helmet.
Always wear proper protective equipment such as; eye protection (goggles or face
shield), gloves, boots, long sleeved shirt or jacket and long pants.
Never operate this product barefoot or in sandals as this increases the risk of
injury.
Always obey all local traffic laws
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
___________________________________________________________
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OM Chain Drive Scooters - 2012.indd
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OM eZip Chain Drive Scooters 2010 rev-1
37