Cruza XR500 User manual

XR500 Electric Scooter
User Manual
Revised 01/12/12
PLEASE BE SAFE WHEN RIDING
ALWAYS WEAR A HELMET AND OBEY ALL LAWS!
The XR500 does not conform to South African Motor Vehicle Standards and is not
intended for operation on public streets, roads or highways. Serious injury can result
from the unsafe operations of the XR500 scooter. The operator can minimize these risks
by using certain safety equipment such as: safety helmet, goggles, gloves, elbow and
kneepads and appropriate footwear.
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DO NOT operate the XR500 in traffic, on wet, frozen, oily or unpaved surfaces or
under the influence of drugs and/or alcohol. Avoid uneven surfaces, potholes,
surface cracks and obstacles.
DO NOT use a water hose to clean the XR500.
This product is recommended for riders 13 YEARS OF AGE and older.
Persons without excellent vision, balance, coordination, reflex, muscle and bone
strength and good decision-making capabilities should not use this product.
Minors should not use this product without adult supervision.
Persons unwilling or unable to take responsibility for their own actions should not
use this product.
The user of the XR500 assumes all risks associated with its use. To minimize these
risks, the user must wear safety helmet, goggles, gloves, elbow and kneepads and
appropriate footwear.
This product is ELECTRIC! DO NOT ride this product in wet conditions, puddles or
rainy weather.
Opening the scooter or performing any maintenance may expose the user to
electric shock and is done at the user’s own risk.
To avoid damage to the motor and controller, do not overload the scooter.
Never ride with more than one person.
Turn the scooter off when not in use.
To avoid damage to the batteries, use only the recommended charger and do not
use a charge if it is damaged in any way.
Do not place the batteries near heat or an open flame.
Keep hands, face, feet and hair away from all moving parts.
Do not touch the motor or wheels while they are rotating.
Practice braking for proper slowing and smooth stops.
Maintain your scooter as recommended in this user manual.
Use only quality replacement parts as recommended by the manufacturer.
Inspect the scooter prior to use – replace any part that is cracked, chipped or
damaged in any way before use.
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Quick Start
Page
3
– General scooter do’s and don’ts
4
– Getting to know your XR500
5
– Package Contents & Assembly
6
– Assembly Cont. - Front Wheel & Fuses
7
– Assembly Cont. – Seat Post & Charging
8
– Riding Your Scooter
8
– Braking System
9
– Braking System Cont. & Tyres/Wheels
10 – Maintenance – Adjusting the handlebar bearings
11 – Adjusting the chain
12 – Caring for the batteries
12 – Maintenance Schedule and other information
13 – Troubleshooting Guide
General Scooter Do’s and Don’ts
Don’t:
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Leave your scooter with a flat battery for long periods of time.
Push-ride your scooter while it is switched on.
Ride your scooter when the battery is flat.
Expose your scooter and it’s components to water.
Ride your scooter if its tires are flat.
Ride your scooter on any public roads.
Do:
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Keep your scooter clean, and moving parts lubricated.
Leave your scooter off in a safe place away from small children.
Keep the battery fully charged – you can’t over-charge the batteries.
Always ride with a helmet.
Ride in spacious areas away from obstacles or water.
Have fun while riding your scooter!
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GETTING TO KNOW YOUR CRUZA XR500
4
PACKAGE CONTENTS
Your Cruza XR500 comes with the following items in the box. Please locate
all of the following:
1.
2.
3.
4.
5.
6.
The Cruza XR500 Scooter
36V Battery Charger
Tool Kit
20amp Fuse(s)
Product Handbook
Seat & Seat Post
GETTING STARTED
Please read and understand these instructions and the OPERATING
PROCEDURES section, prior to starting or riding your XR500
Assembly
1. Carefully remove the XR500 from the box.
2.
To unfold the XR500, begin by pressing
down on the FOLDING HANDLE with one
hand (Fig.1), while gently pulling up on the
handlebars with the other (Fig.2)
3. Fully extend the handlebars to their upright
position until you feel the mechanism lock
into place (Fig. 3).
4. Attach the handlebars by first attaching the
large handlebar clamp to the top of the
handlebar down tube. Then attach the
handlebars to the clamp. Tighten all bolts
after adjusting the handlebars to the
desired tilted position. (Fig. 4)
5. The BRAKE LEVER is in the down position
for shipping. Using the provided Allen
Wrench, loosen the tension bolt, and adjust
the levers to a comfortable position.
* Be careful not to pull on the cables!
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Front Wheeel Assembly
Using a 17 or shifting spanner, remove the nut from one side of the axle. Remove the axle and
both spacers. The shorter of the two spacers fits next to the brake disc. For the easiest fit,
insert the axle partially into the fork with the brake caliper. Slide on the shorter of the two
spacers. Next, place the wheel up between the forks and slide the axle into the wheel. The
brake caliper can be moved around to get the disc between the two brake pads. Once the
wheel is in position, slide the axle through to the other side of the wheel. Hold the longer of the
two spacers in position between the hole of the wheel and the hole of the fork and slide
through until the the nut can be attached. ** This is made slightly easier by holding the wheel
skew to get the spacer between the two front forks.
Fuses
Revised model XR500 scooters will be fitted with a 30A Blade fuse that is located inside
the scooter. The fuse can be accessed by removing the deck from the scooter. Consult the
troubleshooting guide / contact the supplier before attempting to open the scooter or
replace the fuse.
The majority of pre-2013 XR500 scooters will be fitted with a 30A glass tube fuse that is
located in the fuse holder beside the charging socket. Unscrew the cap to gain access to
the fuse. Consult the troubleshooting guide / contact the supplier before attempting to
replace the fuse.
The scooter should be lifted off of the ground / placed on its side before repla cing the fuse
or making repairs.
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Seat and Seat Post Installation
1.
2.
3.
Place the seat onto the seat post and tighten the nut on the underside of the seat.
Ensure that the front of the seat is aligned with the brass button at the bottom of the
seat post.
Insert the seat post into the bottom of the seat and tighten securely.
Next, insert the seat post into the post receiver that is already attached to the
footplate on the scooter and tighten the clamp securely.
Charging
Your scooter comes charged out of the carton. We still recommend charging the unit for
6-8 hours prior to its first use. We also recommend charging your scooter after each use
and prior to storage.
WARNING: Do not allow your scooter to batteries to run completely flat, as this will
damage the batteries.
1. Make sure unit is turned off.
2. Open the charging socket cover
located on the right side of the
scooter frame, under the footplate.
(Fig. 5)
3. Locate your Battery Charger. (Fig.
6) Find the charger socket end
that has a three-prong socket and
plug it into the scooter.
4. Next, plug the AC plug into a wall
outlet.
Fig. 5
When first plugged in, the charger has two
red lights that will illuminate at the same
time, indicating that the charging process
has started. Once the light on the charger
turns green, you may remove the charger
and close the safety cap.
Fig. 6
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Riding
1.
Make sure that all of the exposed bolts and screws are
tightened.
2. Raise the kickstand to its upright position.
3.
Push the on/off switch (located on the left handlebar) to the ON
position.
4. Put one foot on the deck of the XR500 while pushing off with the other foot; gently
rotate the THROTTLE GRIP, on the right side of the handlebars. The XR500 will
begin to move on its own power.
**Your scooter has a variable speed hand throttle. You can control the speed of your
scooter by the amount of pressure you use when rotating the hand throttle. The more
you rotate, the faster you will go.
Stopping/Braking
1.
To brake, release the THROTTLE GRIP and depress the BRAKE LEVERS (on
the left/right side of the handlebars. Depressing the brake will disengage power to
the motor. When the unit feels like it is losing power or not accelerating to full
speed, the scooter is ready to be re-charged.
Folding & Storage
When you are done riding the XR500 you can fold it down for compact storage and
transportation. To fold down the XR500, use one hand to push down on the folding
handle while gently pushing down on the handlebars. BE CAREFUL NOT TO HIT
YOUR HEAD WITH THE HANDLEBAR. Push down until you feel the mechanism lock
into the down position.
BRAKING SYSTEM
The XR500 uses a pinch braking system for the front, and a disc/caliper system
for the rear. They are both activated by a hand brake lever on the left and right
side of the handlebar. Squeezing the hand brake lever with your left hand
activates the rear brake. Squeezing the hand brake lever with your right hand
activates the front brake. Make sure to release the HAND THROTTLE GRIP
when engaging the brakes.
Practice braking on a smooth, dry surface to get used to the feel of the braking
system. Braking distance is affected by wet conditions and loose and uneven
riding surfaces.
Adjusting the Brakes
The Brakes on the XR500 should come fully adjusted from the factory.
However, it may be necessary to adjust the brakes from time to time.
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To adjust the rear brakes:
1. With one hand, depress the brake
caliper using your thumb and
forefinger (Fig.12).
2. With the other hand, adjust the
tension screw on the brake line.
a. Turn the
tension screw
clockwise to loosen the brake.
b. Turn the
tension screw
counterclockwise to tighten
brake.
Fig. 12
To adjust the front brakes:
For brakes that are adjusted too tight:
1. Loosen the tension screw on the
right hand brake lever by rotating it
counter-clockwise until the wheel
spins freely.
For brakes that are adjusted too loose:
1. Tighten the tension screw on the
right hand brake lever by rotating it
clockwise until the wheel has a
slight drag.
Fig. 13
For further adjustment:
1. Locate the adjustment screw on the
front brake assembly (located
above the front wheel, Fig. 13)
Tighten or loosen as necessary.
Squeaky Brakes
The brakes may squeak before they are broken in. This is normal and will not
affect the function or performance of the brakes. With continued use the
squeak should go away.
TIRES
AND WHEELS
The Cruza XR500 uses a similar rim and tire assembly on the front and rear
wheels, which means that the tires can be rotated. The wheels are actually
two wheel halves (split rim) bolted together to make it easier to remove and
replace the tire and tube.
The rear wheel is fitted with a special spacer to accommodate the chain
sprocket, while the front wheel has a bracket for the disc brake.
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Tire wear will differ based on rider weight, riding conditions and care.
Replacement tires can be obtained at your local Cruza dealer, through
motorcycle shops, or from the Cruza website at www.SAscootershop.co.za.
Tire Pressure
The tire must be inflated to a maximum of 32 P.S.I. It is also recommended to
use a tube additive like ‘slime’ available from any motorcycle shop, to avoid
inconvenient punctures.
Empty all air from the tire, prior to loosening the bolts to split the rim.
MAINTENANCE
RECOMMENDED TOOLS
To adjust and service the Cruza XR500 you will need the following tools:
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Allen Wrenches: 3/4/5/6 mm
Wrenches: 10/13/13 mm Open end wrench
Large Adjustable Crescent Wrench
Philips Head Screwdrivers
Oil, Grease or generic lubricant
ADJUSTING THE
HANDLEBAR BEARINGS
There are two headset bearings that hold the handlebars in place against the frame.
These bearings have a tendency to work loose due to the vibration caused by riding. You
will need an adjustable spanner for this easy fix.
The top bearing should be relatively firm - it shouldn't spin easily when turned by hand.
The bottom bearing and lock nut is the part you will be adjusting.
To adjust the handlebars:
1. Rotate the handle bar as far right as it will
go to expose the HEAD UNIT. (See fig
left)
2. Using a large adjustable wrench, gently
turn the ‘Adjustable Race’ clockwise to
tighten. Do not over-tighten, as this will
cause damage to the bearing.
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3. After tightening the ‘Adjustable Race’, you will
need to tighten the locknut below to hold the
components in place.
4. Once the bearings have been successfully
Tightened, the handlebars should no longer
shake or rock back and forth, and the
handlebars should turn freely.
ADJUSTING THE CHAIN
The chain will come adjusted from the factory. However, it may be necessary
to adjust the chain from time to time. The chain must be well aligned onto the
sprockets in order to avoid uneven wear. This will result in shortened chain
life.
How tight should the chain be?
If the chain is skipping or jumping on the sprockets, this is too
loose and may be harmful.
If the chain is making a humming sound when the wheel is
turning, this is too tight and may cause the chain to snap.
The correct tension is achieved by adjusting the chain from its
loose position to when it becomes lightly tense.
To tighten the chain:
Slightly loosen the two axle bolts on both
sides of the rear wheel. (Fig.14). Then slowly
adjust the two adjusting screws on each side
of the rear tire (Fig.15) until chain reaches the
proper tension.
Rotate the rear wheel to make sure
the chain is aligned.
Finally, lock and tighten the rear
axle bolts prior to riding.
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CARING FOR THE BATTERIES
The XR500 Scooter uses three 12V 12ah sealed lead-acid batteries that are
connected in series. To prolong the life of the batteries, there are a few important
rules to adhere to.
- Keep your batteries charged at all times – batteries like being charged up,
so it is not possible to over-charge them
- Avoid riding your scooter until the batteries are completely flat. Overdraining the batteries can cause permanent damage, and the batteries will
no longer be able to hold a charge.
- Avoid storing your scooter for lengthy periods of time when the batteries
are flat. The batteries need to be charged at least once a month when the
scooter is not in use. If you are planning to store your XR500, make sure
the batteries have been fully charged first.
- Water and heat exposure will cause permanent damage to the batteries, as
well as the rest of the scooter – so these elements are best avoided.
MAINTENANCE SCHEDULE
Proper care of your Cruza XR500 will ensure optimal performance and longer
Life-span. The following are a few maintenance suggestions that will keep your
Cruza
XR500 running in top condition:
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Daily Maintenance
Perform each time you ride your XR500
Clean the exterior of the unit with a soft, damp rag.
Check that all nuts and bolts are securely tightened.
Lubricate the chain with any silicone spray, 3&1 oil or any
good clean motor oil.
Check battery charger for any frayed/cut wires.
OTHER QUESTIONS
For additional questions, service instructions, further information and
important phone numbers; please go to the Cruza website at
www.SAscootershop.co.za
Thank you for purchasing a Cruza XR500 and please tell your friends how
much fun you’re having on your scooter
12
Troubleshooting Guide
* The diagram below should be used as a reference only. Any repairs attempted are
done at the user’s own risk.
For spare parts and accessories contact SA Scooter Shop at
www.sascootershop.co.za
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