Transcript
X-Treme TM Electric Scooters
XG-550 Gas Scooter
Owner’s Manual
PLEASE BE SAFE WHEN RIDING ALWAYS WEAR A HELMET AND OBEY ALL LAWS! Page1
IMPORTANT T ENGINE THIS IS A 2-CYCLE IT REQUIRES A MIXTURE OF GAS AND 2-STROKE ENGINE OIL 1. You must always use a gas oil mixture. FAILURE TO DO SO WILL VOID YOUR WARRANTY! 2. Use 32:1 Gas/Oil Mixture. Combine 4oz of oil for every gallon of High-Octane Gasoline. 3. Tanaka Perfect Mix, or similar quality 2-Cycle Engine Oil recommended. Oil can be purchased from your local X-Treme Dealer, Outdoor Power Equipment Dealer or Power Sports Dealer. 4. High-Octane Fuel Recommended. (90 octane or higher) Failure to follow these INSTRUCTIONS will VOID YOUR WARRANTY! This PRODUCT IS NOT INTENDED FOR EXTREME or OFF-ROAD Use! Please take care of your XG-550 DO NOT JUMP or ABUSE THIS PRODUCT! DO NOT RIDE IN WET/ICY CONDITIONS!
Failure to follow these instructions properly or abusing your scooter will VOID YOUR WARRANTY!
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IMPORTANT PLEASE READ BEFORE USING THIS PRODUCT
READ THIS FIRST!
WARNING This product does not conform to Federal Motor Vehicle Standards and is not intended for operation on public streets, roads or highways. Serious injury can result from the unsafe operations of this product. Operator can minimize these risks by using certain safety equipment such as: safety helmet, goggles, gloves, elbow and kneepads and appropriate footwear. DO NOT operate this product 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 this product. See Product Handbook for more information. This product is recommended for riders 16 YEARS OF AGE and older. SAFETY
Persons without excellent vision, balance, coordination, reflex, muscle and bone strength and good decision-making capabilities should not use this product.
Minors without adult supervision should not use this product.
Persons unwilling or unable to take responsibility for their own actions should not use this product.
The user of this product assumes ALL risks associated with its use. To minimize these RISKS, the user must wear appropriate safety gear such as helmet, goggles, gloves, elbow and kneepads and appropriate footwear.
Never start the engine inside a closed room or building. Breathing exhaust fumes can be fatal.
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QUICK REFERENCE SAFETY GUIDE Fuel Safety
Mix and pour fuel outdoors away from sparks or flames. Only use a container approved for fuel Do not smoke or allow smoking near the X-Treme XG-550 while working on the engine, or while the engine is running. Wipe up and clean all fuel spills before starting the engine. Move at least 10 feet away from where you fueled before starting engine. Stop engine before removing the fuel cap. It is recommended that you empty the fuel tank prior to shipping or storage to prevent fuel leaks. Do not store your X-Treme XG-550 near open flames, furnaces, electric motors or switches. Maintenance
Maintain your X-Treme XG-550 as recommended in this Product Handbook. Disconnect the spark plug cap before performing any engine maintenance, except for carburetor adjustments. Keep others away while making carburetor adjustments. Use only quality replacement parts as recommended by the manufacturer.
Transportation and Storage
Carry your X-Treme XG-550 by the handle bar tube with the engine off and the muffler away from your body. Allow the engine to cool, empty the fuel tank and fold the X-Treme XG-550 before carrying or storage. It is recommended that you empty the fuel tank prior to shipping or storage to prevent fuel leaks. Clean the X-Treme XG-550 carefully and store in a cool, dry place.
Product Safety
Keep hands and feet away from moving parts. Inspect the entire product prior to each use. Replace damaged parts. Check for fuel leaks and make sure all fasteners are in place and securely fastened. Replace all parts that are cracked, chipped or damaged before use. Use only parts and accessories that are recommended by the manufacturer.
If a situation arises that is not covered in the manual, proceed with caution and use good judgment. Contact your dealer or X-Treme (www.x-tremescooters.com/support/) if you need further assistance
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TABLE OF CONTENTS IMPORTANT INFORMATION…………………………………….…………………………………….. 2 QUICK REFERENCE…………………………………………………………………………………… 4 TABLE OF CONTENTS……………………………….……………...................................................5-6 GETTING TO KNOW YOUR X-TREME XG-550…………………………………………………….. 7 PACKING CONTENTS…………….……………………………………………………………………. 8 GETTING STARTED………………...……………………………..……………………………………. 8 Unfolding……………………………….………………….….…………………………………… 8 Fuse Installation..……….….…………………………………………………………………….. 8 Fueling..…..………………………………………………………………………………………… 9 Starting…..………………………………………………………………………………………….. 9 Riding/Braking……………………………………………………………………………………… 10 FOLDING AND STORAGE……………..…………………..…………………………………………... 10 OPERATING PROCEDURES…………………………………….……………………………………. 11 MAINTENANCE………………………………………………………………………………………….. 12 Recommended Tools…………………………………….......................................................... 12 Carburetor
Adjustment…………………………….……………………………………………. 12
Brake System………………………………………………………………………………………. 13 Tire And Wheels……………………………………………………………………………………. 14 Adjusting the Head Unit…………….…………………………………………………………….. 15 Adjusting the Chain.……………….……………………………………………………………… 15 MAINTENANCE SCHEDULE………………………………………………………………………….. 16 OTHER QUESTIONS….………………………………………………………………………………… 16 HOW TO INSTRUCTIONS……………………………………………………………………………… 17-25 How To Adjust Chain……………………………………………………………………………… 17 How To Install Handlebars……………………………………………………………………….. 17 How To Install Front Brakes……………………………………………………………………… 17 How To Mount Front Wheel………………………………………………………………………. 17-18 How To Adjust Front Hub Brakes………………………………………………………………… 18 How To Adjust Rear Hub Brakes………………………………………………………………… 18 How To Install Throttle Cable……………………………………………………………………. 18-19 How To Change Electric Start……………………………………………………………………. 19-20 How To Install Fuel Lines………………………………………………………………………… 20 How To Install Engager…………………………………………………………………………... 20 How To Install Pull Starter………………………………………………………………………… 20 How To Install Yellow Start Button………………………………………………………………. 21 How To Remove And Install Transmission…………………………………………………….. 21 How To Remove Engine………………………………………………………………………….. 21 How To Know What Each Battery Connection Wire Is………………………………………… 22 How To Check Restricted Fuel Lines……………………………………………………………. 22 How To Replace A Starter Solenoid……………………………………………………………... 22 How To Remove And Replace Transmission Bell…………………………………………….. 22 How To Install Bearings………………………………………………………………………….. 23 How To Check For Spark…………………………………………………………………………. 23 Page5
How To Adjust Carburetor Air/Fuel Mixture……………………………………………………… 23-24 How To Change Charger Socket………………………………………………………………… 24 How To Remove Free Wheel Clutch……………………………………………………………. 24 How To Change Fuse Holder……………………………………………………………………. 24-25 TROUBLESHOOTING………………………………………………………………………………….. 25-26 Getting Broken Bolts Out………………………………………………………………………… 25 Scooter Won’t Move………………………………………………………………………………. 25 Bad Starter Solenoid……………………………………………………………………………… 26 DIAGRAMS……………………………………………………………………………………………….. 26-30 Front Brake Diagram……………………………………………………………………………… 26 Wiring Diagram……………………………………………………………………………………. 27 Rear Wheel Assembly Diagram………………………………………………………………… 28 Voltage Regulator Diagram……………………………………………………………………… 29 Front Fork Assembly Diagram…………………………………………………………………… 29 Motor Diagram…………………………………………………………………………………….. 30 GENERAL INFORMATION/TECH SUPPORT……………………………………………………….. 31
DO NOT RETURN TO STORE! Do not use this vehicle for the first time until you have inflated the tires to the correct PSI and completely charged the battery.
Failure to follow these instructions may damage your
vehicle and void your warranty. CALL 253-777-0690 OR GO ONLINE www.x-tremescooters.com/support/
For General Information or Parts Visit www.x-tremescooters.com
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GETTING TO KNOW YOUR X-TREME XG-550
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PACKAGE CONTENTS Your X-Treme XG-550 comes with the following items in the box. Please locate all of the following: 1. 2. 3. 4. 5. 6.
X-Treme XG-550 Gas Scooter Tool Kit Product Handbook 10amp Fuse Tire Tube Air Extension Valve (may be inside tool kit) 12V Charger
GETTING STARTED Please read and understand these instructions and the OPERATING PROCEDURES section, prior to starting or riding your Scooter
Unfolding 1. Carefully remove the XG-550 from the box. 2. To unfold the XG-550, 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. When you first take the XG-550 out of the box, the left and right hand brakes are in the down position for shipping. Using the provided Allen Wrench, loosen the tension bolt, and adjust the hand brake levers to a comfortable position (Fig.4). *BE CAREFUL NOT TO PULL ON THE CABLES!
Fuse Installation Your scooter comes with 10amp fuse that is NOT installed at the factory. Follow the instructions below to properly install the fuse before attempting to use your scooter. 1. Locate the 10-amp glass fuse that came with your scooter. 2. Locate the fuse holder on the right side of the scooter frame under the footplate. 3. Remove the fuse holder cap and insert the fuse into the cap first. Then insert fuse/cap into fuse holder and gently tighten. DO NOT OVER TIGHTEN THE CAP. Page8
Fueling This is a two-stroke engine. Only run the engine using a mixture of gasoline and 2-cycle engine oil. PLEASE READ OPERATING PROCEDURES BEFORE FUELING! 5. Mix fuel (minimum 90 octane) and 2-cycle engine oil in separate container. Use Tanaka Perfect Mix or a quality 32:1 mixed by shaking the container. 6. Make sure that the engine is off! 7. Slowly open the GAS CAP, so that possible over-pressure disappears. 8. Clean the tank cap area to make sure that it is free from excess dirt and debris. *Make sure that no dirt falls into the gas tank. 9. Pour pre-mixed Gas/Oil mixture into the GAS TANK. *Do not overfill. 10. After fueling, replace the GAS CAP and tighten. Starting – Electric Push Start To operate electric start, squeeze the left brake handle and push the yellow starting button located on the right side handle throttle assembly. (battery must be fully charged for this feature) Starting – Pull Start Move at least 10 feet away from where you filled up the gas. 11. Set the CHOKE LEVER to the CHOKED (UP) position (Fig.5). 12. Pull the RECOIL STARTER briskly, making sure to hold the handle in your grasp. (Fig.6). *Note: Do not allow it to snap back, let it back slowly, You may want to give it a little throttle by gently squeezing the GAS LEVER. 13. It may be necessary to repeat step 12 several times until the motor starts When starting the XG-550 for the first time, it may be necessary to pull the starter handle multiple times until it starts. *This is because the gas needs to be drawn into the carburetor.
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14. Once the engine has started, quickly move the CHOKE LEVER into the RUN (DOWN) position. (Fig.5) 15. After engine is started, let it warm up for 2-3 minutes before riding Riding 16. Make sure that all of the exposed bolts and screws are tightened. 17. Raise the kickstand to its upright position. 18. Make sure the engine is running. 19. Put one foot on the deck of the XG-550. While pushing off with the other foot, gently rotate the THROTTLE toward the rider, on the right side of the handlebars. The XG-550 will begin to move on its own power. 20. Control the speed by rotating the hand throttle either towards the rider or away.
IF THE MOTOR KEEPS STALLING AT IDLE SPEED, IT MAY BE NECESSARY TO ADJUST THE IDLE SPEED ON THE CARBURETOR. Please refer to Carburetor Adjustment in the Maintenance section on page 12 for instructions on how to adjust idle speed.
Braking 21. To brake, release the hand throttle and depress the hand brake levers (on the left/right side of the handlebars). (Fig.7) Stopping/Shutting down 22. Gradually decrease the engine speed to idle and press the kill switch button on the handlebar tube. (Fig.8) This will turn the engine OFF.
FOLDING AND STORAGE When you are done riding the XG-550 you can fold it down for compact storage and transportation. To fold down the XG-550, use one hand to push down on the folding handle while also 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. *NOTE: If the lever is pulled aggressively, the locking spring may become stretched and then the steering will not lock into position, it is also advisable to ensure the handlebar locks firmly, prior to riding. You can now carry the XG-550 by the handlebar tube.
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OPERATING PROCEDURES Mixing Fuel WARNING! This is a two-stroke engine. Only run the engine on fuel, which is properly mixed with 2-cycle engine oil. Provide good ventilation when fueling or handling fuel.
Always use gas with a minimum octane number of 90. Use 2-stroke engine oil only. Mix 32:1 (or 5%), gas/oil mixture. Never use multi-grade (10W/30) or waste oil. Always mix fuel and oil in a separate clean, gas safe container. Always start by adding half the amount of fuel, which is to be used. Then add the whole amount of 2-cycle oil. Mix (shake) the fuel container. Add the remaining amount of fuel. Mix or shake thoroughly before filling the fuel tank.
Fueling WARNING!
Always shut the engine off before refueling. Slowly open the fuel tank, so that possible over-pressure disappears. Before fueling, clean the tank cap area carefully, to insure that no dirt falls into the tank. Make sure that the fuel is well mixed by shaking the container. Tighten the fuel cap carefully, after fueling. Always move the unit at least 10 feet from the fueling area before starting.
Starting Your scooter comes with an electric start. For this feature to function, you must first plug the scooter into the supplied charger and charge the battery for 4-6 hours. Otherwise, your electric start will not operate and you must manually start the scooter utilizing the pull start method. 1. Electric Push Start Method: a. Set the CHOKE LEVER to the CLOSED (UP) position. b. Using your left hand depress the left hand brake and hold it. c. Use your right hand and press the electric start button located next to the hand throttle. d. Once the engine is running, move the CHOKE LEVER to the RUN (DOWN) position. 2. Pull Start Method: a. Set the CHOKE LEVER to the CLOSED (UP) position. b. Pull the pull starter handle briskly, making sure to keep the handle in your grasp, and not allowing it to snap back. c. Once the engine is running, move the CHOKE LEVER to the RUN (DOWN) position. Page11
Note! At this stage, if the engine does not start, repeat the starting procedure. After starting the engine, allow the engine 2-3 minutes to warm up prior to riding. Stopping Gradually decrease the engine speed to an idle speed and press the stop switch on the handlebar tube.
MAINTENANCE RECOMMENDED TOOLS To adjust and service the X-Treme XG-550 you will need the following tools:
Allen Wrenches: 3,4,5,6 mm. Wrenches: 10,13,13 mm Open and ring combination. Short reach Spark Plug Socket Large Adjustable Crescent Wrench Spark Plug Sockets Philips & Standard Head Screwdrivers Oil, Grease or Lubricant (such as WD-40)
CARBURETOR ADJUSTMENT WARNING! Never start the engine without the complete clutch cover assembled! Otherwise the clutch can come loose and cause injuries. In the Carburetor, fuel is mixed with air. When the engine is tested at the factory, the Carburetor is basically adjusted. Further adjustment may be required from time to time, depending on climate and altitude. The Carburetor has two possible adjustments: 1. Idle speed adjustment (US Models – only option available, EPA approved) Due to EPA air quality regulations, on US models the Air/Fuel Mixture adjustment is pre-set on these carburetors by the factory and can’t be adjusted by the consumer.
2.
Air/Fuel Mixture adjustment (NON US Models Only) Idle Speed Adjustment 1. Start the engine. 2. Using a long, Philips head screwdriver gently turn the top screw clockwise until the XG-550 starts to move forward. 3.Then back out by turning the screw counterclockwise until the XG-550 stops. *Correct idle speed is obtained when the engine runs smoothly just below the RPM when the XG-550 starts to move.
Air/Fuel Mixture Adjustment 1. Start the engine. 2. Using a long, standard screwdriver and Note: Standard idle RPM is about while holding the throttle wide open, turn 2500-3000RPM. the bottom screw (with spring) clockwise as Page12 far as possible, then back out 1 & ¼ to 1 & ½ turns until the engine rums smoothly.
WARNING! When the engine is idling, under no circumstance should your XG-550 be moving. If the XG-550 continues to move after idle speed adjustment, contact X-Treme or your local X-Treme service center. Cleaning the Air Filter It is a good idea to occasionally clean the air filter to insure optimum performance. To clean the air filter: 1. Using a Philips head screwdriver, remove the carburetor cover by turning the cover screw counted clockwise. (Fig.10). 2. Remove and clean the air filter (the spongy material on top of the air intake), with a damp rag. (Fig.11). 3. Put the air filter back into its original position and replace the cover.
BRAKING SYSTEM The XG-550 uses both a front wheel disc/caliper braking system activated by a hand brake lever on each side of the handlebar. Squeezing the hand brake lever with your left hand activates the front brake. Squeezing the hand brake lever with your right hand activates the rear 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 XG-550 should come fully adjusted from the factory. Page13
However, it may be necessary to adjust the brake from time to time.
To adjust the 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.
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 X-Treme XG-550 uses an identical rim and tires 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. Tire wear will differ based on rider weight, riding conditions and care. Replacement tires can be obtained at your local X-Treme dealer, through motorcycle shops, or from the X-Treme website at www.x-tremescooters.com Tire Pressure The tire must be inflated to a maximum of 50 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 bolt to split the rim.
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ADJUSTING THE HEAD UNIT The head unit will should come adjusted from the factory. However, riding on rough terrain and general use may cause the head unit to become loose over time. It may be necessary to adjust the head unit from time to time.
To adjust the head unit: 1. Rotate the handle bar as for right as it will go to expose the HEAD UNIT (Fig.13). 2. Using a large adjustable wrench, gently turn the BEARING LOCK clockwise to tighten. *DO NOT OVER TIGHTEN OR IT WILL DAMAGE THE BEARINGS.
ADJUSTING THE CHAINS The chains will come adjusted from the factory. However, it may be necessary to adjust the sprockets from time to time. The chain must be well aligned with the sprockets otherwise they may start to rub and chafe. Which will result in shortened chain life. How tight should the chain be? If the chain is skipping or jumping on the pulley teeth, it is too loose and may be harmful. If the chain is making a humming sound when the wheel is turning, it is to 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 chains: 1. Slightly loose the two Axle bolts on both sides of the rear wheel. (Fig.14). Then slowly adjust the two chain adjusting screws on each side of the rear tire (Fig.15) until chain reaches the proper tension.
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Occasionally rotate the rear wheel to make sure chain is aligned. Finally lock and tighten the rear axle bolts prior to riding.
MAINTENANCE SCHEDULE Proper care of your X-Treme XG-550 will insure optimal performance and a longer life span. The following are a few maintenance suggestions that will keep your X-Treme XG-550 running in top condition: Daily Maintenance Perform each time you ride your XG-550 Clean the exterior of the unit with a soft, damp rag. Check that all nuts and bolts are securely tightened. Weekly/Monthly Maintenance Check the pull starter, especially the cord and return spring. Remove the spark plug and check the electrode gap. Adjust it to 0.6mm, or change the spark plug. Clean the cooling fins on the cylinder head and check that the air intake at the starter is not clogged. Clean the air filter. OTHER QUESTIONS For additional questions or technical assistance, go to www.x-tremescooters.com/support/ Thank You for purchasing an X-Treme XG-550. Please tell your friends about how much fun you had on the X-Treme XG-550
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How To Adjust Chain Tension 1.) To set the chain tension, loosen the axle nuts. 2.) Then locate the chain tension bolts. These bolts go from the rear axle to the frame. When you tighten the nuts on these bolts, they pull the whole axle and wheel back, tightening the chain. 3.) Adjust the chain until when pushing down in middle you achieve 1/8 to 1/4 inch movement. These bolts also controls wheel alignment, be sure to center the wheel in the center of frame. 4.) After you have adjusted your chain and aligned your wheel tighten the axle nuts.
How To Install Handlebars 1.) 2.) 3.) 4.)
Place handlebars on lower half of bar clamp. Locate top half of bar clamp and the four allen bolts. Install top half of clamp with the four supplied allen bolts. Adjust bars and tighten bolts.
How To Install Front Brake 1.) The assembly is held in place on the front side of the bracket on the fork and with the single 10mm bolt from the front. Tighten this bolt until it is "snug" but not so tight that the brakes will not move in and out. 2.) Once the brake assembly is mounted the pads are held in place magnetically with the Wide Side up, the pad with One Slot to the outside and the pad with Two Slots on the wheel side. 3.) The brake cable should be adjusted loose until the wheel is installed and then adjusted first where it goes through the bolt, then at the brake handle and at the brake assembly until smooth braking is achieved. Adjustment of brakes takes time to achieve proper stopping. 4.) With brake assembly mounted proceed to the directions for mounting the wheel.
How To Mount Front Wheel 1.) Set the scooter on a box that holds the front far enough off of the ground for the wheel to clear while installing. It may be helpful to have an extra set of hands to hold and align the brakes, wheel, axle & spacers. 2.) Start by putting the axle through the Left Side Fork (as determined by standing on the scooter and facing forward). 3.) Place the Smaller Spacer into the Wheel Hub and then place the Wheel between the Forks with the Disk sandwiched between the Brake Pads. Page17
4.) 5.) 6.) 7.) 8.)
Verify brake pads are position correctly. Push the axle through until it just sticks out the other side of the wheel. Add the Larger Spacer and push axle through the fork on the Right Side. Start Nut on end of Axle. Using two 17mm wrenches tighten the outside Axle Nuts snugly and evenly. To have both Nylock nuts screwed on fully you may need to use the spare nut on one side. The double nuts will allow the opposite side nut to screw on until the threads are fully through the nylon locking portion. 9.) Spin front wheel to check that it spins freely. Some rubbing on the brakes is expected. 10.) Adjust brakes for proper stopping.
How To Adjust Front Hub Brakes 1.) Adjust cable tensioner on the front brake handle almost all the way tight or in. 2.) Block front wheel off the ground. 3.) Loosen the 10mm pinch nut on the gold brake lever just enough so it will slide on the brake cable. 4.) Grab the end of the cable with a pair of pliers or vice grips and pull tight. 5.) Move the gold brake arm up the cable until the brake just begins to drag on the brake drum. 6.) Tighten the 10mm nut on the gold brake arm. 7.) Further adjustment can be done with the adjusters at the brake lever. This will need to be adjusted over time as the brakes are used.
How To Adjust Rear Hub Brakes 1.) Block rear wheel off the ground. 2.) Loosen the 10mm pinch nut on the gold brake lever just enough so it will slide on brake cable. 3.) Grab the cable with a pair of pliers or vice grips and pull the cable tight. 4.) Move the gold brake arm up the cable until the brake just begins to drag on the brake drum. Tighten the 10mm nut on the gold brake lever. 5.) Further adjustment can be done with the adjusters at the brake lever. _______________________________________________________________________
How To Install Throttle Cable 1.) Unhook the throttle cable from the carburetor. Unscrew the screw from the center of the air filter cover. Push throttle on carb to the open position and unhook cable using a pair of needle nose pliers. 2.) Unthread the cable through the scooter. You may need to remove the deck plate to Page18
get down to the cable within the scooter. Pull it through the body and then through the handle bar down tube. 3.) Unscrew the two screws on the electric start section of the throttle. This piece should split to allow you to remove the throttle cable from the handle. Release the throttle cable from the handle. 4.) Unscrew the metal "L" piece that goes into the electric start. 5.) Screw the new throttle's "L" joint into the old electric start. 6.) Attach the cable to the old throttle handle. 7.) Replace the top portion of the split electric start plastic piece and tighten down onto handle bar. 8.) Thread cable through the handlebar down tube and through the scooter. 9.) Reconnect it to the throttle on the carburetor. Make sure the throttle cable end settles down into the groove on the throttle on the carb. 10.) Replace air filter cover and deck plate.
How To Change Electric Start 1.) Unhook the throttle cable from the carburetor. Unscrew the screw from the center of the air filter cover. Push throttle on carb to the open position and unhook cable using a pair of needle nose pliers. 2.) Unthread the cable through the scooter. You may need to remove the deck plate to get down to the cable within the scooter. Pull it through the body and then through the handle bar down tube. 3.) Unscrew the two screws on the electric start section of the throttle. This piece should split to allow you to remove the throttle cable from the handle. Release the throttle cable from the handle. 4.) Unscrew the metal "L" piece that goes into the electric start. 5.) Remove the deck plate if it is not off already. 6.) Locate the wires that attach to the electric start and where they are attached cut (Leaving plenty of room to splice) and label them with masking tape so that after you have installed the new electric start you will know where they go. 7.) Cut the wire at the base of the old electric start near the handle bar. Take these ends and tape them tightly to the ends on the new electric start. Grab hold of the old wires inside of the scooter and pull the new wires into place. This should thread the new wires through the down tube and into the body a lot easier. 8.) Cut and splice the new wires onto the old wires. This can be done by using small butt connectors or wire nuts. These can be purchased inexpensively at radio shack. 9.) Screw the new throttle's "L" joint into the electric start. 10.) Attach the cable to the old throttle handle. 11.) Replace the top portion of the split electric start plastic piece and tighten down onto handle bar. 12.) Thread cable through the handlebar down tube and through the scooter. 13.) Reconnect it to the throttle on the carburetor. Make sure the throttle cable end Page19
settles down into the groove on the throttle on the carb. 14.) Replace air filter cover and deck plate.
How To Install Fuel Lines 1.) Attach the larger diameter hose on the nipple that is straight. 2.) Attach the smaller diameter hose on the nipple that is bent at a 90 degree angle. It also has the fuel filter attached. 3.) Squeeze the arms together on the retaining clip to increase the diameter and slide it over the hose.
How To Install Ignition Coil 1.) 2.) 3.) 4.)
Unplug spark plug from wire. Remove air breather assembly. Remove plastic covering motor and exhaust. At this point you can see the ignition coil. Remove the two bolts holding coil in place. 5.) Reinstall new coil using a business card between the fly wheel and the coil as a spacer. Tighten bolts with card in place, when bolts are tight then you can remove the business card. Your coil should be gapped correctly. 6.) Reinstall the plastic motor covers and your scoot should have spark.
How To Install Engager 1.) Stick a screwdriver in the fin's on the right side of pull starter to hold the motor from turning over. 2.) Take off net in center of engager. 3.) Unscrew and remove. 4.) Install new engager and tighten nut. 5.) Install pull starter.
How To Install Pull Starter 1.) Locate the four (4) screws on the Pull Starter. 2.) Unscrew them and the pull starter will come off. 3.) To re-install put Pull Starter on the Motor give it a little pull while holding it. This will line it so that it sits flat on motor. 4.) Install screws and tighten.
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How To Install Yellow Start Button 1.) Remove the old Start Button by removing the two small screws - one on each side of the button. 2.) Split the unit into two parts and you can take it off of the handle bars. 3.) Run the wires of the new switch down under the foot plate. 4.) You can do this either by fishing them through the down tube or running them along the outside of it and zip tying them on. 5.) Once you have the new wires in place swap the connectors out with the original ones in the clip. 6.) Replace the new unit on the handle bars and test.
How To Remove And Install Transmission 1.) Loosen the axle nuts but do not remove axle 2.) Loosen the chain tensioners so wheel can move forward and remove the chain. 3.) On the transmission side remove the two 8 mm motor mount bolts - go through the holes in the metal plate on the right side of scooter. 4.) On the other side remove the allen head bolts that hold the motor in place. 5.) Remove the motor & transmission. 6.) Remove the bolts on the outside corners of the transmission 7.) Remove the transmission 8.) Re-assemble is reverse order and add 1 ounce of 30 weight oil to the transmission.
How To Remove Engine 1.) On the rear of your scooter there is a chrome fender; remove the 7- 5mm allen head bolts. 2.) Remove the plate on the side of the scoot that has two 10mm nuts and three 5mm allen head bolts. 3.) Remove the air breather assembly, that way you can get to the throttle cable. 4.) Twist throttle handle while placing finger on the black throttle body on the carburetor. Then release throttle handle to allow cable to dislodge from the throttle body. You may have to try more than once, it can be tricky. 5.) Next you remove the transmission by removing the four gold 8mm bolts in a square pattern. 6.) Remove the ground wire by loosening 4mm allen head bolt. 7.) Release white quick connection to free motor, this is your kill switch. 8.) Remove gas tank by loosening the two bolts at the top of tank; this needs to be done for shipping purposes.
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How To Know What Each Battery Connection Wire Is 1.) The heavy gauge red wire connects from the battery positive to the starter relay. 2.) The small gauge red wire connects from the battery positive to the fuse holder via the white connector. 3.) The heavy gauge black wire connects from the battery negative to the engine crankcase. (ground) 4.) The small gauge black wire connects from the battery negative to the voltage regulator via the white connector.
How To Check Restricted Fuel Lines 1.) 2.) 3.) 4.)
Check the lines from your fuel tank. Look at the lines where they enter the tank, through the rubber grommet. Make sure these are not pinched or restricted in any way. If they appear to be pinched by the rubber grommet simply pull the lines out and bore the hole out slightly with something like a screw driver.
How To Replace A Starter Solenoid 1.) 2.) 3.) 4.) 5.) 6.) 7.)
Remove the deck plate Locate the starter solenoid Open it by removing the black tape or the zip tie Remove one wire at a time and transfer to the new solenoid. Disconnect white plastic connection and connect to new solenoid Re-tape the closed solenoid Reattach the deck plate
How To Remove And Replace Transmission Bell Housing 1.) You will need to remove the transmission. There will be 4 silver bolts on the outside. Do not remove the black bolts. 2.) Take a photo of the transmission, so you will remember how it looked and went on the scooter. That will help you in putting that back on. 3.) On the inside of that transmission, is the transmission bell housing. You will see a nut that you will need to remove. Remove that, and you should be able to place the new bell on. 4.) Tighten that down and put the transmission back on.
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How To Install Bearings 1.) Remove the rear wheel. 2.) Remove the old bearing. To do this, you will need to insert something, like a screw driver, from the opposite side and simply push it out. 3.) Put the new bearings in. You will want to use something like a rubber mallet so you do not crack the bearings. Set the wheel on a flat, absorbent surface, like a work bench. Tap the bearing into the wheel evenly. 4.) Re-install the tire and test ride.
How To Check For Spark ***Use Caution when testing in proximity to gasoline or gas vapors. 1.) Remove the spark plug wire from the spark plug. 2.) Remove the spark plug. 3.) Install the spark plug wire back on the spark plug. 4.) Place the spark plugs metal end against the side of the motor or frame. ** ATTENTION** THE NEXT STEP WILL CAUSE A SPARK!! 5.) Pull the rope or use the electric start and watch for a spark between the spark plugs electrodes. 6.) If there was not a spark try to disconnect this kill switch wires. This will be the wire that comes out of the top of the motor, and runs down under the deck plate. Disconnect it at the white plastic connection. 7.) Repeat step 5 to see if there is a spark. 8.) If you still do not see a spark the problem is likely the ignition coil. 9.) If you have spark after disconnecting the kill switch wire it is possible that your kill switch is bad or the wire is shorted to ground.
How To Adjust Carburetor Air/Fuel Mixture (If your engine has an air/fuel mixture screw – NON US Models Only)
1.) Block the rear wheel off the ground and make sure that it will not come down. 2.) Adjust the screw on the carburetor (the one with the spring) in all the way (do not over tighten as this will ruin the mixture screw) and then out a turn and a half. 3.) Start the scooter and let it warm up. 4.) Snap the throttle wide open. If the motor hesitates adjust the mixture screw open till it no longer hesitates. 5.) Test ride the scooter. 6.) If the scooter does not seem to develop full power adjust the mixture screw in or out 1/8 of a turn at a time until motor has full power and does not hesitate when the Page23
throttle snapped open.
Alternative Method: 1.) Run the motor full throttle and adjust slowly until you achieve max rpm. 2.) Give a 1/4 turn counterclockwise to provide just a little rich and ride scooter.
How To Change Charger Socket 1.) 2.) 3.) 4.)
5.) 6.) 7.) 8.)
Locate the rear of the charging socket. Follow wires and disconnect white plastic connector from controller. Remove nut on back of charger socket. Look down inside the connector; you will see the two metal pins. They are held in place by a small tab that bends outward. Reach inside the front of the connector with a dental pick or jeweler’s screwdriver and bend the tab in then pull the metal pin out the back of the connector. Install the new charging socket and secure the nut. Reinsert the wires into the white connector making sure to match red-to-red and black-to-black in the connection. Test new charger socket with charger. Re-assemble.
How To Remove Free Wheel Clutch To remove your free wheel you must first remove the rear wheel from the scooter then proceed to the directions below. 1.) Remove the sprocket from the free wheel. 2.) Place penetrating oil (WD-40) where the free wheel and wheel hub meet. Let it set over night. (optional) 3.) Use a small punch or place the edge of a regular screwdriver into one of the small holes in the face of the free wheel. 4.) Take a hammer and strike the screwdriver driving the free wheel counterclockwise. 5.) Remove the free wheel from the wheel hub. 6.) Install the new free wheel by hand with the writing side out. ** Do not tighten the free wheel by striking with a screwdriver and hammer. 7.) Reassemble everything in reverse order.
How To Change Fuse Holder 1.) Remove the six Allen head bolts securing the deck plate.
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2.) Unplug the two white connectors at the end of the fuse holder wires. 3.) Remove the large nut on the back side of the fuse holder. 4.) Slide the nut over the wire connectors one at a time and remove fuse holder from frame. 5.) Assemble in reverse order.
Troubleshooting: Getting Broken Bolts Out Okay, let's look at some of the more routine steps in removing a broken bolt. In all cases the best rule of thumb is to start with the simplest procedures and work your way up from there, as each approach fails to get results. First, let's assume part of its shaft is protruding from the metal surface. In such cases it's always best to try to remove it by clamping the Vise Grips (very tight!) onto the shaft and attempting to turn it out. In our years of experience we've found that in about half the attempts the bolt or screw comes out, so it's well worth trying. Didn't work or the bolt broke off again? Now it's time to get out the drill, but first you need to grind or file the bolt's shaft perfectly flat. Once you do you can use a drill bit or center punch to locate the center of the shaft, then to create a starter-hole for the drill bit. Choose a bit that's smaller than the diameter of the bolt shaft and start drilling. In this case it's going to work better if you have a left-hand drill set, because once you've drilled far enough into the bolt the drill will bind up and probably unscrew the remaining shaft. If the drill goes all the way through the bolt shaft you can drill again, using a slightly larger bit. Eventually you will be left with thin remnants of the bolt's threads which you can remove with a dental pick or run a threading tap into the hole to clean it out. If you do need a tap to clean up the threads, the size tap for the fuel tank bolt holes on the XG series scooter is 5mm x .08mm. If you don't have left-hand drill bits you should have an Easy-Out set. These are little hardened bits with twisted flutes arranged in a left-hand pattern. The top of each bit is squared to allow turning with a wrench. The bits are tapered, so the several sizes in the kit will fit a large range of bolt sizes. The procedure is to drill into the broken shaft a short way, hammer the appropriate Easy-Out bit into the hole until it wedges and then turn it out with an adjustable wrench.
Troubleshooting: Scooter Won’t Move Remove the transmission. This is the part on the engine that has the sprocket attached. Inside you will find the clutch bolted to the engine and you will find a circular piece that is gold or brass in color. It will be bolted to the transmission. This is called the bell housing.
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Either thee spring on the clutch may be gone or the bell has come off the transmission.
Troubleshooting: Bad Starter Solenoid? The starter solenoid is a round piece down under the footplate. It has a rubber cap on it. Remove this cap and you will see two bolts. Take a screw driver and short across those bolts (you might get a little spark, but not enough to hurt you). This should make your scooter start. If this works, then you simply need to switch out the solenoid.
Front Brake Diagram
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Wiring Diagram
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Rear Wheel Assembly Diagram
Left Side consists of these parts from outside nut to inner wheel. 1. Nut 2. Washer 3. Chain tension bolts 4. FRAME-Scooter 5. ½” Spacer 6. Left inner wheel spindle The brake disk is mounted on the left wheel spindle, and the caliper is mounted to frame. Use the knurled screw to center caliper to disk.
Right Side consists of these parts from outside nut to inner wheel. 1. Nut 2. Washer 3. Chain tension bolts 4. ¾” Spacer 5. Right inner wheel spindle Freewheel clutch is screwed into right inner hub
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Voltage Regulator Wiring Diagram
Front Fork Assembly Diagram
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Motor Diagram
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DO NOT RETURN TO STORE! IF YOU NEED HELP CALL 253-777-0690 OR GO ONLINE www.x-tremescooters.com/support/ For General Information or Parts Visit www.x-tremescooters.com
Revised10/26/11 Page31
