iZip™ Hybrid Electric Bicycle Owner's Manual

• All adult bicycles with the iZip™ logo

eZip Hybrid Electric Bicycle Owner's Manual

• All adult bicycles with the eZip logo

Scooters (Direct Drive) Owner's Manual

• 1000DD series scooters
• 750DD series scooters
• 500DD series scooter
• Scoot-E scooter

Scooters (Chain Drive) Owner's Manual

• 300 series scooters
• 4.0 series scooters
• 400 series scooters
• 500CD series scooters
• 650CD series scooters
• 750CD series scooters
• 900CD series scooters

Scooters (Push Start) Owner's Manual

• 130 series scooters
• 130/8 series scooters
• 150 series scooters
• 200 series scooters

TROUBLESHOOTING PDF's

• 2005.05 600 Troubleshooting Guide
• 06 130 Troubleshooting Guide
• 06 150 Troubleshooting Guide
• 06 200 Troubleshooting Guide
• 06 300 Troubleshooting Guide
• 06 500 Troubleshooting Guide
• 06 600 Troubleshooting Guide
• 06 750 Troubleshooting Guide
• 06 1000 Troubleshooting Guide
• 06 ST 1000 Troubleshooting Guide
• 06 CB24V200 Troubleshooting Guide
• 06 CB24V450 Troubleshooting Guide
• 06 CR24V450 Troubleshooting Guide
• 06 CR36V450 Troubleshooting Guide
• 06 CX24V200 Troubleshooting Guide
• 06 CX24V450 Troubleshooting Guide

MOTOR REPLACEMENT GUIDE
This PDF is apllicable to the 2006 500 series scooters and swingarm platforms. Downlooad PDF

PROPER BATTERY CARE
Consumers can call 1-800-8-BATTERY for information on recycling your used Lead Acid battery or go to the RBRC website at www.rbrc.org for additional information.

IMPORTANT - STATE LAWS & ELECTRIC MOTORIZED  SCOOTERS READ CAREFULLY
Launch Motorized Scooter Laws Page

ELECTRIC BICYCLES ARE STREET LEGAL IN ALL 50 STATES
Launch Federal Electric Bicycle Law
Launch Informational Tag

8 INCH 250 SERIES REAR WHEEL ASSEMBLY REPLACEMENT (NEW) Download PDF

SCOOTER DOs AND DONTs (NEW)
Download PDF

DOWNLOAD THE BATTERY CARE GUIDE (NEW)
BATTERY CARE GUIDE

DOWNLOADABLE PDF FORMS
1. TECHNICAL SUPPORT INFO SHEET
2. CONTROLLER REPLACEMENT FORM
3. MOTOR REPLACEMENT FORM
4. THROTTLE REPLACEMENT FORM
5. SCOOTER AIR PRESSURE FORM
6. 12" REAR WHEEL ASSEMBLY REPLACEMENT
7. BAND BRAKE ASSEMBLY
8. 24V DIAGNOSTIC CONTROLLER INSTRUCTIONS
9. CHAIN ADJUSTMENT FOR SLOTTED MOTOR BACKING PLATE
10. 350 SERIES SPROCKET TIGHTENING PROCEDURE

Click on the links below to quickscroll to the information you need pertaining to your troubleshooting issues.

Warranty Claims

Extended Warranty

Patent Numbers

SCOOTER DOES NOT RUN, INDICATOR LIGHT IS ILLUMINATED AND BATTERY IS CHARGED.

CONDUCTING A THROTTLE BYPASS TEST (DETERMINE MOTOR TYPE):
BRUSHLESS MOTOR (WITH FINS) HAVING INTERNAL CONTROL: (TOOLS - PHILIPS SCREWDRIVER)

BRUSH-TYPE MOTOR WITH EXTERNALLY MOUNTED MOTOR CONTROL: (TOOLS - PHILIPS SCREWDRIVER – VOLT METER)

CONDUCTING A BRAKE INHIBITOR BYPASS TEST: (TOOLS - PHILIPS SCREWDRIVER)

ROLLER-CLUTCH INSPECTION:

DRIVE MAKES NOISE.

MOTOR PERFORMS IN A JERKING AND SHUTTERING MANNER, CLICKS.

MOTOR ROTATES, SCOOTER DOES NOT MOVE.

REAR WHEEL WILL NOT ENGAGE:

SCOOTER MOTOR DRIVE WILL NOT STOP WORKING:

MOTOR NOT WORKING, ALTHOUGH BATTERY IS FULLY CHARGED AND INDICATOR LIGHT IS LIT.

BATTERY CHARGER UNIT NOT FUNCTIONING PROPERLY:

FUSE CHECK PROCEDURE: (TOOLS - PHILIPS SCREWDRIVER)

BATTERY TERMINAL CHECK PROCEDURE: (TOOLS - PHILIPS
SCREWDRIVER, PLIERS)

CHAIN BREAKS:

SCOOTER CHAIN TENSION ADJUSTMENT AND INSPECTION: (TOOLS – 15mm WRENCH, 17MM WRENCH, 5MM ALLEN WRENCH)

CHARGER RECEPTACLE (PORT) TROUBLESHOOTING PROCEDURE:
(TOOLS - SCREWDRIVER, DRILL OR PHILLIPS SCREWDRIVER, DC VOLTAGE METER)

FRAME DAMAGE:

HANDLEBAR REPLACEMENT PROCEDURE:

ROLLER-CLUTCH INSPECTION:

INDICATOR LIGHT REPLACEMENT:

WARRANTY CLAIMS:
Most factory-new Currie Technologies, Inc. products have a 6-month warranty. Refer to the Owner’s Manual for specifics. Replacement parts have a 90-day warranty.
Tubes and tires are not warranty items.

Contact CTI customer service and provide the following information…
NOTICE: Proof of purchase (sales receipt) is required for warranty replacement
1. Model name of scooter or e-ride bike
2. Color
3. Model Year (if known)
4. Does your scooter or bike have front shock absorber?
5. Original purchase date
6. Where purchased
7. Serial number

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EXTENDED WARRANTY:
Extended warranties may be offered by dealers and retail stores, these are unrelated to the Currie warranty. Currie does not offer an extended warranty plan. Contact your retailer for information on their extended warranty plan.

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PATENT NUMBERS:
US Patent #’S: 5,934,401; 5,937,964; 6,268,898
International Patent #’s: PCT/US98/03804 & W098/41438

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SCOOTER DOES NOT RUN, INDICATOR LIGHT IS ILLUMINATED AND BATTERY IS CHARGED.
STEP 1- Conduct THROTTLE BYPASS TEST.
STEP 2- Conduct BRAKE INHIBITOR BYPASS TEST.
STEP 3- Conduct the CHARGER RECEPTACLE (PORT) TROUBLESHOOTING
PROCEDURE
STEP 4- Conduct the BATTERY TERMINAL CHECK PROCEDURE

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CONDUCTING A THROTTLE BYPASS TEST (DETERMINE MOTOR TYPE):
BRUSHLESS MOTOR (WITH FINS) HAVING INTERNAL CONTROL: (TOOLS - PHILIPS SCREWDRIVER)
1. Remove the deck plate of the scooter.
2. Turn the scooter (or bike) on.
3. Lay it down on its right hand side so the rear wheel is not touching the ground.
4. Now follow the cable from the throttle all the way down the side until you see a white connector. Disconnect the connector.
5. You are going to need a jumper wire. (A small metal paperclip or other conducting material can serve as a jumper. Bend the paperclip into a U shape.)
6. Insert the jumper into the two outside holes (pins) of the connector on the wire leading to the motor. By doing so, the back wheel might spin.
• If the back wheel spins, your motor is good and your throttle is bad. And vice versa, if it does not spin your controller is bad.

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BRUSH-TYPE MOTOR WITH EXTERNALLY MOUNTED MOTOR CONTROL: (TOOLS - PHILIPS SCREWDRIVER – VOLT METER)
1. Remove the deck plate of the scooter.
2. Turn the scooter on.
3. Lay it down on its right hand side so the rear wheel is not touching the ground.
4. To the rear of the battery tray locate the motor controller with several wire connectors. Locate the only connector that has 3 wires, and disconnect it.
5. Hold the half of the disconnected clip that comes from the controller so that the latch extension is pointing up and the left edge has two rounded corners.
6. Make sure that nothing can get caught in the drive system
7. Insert Phillips screwdriver between left and center gold pin. By doing so, the back wheel might spin at full speed!
a. If the back wheel spins, your motor and motor control is good and your throttle is bad. And vice versa, if it does not spin your motor or control is bad and continue to step 7.
8. Connect a Volt meter to the output leads that go to the motor, set the meter to the correct mode (24-Vdc or greater).
9. Operate the throttle, checking the meter voltage.
a. The voltage should range from 0 to 24~27Vdc (voltage of the battery). This will tell you if the controller and throttle is working.

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CONDUCTING A BRAKE INHIBITOR BYPASS TEST: (TOOLS - PHILIPS SCREWDRIVER)
1. Remove the deck of the scooter.
2. Locate the brake inhibitors lead to the battery wire harness.
3. Disconnect.
4. Turn on scooter.
5. Engage throttle.
∑ If scooter runs when the brake inhibitor is disconnected there is most likely a problem with the brake inhibitor mechanism and it should be replaced

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ROLLER-CLUTCH INSPECTION:
If the scooter motor appears to be running but will not provide power to the wheel, the motor roller clutch may be stripped. The roller clutch engages the wheel in a clockwise (CW) rotation, when viewed from the motor side. The clutch will freewheel in the counter-clockwise (CCW) direction of rotation. Turn on the scooter and slowly engage the throttle while holding the scooter stationary. The wheel should rotate smoothly in the CW direction.

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DRIVE MAKES NOISE.
Conduct ROLLER CLUTCH INSPECTION.

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MOTOR PERFORMS IN A JERKING AND SHUTTERING MANNER, CLICKS.
Conduct ROLLER CLUTCH INSPECTION.

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MOTOR ROTATES, SCOOTER DOES NOT MOVE.
Conduct ROLLER CLUTCH INSPECTION.

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REAR WHEEL WILL NOT ENGAGE:
Conduct ROLLER CLUTCH INSPECTION.

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SCOOTER MOTOR DRIVE WILL NOT STOP WORKING:
Conduct THROTTLE BYPASS TEST.

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MOTOR NOT WORKING, ALTHOUGH BATTERY IS FULLY CHARGED AND INDICATOR LIGHT IS LIT.
Conduct the brake inhibitor bypass test.

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BATTERY CHARGER UNIT NOT FUNCTIONING PROPERLY:
Check the charger for proper operation. Refer to the individual scooters or bike owner’s manual for proper charger operation as the charger models vary. Check the charger for any damage to the wires or the plugs. Make sure that the lights on the charger are working properly by plugging the charger into a wall outlet. If the lights do not turn on or work properly or if the charger is damaged in any way the charger should be replaced. The charger is a non-serviceable item and Currie Technologies does not recommend attempting to repair it or any of its components.

• Solid green light on charger unit. Cause: a poor electrical connection somewhere in the wiring harness.
Solution: Check all connectors for loose fitting plugs. Also refer to battery terminal check and indicator light replacement procedures. Examine for corrosion on connectors and broken or frayed wires.

• Flashing green light on charger unit: Cause: Blown or loose fuse or motor failure.
Solution: Check for loose fuse connection, refer to fuse check procedure. Replace fuse as required. Contact Currie customer service for motor troubleshooting assistance.

• When the charger has a blinking green or yellow light when plugged or not plugged into the scooter, this maybe a loose battery wire condition. Look at the batteries, making sure all wires are crimped well and terminals fit snug onto the battery. Then completely dis-connect the charger from the wall and scooter for a complete minute to let it cycle down and it should re-set itself.

• Red Flashing light on charger unit:
Cause: Failure of charger.
Solution: Replace charger.

• Also see charger receptacle (port) troubleshooting procedure

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FUSE CHECK PROCEDURE: (TOOLS - PHILIPS SCREWDRIVER)
Remove the deck of the scooter and inspect the fuse, which is housed in a flat, rectangular, black box on the wire assembly. Open the fuse holder and remove the 40-amp fuse. Inspect it for damage or blackening. If the terminal that runs through the middle of the fuse is broken in half than the fuse has blown and should be replaced. If replacement fuses continue to blow it is most likely a more serious problem either with the motor or wire assembly. It is recommended that the motor be sent in for evaluation.

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BATTERY TERMINAL CHECK PROCEDURE: (TOOLS - PHILIPS
SCREWDRIVER, PLIERS)
Remove the deck. Tip the batteries up and check the wires to make sure they are firmly connected and that there is no damage. You can use the hole located under the scooters battery tray to push the batteries up and out of the tray. If the leads on the wires slip off of the battery terminals too easily use a pair of pliers and gently clamp down on the middle of the leads closing them together. Do not use metal tools on the battery terminals. Batteries are a hot connection and should be handled with care.

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CHAIN BREAKS:
Inspect chain, replace if damaged. Master links and replacement chains are available from Currie customer service.

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SCOOTER CHAIN TENSION ADJUSTMENT AND INSPECTION: (TOOLS – 15mm WRENCH, 17MM WRENCH, 5MM ALLEN WRENCH)
There are two types of chain tension adjustment methods. Make sure scooter is in the off position while working on the chains adjustment.

• 2003 and prior scooters use a chain block (cam device) located just below the roller clutch mechanism. To adjust, remove the deck of the scooter and locate the chain block. Loosen the bolt that secures the chain block to the motor mounting plate (10mm. open ended wrench). Adjust the block so that there is 1/4” sag in the chain. The chain block will make contact with the chain. Make sure chain slides easily over the beveled section and does not cross over the corner of the chain block. Retighten the chain blocks mounting bolt making sure not to displace its position. You can use pliers to secure the chain block while tightening the bolt. Test the scooter. The chain should make minimal noise without excess grinding. Adjust as necessary.

• 2004 and newer scooters use a sliding dropout to position the motor mounting plate forward or aft to adjust chain tension. Loosen the right side (drive side) axle nut to the end of the axle. (15mm. wrench). Loosen the washer with the safety tab on the drive side of the scooter so that it hangs loose on the axle. Loosen the motor mounting plate nut that holds the motor mounting plate in place. (17mm wrench). Loosen the Allen bolt below and on the front of the motor mounting plate that holds the plate assembly to the frame. (5mm. Allen wrench). Move the entire plate assembly including motor forward to tighten the chain and backward to loosen the chains slack. Retighten the motor mounting plate assembly and the axle nuts on the rear wheel. Test the scooter to make sure chain is in proper adjustment. Adjust as necessary

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CHARGER RECEPTACLE (PORT) TROUBLESHOOTING PROCEDURE:
(TOOLS - SCREWDRIVER, DRILL OR PHILLIPS SCREWDRIVER, DC VOLTAGE METER)
Using a voltmeter set to DC (direct current) insert the voltmeters prongs into the two parallel holes in the charger port. Make sure the rear wheel is off of the ground by tipping the scooter on its side. With the scooter in the on position engage the throttle with the voltmeter in place. You should get a reading if the charger port is connected and working properly.

To inspect wiring connection or replace the charger port: The charger port may be riveted or screwed in. If it is riveted the rivets must be drilled out. After removing the screws or rivets, use a flat-edged screwdriver to gently pry the charger receptacle from the frame. Be careful not to damage the paint. Pull the charger receptacle out until you come to the white connection that goes to the rest of the main wire harness. Make sure it is connected properly. Broken ports may be replaced, contact Currie Customer Service to obtain the proper port.

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FRAME DAMAGE:
If the frame is damaged due to an accident or product failure it may need to be replaced. An Authorized Currie Technologies Dealer or representative should inspect it for safety.

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HANDLEBAR REPLACEMENT PROCEDURE:
If the handlebar is damaged due to an accident or product failure it may need to be replaced. An Authorized Currie Technologies Dealer or Representative should inspect it
for safety.

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ROLLER-CLUTCH INSPECTION:
If the scooter motor appears to be running but will not provide power to the wheel, the motor roller clutch may be stripped. The roller clutch engages clockwise and freewheels counter clockwise. Turn on the scooter and slowly engage the throttle while holding the scooter stationary.

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INDICATOR LIGHT REPLACEMENT:
Pull the pilot (indicator) light out of the down tube of the scooter. You can use a thin screwdriver to help to pry the pilot light out of the scooter. Be careful not to scratch the frame. Once the pilot light is loose you can gently pull it out until you find the white connection that leads to the rest of the wire assembly. Check for loose connection, this could be the only trouble. Should the connections be good, disconnect the pilot light. Connect the new one and reinstall. Pilot lights available from Currie Customer Service.

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