ewheels EW-72 Service & Repair Manual
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ewheels EW-72 Service & Repair Manual

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EW-72
Service & Repair Manual

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  • Page 1 EW-72 Service & Repair Manual...

  • Page 2: Table Of Contents

    www.ewheelsdealers.com (888) 571-2845 - Service Table of Contents (888) 305-0881 - Sales (888) 571-2845 Service Contents Customer Diagnosis ......................... 3 Complete Loss of Power: ........................3 Loss of Throttle Response: ....................... 3 Section 2 – Technician Diagnosis Guide ................... 4 All Possible Tools Needed: ......................

  • Page 3: Customer Diagnosis

    If neither of these steps returns power or the charger light is staying green, please contact EWheels service department directly for assistance. Loss of Throttle Response: 1.) If the throttle does not respond when turned, the first thing to check is the current battery charge.

  • Page 4: Section 2 - Technician Diagnosis Guide

    2.) The only feature of the EW-72 that can cut off power to the motor is the brake sensors that are within the brake handles. To check the brake sensors, pull the brake handle while looking at the taillights with the scooter’s power turned on. If the sensors are working correctly, the brake lights will illuminate when the brake handle is pulled and turn back off when the brake handle is released.
  • Page 5 10.) Box cutter 11.) Wire stripper 12.) 3/8 Rachet ( Extensions If Needed )

  • Page 6: Complete Loss Of Throttle Response

    Complete Loss of Throttle Response: Checking Connections Start by checking all connections on both ends of the wire harness, focusing specifically on the three-wire throttle connector and motor wires. Make sure no pins are pulling out of the backside of any connectors, and that the pin s on the female side of connectors are not folded over to the side of the connectors.

  • Page 7: Testing The Throttle

    1.54 volts. If all steps above are followed, and the scooter is not driving, the throttle is not the component causing the problem. If the throttle is not working properly, please contact EWheels service department directly for a replacement.

  • Page 8: Testing The Rheostat (Speed Knob/Potentiometer)

    Twist the knob with your leads attached, and check that the rheostat varies from approximately 0, to the 100k OHM's it is rated for. If the rheostat (speed knob/potentiometer) is not working properly, please contact EWheels service department directly for a replacement.

  • Page 9: Testing The Wire Harness

    Testing accessory wiring is not needed when diagnosing drivability issues. If the wire harness has breaks that are not able to be repaired, please contact EWheels service department directly for a replacement.

  • Page 10: Testing The Controller

    Testing the Controller: To test that the controller is working properly, checking the output voltage for the throttles positioning sensor will be necessary. Leave the scooter power turned on while testing, but Do Not cross the throttle wires or a short may occur which can cause damage, personal injury, or death.
  • Page 11 This reading should be obtained at the black and red, yellow and green, and green and blue sensors wires while not under load. If the controller is not working properly, please contact EWheels directly for a replacement.

  • Page 12: Testing The Motor

    Testing the Motor Start by testing the resistance at the motor phase lines using all color combinations. If your meter displays any resistance levels other than infinite/zero, then the motor needs to be replaced. Next, check that the Hall Effect positioning sensor’s voltage is decreasing when the wheel is being rotated.

  • Page 13: Intermittent Or Random Loss Of Throttle Issue

    Intermittent or Random Loss of Throttle Issue The scooter could be intermittently driving, or not consistently accelerating for three different reasons. It could be a loose connection, a tension issue in the brake handle, or an issue with the batteries under load.
  • Page 14 *Continued next page* Brake Tension Continued- Increasing tension in the brake lines will eliminate this issue. The right-hand brake controls the front brake. The left-hand brake controls the back brakes. Tighten the adjustment nut on the effected handle to eliminate the issue. 3.
  • Page 15 If the charger is working properly, it should be emitting anywhere from 54 volts, to 57 volts. If the charger is not working properly, please contact EWheels service department directly for a replacement.

  • Page 16: Section 3- Upkeep And Maintenance

    If the charger port, battery terminal wiring, or wire harness need to be replaced, please contact EWheels service department directly. Section 3- Upkeep and Maintenance...

  • Page 17: Daily Checks Before Riding

    Daily Checks Before Riding 1. Charge Level Make sure there is enough charge in the batteries to complete the distance you intend to travel. If you are going to be traveling more than half the rated capable mileage, a full charge is recommended. Never let the batteries become completely depleted or sit for an extended period uncharged.
  • Page 18 If there is a hole on the tire from a puncture, a “tubeless tire repair kit” can be used to repair the hole in the tire. EWheels directly does not sell “tubeless tire repair kits”, but they can be obtained at local stores or online.
  • Page 19 Monthly Checks It is recommended monthly to check that the rear axle securing nuts, front axle bolt, seat bolts, headset bolt, transaxle to swing arm bolts, and the motor to axle bolts. There are four 0bolts that on the rear axle that secures the back wheel on either side.
  • Page 20 You will be using a 19mm wrench and a 6mm allen wrench to loosen the nut to take the axle bolt off.
  • Page 21 The seat is securing by two bolts, and the seat latch. The seat bolts are a 5mm hex head bolt on the bolt side, and 10mm on the nut side. Avoid overtightening or the seat will not be able to be lifted easily. The headset bolt is a 13mm.
  • Page 22 There are two transaxles to swing arm bolts on each side of the scooter. The bolt side is a Correct Size To Use. Make sure the bolts are tight on each side. If there is a gap between the axle bracket and the swing arm, this is normal.
  • Page 23 Yearly Maintenance It is recommended to change the transaxle oil between from one to three years. Unlike a gasoline engine, the motor does not require a specific amount of oil to operate properly. It is strictly the lubrication method to avoid overheating in the differential assembly.
  • Page 24 There is a total of eight removable painted body panels on the EW-72. Removing paneling may be required for gaining access to different parts of the scooter for normal maintenance or diagnosing issues. See below for specific panel removal. Headset panel, Headlight Shroud Removal Start by removing the mirrors.
  • Page 26 Running Boards (Side Skirts) You’re going to want to remove the screw closest to the main boy shroud first then the other one on the side of the running board. Once they are out pull and pop it off the unit, follow the same steps for the other side. The tool need for this will be a Philips screw driver.
  • Page 27 Front Wheel Fender’s On each front fender there is going to be a total of 3 bolts that use a 10mm socket and rachet or a 10mm wrench. Once they are removed the plastic colored fender will come off. Main Body Shroud To remove the main body shroud, power to the machine must be turned off via the circuit breaker, and the seat and storage box underneath the seat need to be dismounted or unplugged.
  • Page 28 Your going to want to remove both wires going to the circuit breaker before removing the storage box. Once complete you will remove the storage box and this is what you will see. Remove the cable that goes to the truck lock. Your going to want to pull up in the meal/plastic part and remove the end of the cable.
  • Page 29 You’re going to want to remove these the bolts along the running boards on both sides and in the middle. Remove the bolts on the back of the floorboard on the left and right side. Its going to be a Philips screw with a bolt that you must hold on to, to be removed.
  • Page 30 The next step would be to remove the connectors that go to both taillight fob. Once all these steps have been followed, the main body shroud can now be lifted off. Tilt the main body shroud’s back end towards the front of the scooter, without lifting the front end.
  • Page 31 Section 5 – Parts Replacement Guide Wear and Tear Item Replacement (Tires, Brake Pads, Bulbs, Batteries, Back and Front Shocks, Axels, Motor and Throttle) Tires - The tires may need to be replaced every 6 months - 3 years, depending on usage. The back wheels are secured by a single wheel securing nut located in the middle of the wheel.
  • Page 32 Brake Pads - The brake pads may need to be replaced every 6 months - 3 years, depending on usage. To replace the brake pads, remove the front and back tire. The brake pads are held onto the axle's brake pad catch, and to the actuating brake tension arm with spring tension.
  • Page 33 Front Headlight Fob Replacement With the EW-72 there are not going to be bulbs that can be replaced on this unit. When replacing the headlight fob on this unit you will need to remove the front shroud. There is going to be a total of 6 philip screws to remove the headlight fob.
  • Page 34 (This battery style is for older style of EW-72) This is 2 battery packs that are connected by a cable once the battery pack is close and screwed back down. These are still the 12V-20AH batteries as well. Current Model - The batteries are now wired in a positive to negative series. There is one wire harness wire that connects the first batteries positive.
  • Page 35 Back Shocks - removing the storage box underneath the seat will be necessary. Replace the shocks separately to avoid frame to frame contact. The top, and bottom bolt for the rear shocks are going to be a socket and wrench.
  • Page 36 Transaxle, Motor, or Axle Replacement Transaxle - The transaxle refers to the entire motor, differential, axle assembly. The motor and axles can be replaced separately. Follow both the motor, and axle replacement guide for full transaxle replacement. Motor - To remove the motor, you must first start by removing both rear wheels.
  • Page 37 Once the transaxle has been dropped from the swing arms, the next step is to disconnect the motor wires. The three heavier gauge motor phase wires will be connected to the controller unit in a yellow junction box. The thinner gauge motor hall sensors will be housed in a clip style connector.
  • Page 38 Motor Oil - The EW-36 uses 5W-30 motor oil (synthetic or non-synthetic). If completely empty, refill the motor with up to ½ quart of oil. Wire Harness and Brake Cable Replacement Wire Harness - The wire harness runs the length of the machine, from front to back. Replacing the wire will require removing the seat, storage box underneath the seat, main body shroud, headlight body panel, and front sliding plate.
  • Page 39 Front Brake Cable - Removing the headlight body panel will be necessary to replace the front brake cable. Once done, the brake handle cable mount will be exposed. Before you remove the cable from the handle, first remove the adjusting nut, spring, and mounting spacer. Once the brake cable hardware is removed, the brake line will have no tension.
  • Page 40 Removal or Swapping of Voltage Regulator - Removing the main body shroud is going to be necessary for this. Its going to be in the back and have 1 bolt and 1 connector keeping it in place, remove those and its out. Please see the photo below for a visual. Rear Brake Pads/hardware Removal Remove the rear wheel as well to get to the caliper.
  • Page 41 Controller – To remove or replace the controller, the seat, storage box and the main body shroud must be removed. Once removed, the controller will be exposed. All EWheels controllers will be plug and play (no modifications required) replacements. If any connector differences occur, please contact EWheels service department.
  • Page 42 Seat Latch and Seat Latch Cable Replacement Seat Latch Cable – To replace the seat latch cable, the seat and storage box, and main body shroud must be removed. Once removed, dismount the original seat latch cable from the seat latch release lock cylinder, and install the replacement seat latch cable into the original seat latch release lock cylinder.
  • Page 43 from the wire harness and install the new charger port. Ignition Replacement – Once the front big headlight shroud is removed you can now access the ignition to get it replaced. There will be 2 Phillip screws that hold the ignition into place, after being removed with a snub noise screw driver you can now go to the back side.
  • Page 44 Throttle Replacement –To replace the throttle, start by removing the headset shroud. Once removed, separate the original throttle’s electrical connector, and loosen (but do not remove) the 3 MM set screw for the original throttle. Disconnect both connectors and your job is complete. Right (Front)Brake Handle Replacement –...
  • Page 45 Left Brake Handle Replacement - To replace the left brake handle, start by removing the headlight shroud. Once removed, take of the securing nut and bolt. Both the nut and the bolt are 10MM. Speed Knob and Button Replacement Speed Knob Replacement – To replace the speed knob, start by loosening the set screw for the speed knob...
  • Page 46 Seat Backrest, Seat Bottom, Arm Rest, and Basket Replacement Seat Backrest Replacement – To replace the backrest, start by removing the basket and triangle seat mechanism covers. Once removed, take out the four 5MM Allen wrench basket bolts, and two 6MM Allen of the seat.
  • Page 47 Bottom Rest Replacement Step One -To replace the bottom portion of the seat start by removing both seat mechanism covers with a Phillips screw driver. Lifting the seat up may make it easier to get to the screw on the bottom side. You will slide this plastic cover off the lever on the seat as shown in the photo.
  • Page 48 Step Two - Remove the 2 bolts holding the seat mechanism on each side of the seat. You can remove them with either tool as shown in both photos. ( The back rest will the come off once all bolts are removed on each side in above photo ) Step Three –...
  • Page 49 Floorboard and Horn Replacement Horn – To replace the horn, start by removing the front body shroud and sliding front plate. Once removed, unplug the electrical connectors that plug in the horn. Then, use a 10MM wrench or flat head screwdriver to remove the bolt that secures the horn to the frame.
  • Page 50 Black Tiller Guard Removal First - Remove the headlight first with a Phillips screwdriver as shown in photos. Then there will be a total of 3 screws to be removed for this shroud to be removed, 2 of then on the inside and 1 on the ( Update Photos and Description ) outside of it as well.
  • Page 51 Wire Harness (Older Style Schematic)
  • Page 52 Wire Harness (Newer Style Schematic)

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