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5- TABLE OF CONTENTS
SPORTSTER – SE
Maintenance Manual
Afikim Electric Vehicles
Kibbutz Afikim 15148, Israel
Tel.: 972- 4-754814
Fax : 972-4-751456
Customer Service : 972-4-754180
E-mail:
Website: www.afiscooters.com
p/n - PR00058
Nov.2003
Edition: 03
Product: Sportster SE - all models
TABLE OF CONTENTS
Chapter 1 - Drawings Showing Position of Parts and Assemblies / 1Chapter 2 – Maintenance / 2
2.1 / General and Safety Instructions to the Technician / 2.1
2.2 / List of Recommended Tools and Spare Parts/Assemblies / 2.2
2.3 / Periodic Maintenance / 2.3
2.4 / Handling (Wet) Batteries / 2.4
2.5 / Basic Cleaning of the Sportster SE / 2.5
Chapter 3 –Troubleshooting - General Faults / 3
Chapter 4 - Electrical and Electronic Systems / 4
4.1 / Main Electric Wiring / 4.1
4.2 / Electronic / Electrical Systems in the Sportster SE / 4.2
4.3 / Troubleshooting - Electrical and Electronic Faults / 4.3
Chapter 5 – Replacement and Adjustment of Parts and Assemblies / 5
5.1 / Replacement of Front Section Assemblies / 5.1
5.1.1 / Replacement of Headlight
5.1.2 / Replacement of Front Board
5.1.3 / Replacement of Horn
5.1.4 / Replacement of Display Assembly
5.1.5 / Replacement of Handlebars
5.1.6 / Changing the Front Wheel
5.1.7 / Adjustment of the Brake Cable
5.2 / Replacement of Rear Frame Parts and Assemblies / 5.2
5.2.1 / Replacement of Rear Board
5.2.2 / Replacement of the Controller
5.2.3 / Replacement of Rear Light Bulb
5.2.4 / Replacement of Blinker Bulb
5.2.5 / Replacement of Main Harness
5.2.6 / Replacement of Motor
5.2.7 / Replacement of Electro-Magnet
5.2.8 / Replacement of Transaxle (The Power Unit)
Chapter 6 – EMI Warnings / 6
CHAPTER 1
DRAWINGS FOR TRACING PARTS AND ASSEMBLIES
To open drawings click the File Name : SE-SINGc.PDF
CHAPTER 2 - MAINTENANCE
2.1 GENERAL AND SAFETY INSTRUCTIONS TO THE TECHNICIAN
Warnings
1. When handling the Sportster SE's mechanical systems such as the motor, transaxle, wheels and electro-magnetic unit, the main supply should be disconnected by removing the battery cables in order to prevent accidental operation.
2. When conducting electrical tests, elevate the rear wheels using a jack or stable block of wood. Avoid touching moving parts such as wheels and axels.
3. Any maintenance operations must be carried our by a trained and authorized technician only.
The following instructions are directed to the technician responsible for the maintenance or repair of the Sportster SE:
1. Always ensure that the Sportster SE is positioned on a straight horizontal surface, the key is removed from the key switch and the handbrake is locked in the parking position.
2. Before commencement of any operations, perform a visual examination of the Sportster SE for a preliminary identification of problems.
3. Before replacing or repairing front wheel, elevate the front section of the Sportster SE.
4. When a Sportster SE is brought for repair, the fault should be identified using the table in Chapter 3 – Troubleshooting and Repair of General Faults.
5. When a Sportster SE is brought for a routine check or regular maintenance work, use this chapter for information.
2.2 RECOMMENDED TOOLS AND REPLACEMENT ASSEMBLIES
Specific Tools:
· Standard tool box (wrenches, socket-head capscrew, hexagon keys, phillips tip screwdrivers, etc.)
· Multimeter
· Air pressure gauge
· Batteries tester (under load)
· Density meter
· Valve Wrench
· Wooden blocks to elevate the Sportster SE during checks, maintenance and repairs:
ü 2 blocks 13-15 cms. in height for the front section .
ü 2 blocks 25-28 cms. in height for the back end.
Recommended Replacement Assemblies:
Catalogue No.Controller Programmer 1225 / PC00065
Rear Board – SE / PC00080
Controller 1225 – SE / PC00086
Front Board – SE / AS00410
Main Harness – SE / AS00669
Operating Handlebars - SE / AS00424
Controller Control Cable - SE / AS00409
Headlight (Spanish model) - SE / AS00445
Display and Led Assembly - SE / AS00428
Automatic Fuse40A / FU00015
Automatic Fuse 15A / FH00005
Automatic Fuse 4A / FU00014
Bulb for Headlight (Spanish model) / 1000479
Bulb for Blinker 5W ( Banana type) / 1000497
Bulb for Rear lamp 3W (Screw-type) / 1000486
Tire 10 x 2.75" / HW00027
Inner Tube 10 x 2.75" / HW00026
Tire 14 x 2.75" / HW00018
Inner Tube 14 x 2.75" / HW00029
Owosso Motor 4" (1HP) / MO00019
Ohio Motor 4.8" (2HP) / MO00026
Electromagnet with Release Lever / AS00419
Cooler Blower / AS00388
Horn / AS00443
Charger 24V / According to local requirements
Red Plastic Cover for Rear Lamp / VP00009
Note: Minimal recommended quantity is one unit of each of the above.
2.3 PERIODIC MAINTENANCE
Although the Sportster SE requires little periodic maintenance, careful compliance with pre-defined maintenance operations will reduce the probability of faults and ensure regular and smooth operation of the Sportster SE.
During the maintenance operations, ensure that the Sportster SE is firmly positioned on a flat horizontal surface, the key is removed from the key switch and the brake is locked in the parking position.
Periodic Maintenance
No. / Nature of Maintenance Operation / Frequency1 / Check air pressure/add air to tires. This operation should be performed by user after receiving instructions from the technician. See below. / Weekly
2 / Check water level in batteries/add water.
Note! (for wet batteries only):
To be performed only by the technician or the user, after receiving instructions from the technician. See below. / Once in two months or according to battery manufacturer's instructions
3 / Check emergency brake. This operation should be performed by technician / Annually
4 / General check of screws, cracks and excess clearance of axles, to be performed by the technician / Annually
Check Tires and Air Pressure (may be performed by the user) / Maintaining correct air pressure in the Sportster SE's tires is important to achieve a smooth ride and the stability of the vehicle.
Checking the tires is extremely important. Perform a visual check of the integrity and appearance of the outer tires and ensure that tires are well placed along the entire circumference of the wheel rim.
Check air pressure in the tires weekly and after any prolonged period of storage.
Correct air pressure in PSI 25-30 (adjusted to passenger's comfort).
Air pressure may be checked and air filled at gas station air pumps or using a manual air pump equipped with a pressure gage. Add air as necessary.
2.4 Battery Maintenance
Faulty batteries may cause many other faults in the Sportster SE. Although the user should provide regular care of the batteries (recharging and filling water on wet batteries only), this is insufficient to handle all problems which may arise. A technician should perform battery density tests and load tests after recharging batteries.
Note: Checking a fully charged battery immediately after recharging may produce misleading results. Checks should be performed on a charged yet not fully charged battery or after a short travel.
Regular Care of Batteries (wet only) / Once every two months - water level in both batteries should be checked, or according to manufacture's instructions, if such exist.Check (for wet batteries only):
o Remove the seat and the gray cover.
o Open the battery cells covers.
o Using a flashlight, check the water level in each of the battery's cells.
o Correct water level should be app. 6 mm above the plates.
o If water level is less than the required level, add distilled water only.
o After completing check, ensure all battery cells covers have been properly replaced and closed. Replace gray cover and seat.
Notes:
1) Only distilled water should be used to fill batteries.
2) Replacement of one battery necessitates the replacement of the other. The manufacture and Manufacturing Date code should be identical for both batteries.
3) When using battery Dry or GEL no maintenance or check is necessary. Any how refer to manufacture's instructions.
Acid Density Test (wet batteries only)
Recommended / o Remove the seat and gray cover.
o Using a hydrometer, check the acid concentration in each of the battery's cells. Ensure correct density (gauge indication in the green area).
o If acid concentration is lower than necessary in a battery cell - add acid or refer to battery manufacturer agent.
o Upon completion of check, ensure that all battery cells are closed. Replace gray cover and seat.
Note: Acid concentration and water level in battery chambers should be performed whenever Sportster SE is brought for a maintenance operation.
Battery Load Test / This test should be performed after fully recharging batteries and a short travel.
o Remove gray cover and seat.
o Disconnect all battery cables (negative and positive poles).
o Perform the test for each battery separately.
o Operate the Tester and check if voltage reading matches the indication of normal performance as specified on the tester display.
o Upon completion of test, reconnect the battery cables and ensure the correct poles are replaced to their original position. Replace gray cover and seat.
2.5 BASIC CLEANING OF THE SPORTSTER SE
(only when basic cleaning is required)
Only use a cloth, soap and water to clean the Sportster SE. Never spray a stream of water directly on the Sportster SE.Preparations / o Remove the seat and gray cover
o Disconnect and remove the batteries from the Sportster SE - see Chapter 5. Avoid causing short circuits when disconnecting the batteries.
o Cover the control and Rear Board box well.
o Cover the motor carefully.
Cleaning / o Clean the inner assemblies, especially the base of the batteries.
o Clean the gray cover on both sides.
o Use a cloth and water. Do not spray water directly on the Sportster SE.
o Clean the chassis.
o Upon completing cleaning, wait for all parts to dry or dry using air jets.
o Replace parts and reconnect electric circuits.
Ensure correct replacement and reconnection. You may refer to the mechanical drawings in Chapter 1 and the electrical drawings in Chapter 4.
o Replace gray cover and seat.
Test / Perform a general test of all Sportster SE functions: forward and backward drive, change of speeds, manual operation of brakes, automatic braking and lights.
CHAPTER 3 –TROUBLESHOOTING GENERAL FAULTS
The following table specifies troubleshooting and repairs of the possible faults in the Sportster SE. The table suggests the recommended method to handle these faults. The table specifies:
a. Fault Description - a description of the manifest problem resulting from the fault.
b. Cause of the Fault - a list of all the possible causes of the fault, in decreasing order of probability of occurrence.
c. Troubleshooting - actions to correct the fault. Each cause has a corresponding solution. If the solution does not correct the problem, refer to a different cause and action.
Note: Additional details pertaining to the repairs appear after the table.
Please do not hesitate to contact the company for additional professional assistance.
Fault Description / Possible Causes / Troubleshooting1 / Tire is flat and ride is uneven and not smooth / · Low air pressure
· Flat tire / · Add air until correct pressure is attained
· Fix the flat tire
2 / The hand brake is fully squeezed yet the Sportster SE does not stop / · Loose hand brake mechanism / · Tighten the brake cable
3 / When squeezing the operating lever, the Sportster SE does not move. / · Key switch is on the OFF position.
· The charging plug is in the charging socket.
· The mechanical release handle of the magnetic brake is pushed forward and disengaged. / · Ensure that the key switch Is ON.
· Disconnect the plug from the Sportster SE
· Pull the lever back to the operating position.
4. / Uneven ride / · Reduction in battery capacity
· Faulty electrical connections
· Faulty battery
· Electric fault
· Excess load / · Perform full charge of batteries
· Remove gray cover and check the battery cables' connections. If connections are rusty, clean the connections with a damp cloth.
· If, after recharging, battery display indicates low capacity or reaches such a state in less than one hour of operation, batteries are probably in need of replacing.
· See Chapter 4
· Remove partial load
5 / Right or left blinker, or front or back headlight does not operate / · Short circuit caused light fuse to pop out. See Figure 1
· Bulb needs replacement
· Electric fault / · Press the light fuse button. See Figure 1 on the following page.
· Change the light bulb.
· See Chapter 4.
6 / When charge plug is connected to charge socket, no recharging takes place. / · No voltage in the mains.
· Charge fuse popped out.
· Faulty wiring
· Faulty charger / · Ensure proper connection to mains and led light illumination. .
· Press lighting fuse button. See Diagram 1.
· Check electric wiring
· Replace charger
CHARGE SOCKET