Scooter DI BLASI mod. R30
SERVICE MANUAL
(Ed. 21.03.2018)

 

INDEX

A)         MAINTENANCE

A.1)      Monthly checks

 

B)         TROUBLE SHOOTING

B.1)      General notices concerning electric failures

B.2)      The traction motor runs irregularly

B.3)      The brake does not work

B.4)      The scooter cannot be unfolded

B.5)      While the scooter is unfolded and when pressing the main yellow button, a beep is audible

B.6)      While the scooter is unfolded and when pressing the main yellow button, no LED lit on control panel

B.7)      The control panel at the handlebar does lit but the scooter does not run

B.8)      At the end of unfolding step a long beep is audible and the control panel does not lit

B.9)      The scooter can be folded but cannot be unfolded

B.10)    The scooter can be unfolded but cannot be folded

B.11)    The scooter does not run backwards

 

C)         OPERATIONS

C.1)      Wheel+Brake Assembly replacement

C.2)      Brake Assembly replacement

C.3)      Handlebar folding control cable replacement

C.4)      Scooter Controller replacement

C.5)      Motor Controller replacement

C.6)      Battery support replacement

C.7)      Folding-unfolding stop switches adjustments

C.8)      Folding/unfolding buttons replacement

C.9)      Front fork returning spring replacement

C.10)    Handlebar returning spring replacement

C.11)    RH loom (pn 3135) and LH loom (pn 3149) replacement

C.12)    Motor-controller loom (pn 3098) replacement

C.13)    Gears assembly (pn 3582+pn3583) replacement

C.14)    Geared rod (LH side) (pn 3595) replacement

C.15)    Geared rod (RH side) (pn 3594) replacement

C.16)    Seat sheet (pn 3021) replacement (Versions until 31-12-2016)

C.17)    Seat sheet (pn 3021) replacement (Versions from 01-01-2017)

C.18)    Cancelling the reverse speed sound (beep) warning

 


A)  MAINTENANCE

A.1)   Monthly checks

A.1.a)      Apply a few drops of light oil on all mechanical joints and in the gears of the folding mechanism.

A.1.b)      All nuts and bolts are equipped with locking devices (lock nuts, self locking nuts, lock washers, thread lock liquid, etc), nevertheless check their tightening.


B)  TROUBLE SHOOTING

B.1)   General notices concerning electric failures
In the sections of this manual concerning the electric failures, the following definitions apply:

B.1.a)      A battery is in good order when:

B.1.a.1)     The tension at its terminals is not less then 25,6V

B.1.a.2)     Charging time of a completely empty battery, when it is a new one, is about 4 hours. However, more the battery is old, less is its capacity to take charge so that the charging time reduces.

B.1.a.3)     The terminals of the battery are not rusty or dirty: this would reveal bad quality of contact at these terminals.

B.1.b)      Integrity of a loom means that:

B.1.b.1)     Each of its wires is firmly connected to the corresponding male/female connector at its ends and each of these connectors is firmly connected to the corresponding female/male connector of the corresponding device.

B.1.b.1)     There are no visible damages, especially in tracts corresponding to the hinges between footboard and main frame (Pic B1.1 + Pic B1.2) and to the handlebar hinge (Pic B1.3).

B.1.b.2)     There is electric continuity in each of its wire. A multimeter allows to detect any steady discontinuity. But sometime a broken wire allows an unsteady electric continuity. To detect such case of failure, raise the front wheel of the scooter from the ground and while pressing the speed control lever move slightly in all directions each cable mainly in the tracts corresponding to the hinges between footboard and main frame (Pic B1.1 + Pic B1.2) and to the handlebar hinge (Pic B1.3): while moving each cable check if any irregularity of the motor. Any irregularity reveals that an internal wire is broken in that point.

B.2)   The traction motor runs irregularly

B.2.a)      Check integrity of the looms (See Sec. B.1.b)

B.2.b)      Carry out the following:

B.2.b.1)     Activate the main switch

B.2.b.2)     Raise the front wheel from the ground

B.2.b.3)     While pressing the speed control lever, move slightly in all directions the cable entering in the motor shaft (W – Pic B2.1) and observe if any irregularity in the motor running. If any irregularity, replace the motor

B.3)   The brake does not work
(The scooter does not stop as soon as the speed control lever is released or the scooter stays in free ride mode also when the brake disconnecting lever (M) is locked by the hook (R) in the position  shown in Pic B3.2 (see also Sec 4.3.d) in the Owner's Manual).

B.3.a)      Tighten the nut (pn 3379) (Pic B3.1) after having added some drops of thread lock liquid in its threads.

B.3.b)      If the nut (pn 3379) (Pic B3.1) is tightened, disassemble the brake and check if

B.3.b.1)     The brake discs are broken or worn

B.3.b.2)     The plastic guide of the steel discs are damaged (due to overheating, for instance)

B.3.b.3)     For disassembling and assembling the brake assembly see Sec C.2

B.4)   The scooter cannot be unfolded

B.4.a)      Check that the brake disconnecting lever is (M) is firmly locked by the hook (R) in the position shown in Pic B4.1 (see also Sec 4.3.d) in the Owner's Manual).

B.4.b)      Check if a beep is audible when inserting the battery:

B.4.b.1)     If no beep is audible

·   Check the tension at the terminals of the battery support

*   If there is no tension, replace the battery

*   If there is tension

-Check the integrity of the loom (pn 3463) from the battery support to connector (J1) at the scooter controller (see wiring diagram).

-If loom (pn 3463) is in good order replace the scooter controller.

B.4.b.2)     If a beep is audible: go to Sec B.4.c)

B.4.c)      Check if a beep is audible when pushing the unfolding green button

B.4.c.1)     If a beep is audible:

·   Check if the unfolding stop switch is defective (see wiring diagram). If it is in good order ...

·   ... check the integrity of the loom (pn 3410) (see wiring diagram). If it is in good order, then ...

·   ... replace the scooter controller

B.4.c.2)     If no beep is audible

·   Check if the lever (A) which connects/disconnects the folding mechanism gears is firmly locked in the position shown in Pic B4.2 (in this position the folding-unfolding mechanism gears are connected each other - See also Sec 2. - Par. "Unfolding the scooter manually " in the Owner's Manual).

·   Check the integrity of the loom (pn 4043) (see wiring diagram)

·   Check the connection between connector (J2) on the scooter controller and connectors (J18) and (J19) on the folding-unfolding motor ( see wiring diagram). In particular check if, while pressing the unfolding green button there is a tension of about 24V at connectors (J18) and (J19)

*   If there is tension, replace the motor

*   If there is no tension, replace the scooter controller

B.5)   While the scooter is unfolded and when pressing the main yellow button, a beep is audible

B.5.a)      Check that the brake disconnecting lever is (M) is firmly locked by the hook (R) in the position shown in Pic B5.1 (see also Sec 4.3.d) in the Owner's Manual).

B.5.b)      Press the unfolding green button and check if a short beep or a long beep is audible.

B.5.b.1)     If a short beep is audible

·   Replace the scooter controller

B.5.b.2)     If a long beep is audible

·   Go to Sec B.8)

B.6)   While the scooter is unfolded and when pressing the main yellow button, no LED lit on control panel

B.6.a)      Disassemble the control panel panel (pn 3553) (see Pic B6.1) and check the integrity of the loom (pn 3149) (see wiring diagram). If it is in good order, then...

B.6.b)      .... check that between the black wire and the green wire at the battery indicator there is a tension of 24V

B.6.b.1)     If there is tension: replace the indicator

B.6.b.2)     If there is no tension: replace the scooter controller

B.7)   The control panel at the handlebar does lit but the scooter does not run

B.7.a)      Check the integrity of the loom (pn 3135) (see wiring diagram). If it is in good order, then...

B.7.b)      ... check at loom (pn 3463) (see wiring diagram) if at both ends of the red wire connecting connector (J10) at the motor controller and the connector (J6) at the scooter controller, there a tension of 24V

B.7.b.1)     If there is no tension: replace the scooter controller

B.7.b.2)     If there is tension: go to Sec. B.7.c)

B.7.c)      Press progressively the speed control lever and check if at the end of the white wire on the connector (J10) at motor controller there is a tension increasing progressively up to about 5V

B.7.c.1)     If there is tension

·   check if the motor controller or the motor itself is defective

B.7.c.2)     If there is no tension

·   Go to Sec. B.7.d)

B.7.d)      Check that there is a tension of 5V at the end of the red wire at the connector (J22) on the control panel:

B.7.d.1)     If there is tension, press progressively the speed control lever and check if at the end of the white wire on the same connector (J22) there is a tension increasing progressively up to 5V

·   If there is no tension

*   replace the speed control lever (pn 4036)

B.7.d.2)     If there is no tension at the end of the red wire at the connector (J22)

·   Replace the scooter controller

B.8)   At the end of unfolding step a long beep is audible and the control panel does not lit

B.8.a)      At the end of unfolding step, the gap between the seat frame protrusion and the geared rod is to be 1χ2 mm as shown in Pic B8.1. If the scooter does not unfold completely, this gap shall remain more than 1χ2 mm so that the unfolding stop switch (pn 4079 (A) - see Pic B8.2) shall not be activated and therefore the scooter cannot run.
Check if the reason why the scooter does not unfold completely is due to some jamming of the folding mechanism: for instance a loosen screw or nut, a cable hanging somewhere, a broken gear in the folding mechanism, etc. To check more easily if and where the folding mechanism jams, fold and unfold manually the scooter (see Owner's Manual, Sec 2, last paragraph). If none jam occurs, then ...

B.8.b)      ...anticipate the unfolding stop switch (see Sec C.7 - 5th paragraph - “To anticipate unfolding stop”).

B.9)   The scooter can be folded but cannot be unfolded

B.9.a)      Check if, when pressing the unfolding green button, a short beep is audible

B.9.a.1)     If a beep is audible:

·   Check integrity of loom (pn 3410) (see wiring diagram). If i is in good order, then ...

·   ... check the unfolding stop switch (pn 4079(A) - Pic B9.1). If in good order, then ...

·   ... replace the scooter controller

B.9.a.2)     If no beep is audible:

·   Checks integrity of  the folding/unfolding buttons loom (pn 4043) (see wiring diagram). If in good order, then ....

·   ... disconnect the two parts of the connector J4 at the scooter controller and while pressing the unfolding green button, check if there is electric continuity between the green and black wires of the loom (pn 4043) (see wiring diagram).

*   If no continuity, replace the green button.

*   If there is continuity, replace the scooter controller

B.10)             The scooter can be unfolded but cannot be folded

B.10.a)  Check if, when pressing the folding red button, a short beep is audible

B.10.a.1)  If a beep is audible:

·   Check integrity of loom (pn 3410) (see wiring diagram). If it is in good order, then ...

·   ... check the folding stop switch (pn 4079 (B) - Pic B10.1). If it is in good order, then ...

·   ... replace the scooter controller

B.10.a.2)  If no beep is audible:

·   Checks integrity of  the folding/unfolding buttons loom (pn 4043) (see wiring diagram). If it is in good order, then ...

·   ... disconnect the two parts of the connector J4 at the scooter controller and while pressing the folding red button, check if there is electric continuity between the grey and black wires of the loom (pn 4043) (see wiring diagram).

*   If no continuity, replace the red button.

*   If there is continuity, replace the scooter controller

B.11)             The scooter does not run backwards

The tests described in this section are to be carried out while the scooter functions are active, i.e. the scooter is not in stand-by mode.

B.11.a)   No beep is audible when the reversing speed rocker switch is ON

- Remove the control panel on the top of the handlebar

- Check if the green and black wires are well connected to the reversing speed rocker switch.  If they are in good order, then ...

- ... check if the rocker switch is in good order (you can use a multimeter for this purpose).
If it is in good order then....

- remove the scooter controller cover on the RH side of the scooter (See the first two paragraphs of Sec C.4) and check if   the green wire is firmly connected to the connector J7 of the scooter controller  (Pic C4.4) (see wiring diagram).
If the green wire is firmly  connected, then...

- ... use a multimeter to check if there is electric continuity on the green wire from its connection to the rocker switch to  the connector J7 of the scooter controller (Pic C4.4) (see wiring diagram).
If there is continuity, replace the scooter controller

B.11.b)   A beep is audible when the reversing speed rocker switch is ON

- Remove the scooter controller cover on the RH side of the scooter (See the first two paragraphs of Sec C.4)

- Check if the blue wire is filmily connected to connector J6 of the scooter controller (Pic C4.4) (see wiring diagram). If it is in good order then....

- ... remove the motor controller cover on the LH side of the scooter (See the first two paragraphs of Sec C.5) and  check if the blue wire is  filmily connected  to connector J10 (see wiring diagram) of the motor controller.

   If it is in good order then....

- use a multimeter to check if there is electric continuity  at the blue wire between its connection to the connector J6 (see wiring diagram) of the scooter controller and connector J10 (see wiring diagram) of the motor controller. If there is continuity ...

-  ... use an extra wire to connect the end of  blue wire at connector J10 of the motor controller at any point of the frame (ground) or to the negative of the battery support and check if the reverse speed works.  If it does not work replace the motor controller. If it works replace the scooter controller.

 


C) OPERATIONS

C.1)       Wheel+Brake Assembly replacement (Pic C1.1)

#       Disconnect the cable (A) from the small screw fitted on the brake disengaging lever;

#       Unscrew the nut of the screw (B) and remove the screw (B)

#       Unscrew the nut of the screw (C) and remove the screw (C) and the round cable terminal below the nut

#       Unscrew the screw (D)

#       Remove the wheel from its LH seat

#       Disconnect the two parts of the round connector (E). To avoid damage to the connector do not disconnect them by pulling the relevant cables but by pulling the two parts.

#       Remove the wheel from the fork

#       When reassembling the wheel+brake assembly on the scooter pay attention to that:

*  when connecting the two parts of the round connector (E), the two arrows marked on each of the two parts have to correspond each other;

*  do not forget to connect the cable (A) at the end of the small screw fitted on the brake disengaging lever and make sure that the screw can move a little bit along its seat in the lever so that the spring inside the seat can push the small screw to certainly contact the screw (C) when the lever is engaged as shown in Pic C1.1

 

C.2)       Brake Assembly replacement (04/19)

#       Pic C2.1b - Fit the brake turning disc holder (PN 3391) on the wheel

#       Pic C2.1b - Fit a first shim  16 x 24 thickness 1 mm (PN 1101) 

#       Pic C2.2b - Fit the washer (PN MMX16) thickness 2,5 mm on top of the first shim.

#       Pic C2.3b - Fit the internal teeth steel disc (PN 3365)

#       Pic C2.4b - Fit the external teeth disc (PN 3397) on top of the steel disc, so that its teeth engage the teeth of the brake turning disc holder

#       Pic C2.5b - Fit the brake main body. For an easier fitting move the brake main body slighly sideways so that its teeth can more easily engage the teeth of the steel disc.

#       Pic C2.6b - Screw and tighten the wheel axle nut (PN 3379)

#       Assemble the wheel+brake assembly on the scooter and test the brake efficiency on the road:

*  If braking is too soft, disassemble the wheel+brake assembly from the scooter, replace  the washer (PN MMX16) thickness 2,5 mm with a washer 2,3 mm. If braking is still too soft, replace the washer 2,3 mm thickness with a washer 2,2 mm

*  If braking is too abrupt, disassemble the wheel+brake assembly from the scooter and add a shim thickness 3/10 mm on the top of the washer MMX16 (Pic C2.7b) . If braking is still too abrupt add a second shim of 2/10 mm or 3/10 mm on the top of the first shim.

C.3)       Handlebar folding control cable replacement

#       Check that the scooter is completely unfolded.

#       Pic C3.1 - Remove the 3 plastic caps (pn 474) on the RH side cover and the three nuts underneath

#       Pic C3.2 - Remove the cover

#       Pic C3.3 - Remove the cap (pn 489) from the end of the steel cable and the plastic cap (pn 474) from the clamp screw

#       Pic C3.4 - Loosen the cable clamp screw (pn 3512)

#       Pull out the cable from its rear end under the RH side of the seat

#       Check that the adjustment device (pn 3163) is completely screwed on as shown in Pic C3.5

#       Introduce the new cable from the rear end (pay attention to the junction point of the two outer cable sections as shown in Pic C3.5. While introducing the cable, apply some grease on it. Routing of the cable on the front fork area is that shown in Pic C3.6. In particular the cable is to go through the hole of the pin (pn 1025)

#       Pic C3.4 - Introduce the front end of the cable in the hole of the clamp (pn 3512) at the handlebar. The correct tension of the steel cable is obtained by temporarily laying the end of the outer cable over the edge of the washer A (Pic C3.7) and then pulling the cable quite tight.

#       Pic C3.4 - Tighten the screw of the clamp (pn 3512);

#       Pic C3.7 - Remove the end of the outer cable from the edge of the washer A

#       Pic C3.4 - Cut the part of the steel cable exceeding 5 mm from the clamp surface

#       Pic C3.3 - Fit the cable cap (pn 489) at the end of the cable and clamp it; fit the plastic cap (pn 474) on the screw of clamp (pn 3512)

#       Pic C3.5 - Press the folding red button and check if while the scooter is folding the top of the handlebar hits against the back rest. If it hits, unscrew a little bit the adjustment device (pn 3163) until obtaining that the top of the handlebar does not hit against the back rest when folding. After having unscrewed the adjustment device tighten the corresponding nut acting as a lock nut.

#       When reassembling the RH side cover on the scooter pay attention to that:

*  the position of the light sensor and of the LED light fitted in the scooter controller correspond to the two holes (A) and (B) in the cover (Pic C3.1)

*  the wires of the electric loom are not pinched between the cover and the frame.

 

C.4)       Scooter Controller replacement

#       Pic C4.1 - Remove the 3 plastic caps on the RH side cover; unscrew and remove the three nuts underneath

#       Pic C4.2 - Remove the cover

#       Disconnect the 8 connectors from the controller

#       Pic C4.3 - Unscrew and remove the 2 nuts (N) using an 8 mm box wrench

#       Remove the controller

#       When reassembling the RH side cover on the scooter pay attention to that:

*  the position of the light sensor and of the LED light fitted in the scooter controller correspond to the two holes (A) and (B) in the cover (Pic C4.1)

*  the wires of the electric loom are not pinched between the cover and the frame

*  when connecting again the connectors on the scooter controller pay attention to the connectors (J5) and (J7) can be distinguished only because the two parts of J5 are red coloured (Pic C4.4)

 

C.5)       Motor Controller replacement

#       Pic C5.1 - Remove the 2 plastic caps (pn 474) on the LH side cover; unscrew and remove the 2 nuts underneath

#       Pic C5.2 - Remove the cover

#       Pic C5.2 - Disconnect the two parts of the 6 wires connector (pn HA4F6+HA4M6)

#       Pic C5.2 - Remove the two plastic caps (pn 474) at the end of the two contacts on the battery support

#       Pic C5.3 - Unscrew the two nuts underneath

#       Pic C5.4 - Disconnect the round connectors from the battery support terminals and remove the plastic sheaths (A) covering the end of the relevant wires

#       Pic C5.4 - Unscrew the 4 screws (pn VTX48013) holding the battery support

#       Remove the battery support

#       Pic C5.5 - Disconnect the two parts of the round connector (C). To avoid damage to the connector do not disconnect them by pulling the relevant cables but by pulling the two parts.

#       Pic C5.6 - Unscrew the two screws (pn VNM05012) which hold the controller to the frame

#       When reassembling pay attention to:

*  when connecting the two parts of the round connector, the two arrows marked on each of the two parts have to correspond each other;

*  when connecting the two parts of the square connector (pn HA4F6+HA4M6) they have to remain engaged each other by the small plastic hook

*  to not pinch the wires between the cover and the frame, especially in the point (A) of (Pic C5.1)

C.6)       Battery support replacement

#       Pic C6.1 - Remove the two plastic caps (pn 474) at the end of the two contacts on the battery support and ...

#       Pic C6.2 - … unscrew the two nuts underneath

#       Pic C6.3 - Disconnect the round connectors (A) from the battery support terminals

#       Pic C6.3 - Unscrew the 4 screws (pn VTX48013) holding the battery support

#       Remove the battery support

 

C.7)       Folding-unfolding stop switches adjustments

#       Notice
The two stop switches (pn 4079) are hidden by the cover (pn 3079) (Pic C7.1). For a better visibility Pic C7.2 shows the two switches after that the cover (pn 3079) has been removed: however for the purposes of this section it is not necessary to remove this cover.
The functions of the two switches are:

*  the switch (A) stops the unfolding of the scooter

*  the switch (B) stops the folding of the scooter.

#       Pic C7.3 - Remove the 3 plastic caps (pn 474) on the RH side cover and the three nuts underneath

#       Pic C7.4 - Remove the cover

#       Pic C7.5 - To delay unfolding stop

*  Loosen the screw of the switch (A), i.e. the screw corresponding to nut (NA) in Pic C7.2

*  move the switch a little bit upwards

*  tighten again the screw

#       Pic C7.5 - To anticipate unfolding stop

*  Loosen the screw of the switch (A), i.e. the screw corresponding to nut (NA) in Pic C7.2

*  move the switch a little bit downwards

*  tighten again the screw

#       Pic C7.6 - To delay folding stop

*  Loosen the screw of the switch (B), i.e. the screw corresponding to nut (NB) in Pic C7.2

*  move the switch a little bit forward

*  tighten again the screw

#       Pic C7.6 - To anticipate folding stop

*  Loosen the screw of the switch (B), i.e. the screw corresponding to nut (NB) in Pic C7.2

*  move the switch a little bit rearward

*  tighten again the screw

#       When reassembling the RH side cover on the scooter pay attention to that:

*  the position of the LED light and the light sensor fitted in the scooter controller correspond to the two holes (A) and (B) in the cover (Pic C7.3)

*  the wires of the electric loom are not pinched between the cover and the frame

 

C.8)       Folding/unfolding buttons replacement

#       Pic C8.1 - Remove the 3 plastic caps (pn 474) on the RH side cover and the three nuts underneath

#       Pic C8.2 - Remove the cover

#       Pic C8.3 - Disconnect connector (pn HA3M4) from the corresponding connector pn (HA3F4) (the position of this connector is marked J4 on the card)

#       Pic C8.4 - Unscrew screw (pn VNM05045) and remove the cover (pn 3541)

#       Pic C8.5 - Unscrew the two screws (pn VNM08016) and remove the cover assembly (pn 3079)

#       When reassembling the cover assembly on the scooter:

*  add some drops of thread lock liquid in the treads of screws (pn VNM08016)

#       When reassembling the RH side cover on the scooter pay attention to that:

*  the position of the LED light and the light sensor fitted in the scooter controller correspond to the two holes (A) and (B) in the cover (Pic C8.1)

*  the wires of the electric loom are not pinched between the cover and the frame.

 

C.9)       Front fork returning spring replacement

#       Pic C9.1 - Unscrew and remove the lock nut (pn DBE08) and the screw (pn VFK08075)

#       Pic C9.2 - Move forward the front fork assembly and remove the spring (pn 3153)

#       Fit the new spring according the steps shown in the following pictures:

*  Pic C9.3

*  Pic C9.4

*  Pic C9.5

*  Pic C9.6

#       Pic C9.6 + Pic C9.7 - Fit the two washers (pn MAX10) centred on the spacer protruding from the steering tube bearings. The bottom washer can be kept on the spacer using a little bit grease as glue

#       Pic C9.8 - Reassemble the front fork on the steering tube. The front fork has to be introduced in the steering tube while in straight position so that the protrusion (A) on the fork fits at the centre of the two ends (B) of the spring

#       Pic C9.1 - Screw the screw (pn VFK08075) on the lower plate of the fork. Screw the lock nut (pn DBE08) after having added some drops of lock liquid in its threads

#       Pic C9.10 - Check that the tip of the LH end of the spring is positioned in the bottom corner (C) of the protrusion (A) (Pic C9.9). If not, bend the spring end using a pliers

#       Fold the scooter and check if, while folding, the handlebar remains centred as regards to the back rest. If it turns toward right or left side, bend a little bit the suitable end of the spring: if the handlebar turns toward the RH side, bend the RH tip of the spring towards the LH side; if the handlebar turns toward the LH side, bend the LH tip of the spring towards the RH side (In this case RH side or LH it that when looking the front of the scooter)

 

C.10)    Handlebar returning spring replacement
(For safety reasons the operations here described should be carried out while wearing suitable gloves)

#       Pic C10.1 - Seize the spring with a pliers

#       Pic C10.2 - Bend forward the spring so to …

#       Pic C10.3 - … so to remove its bended end (A) from the handlebar retainer (B)

#       Pic C10.4 - Turn the spring round the front fork bar until removing it.

#       Pic C10.5 - Put the beginning of the spiral of the new spring in the front fork bar

#       Pic C10.6 - “Screw” the spring round the front fork bar until ...

#       Pic C10.7 - … until the internal bent end (C) of the spring is hooked by the front fork bar. Add a little bit grease inside the spiral of the spring.

#       Pic C10.8 - Hang the external bent end of the spring to a steel cable (like that used for the brakes).

#       Pic C10.9 - Pull the steel cable backwards so to turn the spring of about 180°

#       Pic C10.10 - Keep the spring in this position by seizing it with a pliers and meantime move the cable frontwards

#       Pic C10.11 - Pull the steel cable so to turn the spring for further about 180° until …..

#       Pic C10.12 - … until the bended end (A) of the spring can be hanged to the handlebar retainer (B)

#       To release the steel cable if it remains embedded between the spring and the retainer:

*  or use a pliers (Pic C10.13)

*  or use a screwdriver (Pic C10.14)

 

C.11)    RH loom (pn 3135) and LH loom (pn 3149) replacement

#       Notices

*  RH loom (pn 3135) and LH loom (pn 3149) must be disassembled in the same operation.

*  when pulling the looms as here below described, use caution to avoid damaging to the connectors fitted at their ends.

#       Pic C11.1 - Remove the 3 plastic caps (pn 474) on the RH side cover and the three nuts underneath

#       Pic C11.2 - Remove the cover

#       Pic C11.3 - Disconnect (J8) – (J7) - (J5) connectors (see also wiring diagram)

#       Pic C11.4 - Pull the loom corresponding to the connector (J8) at the RH hinge between footboard and main frame.

#       From the same location pull the loom corresponding to connector (J7)

#       From the same location pull the loom corresponding to connector (J5)

#       Pic C11.5 - Bend a little bit the retainer (A) below the RH side of the mounting of the footboard in order to allow removing of the looms.

#       From the location shown in Pic 11.5 pull the loom corresponding to connector (J8) and then the looms corresponding to connectors (J7) and (J5)

#       Pic C11.6 - Cut the plastic clamp (pn 717)

#       From this location pull the loom corresponding to connector (J8) and then the looms corresponding to connectors (J7) and (J5)

#       Pic C11.7 - Unscrew the screw (pn VQX29009) holding the control board assembly (pn 3553) and remove it from the top of the handlebar (Pic C11.8)

#       Pic C11.8 - Disconnect all the connectors at the control board assembly (pn 3553)

#       From the top of the handlebar pull at same time the two looms corresponding to connector (J7) and (J5), i.e. respectively the LH loom (pn 3135) and the RH loom (pn 3149). While pulling from the top of the handlebar, push the two looms upwards at the bottom of the handlebar (Pic C11.9). Before entering the connectors of the two looms in the handlebar stem, put them one after the other as shown in Pic C11.10

#       When reassembling:

*  the two looms are to be entered in the same time in the different parts of the frame, starting from the upper end of the handlebar, always keeping the two connectors one behind the other as shown in Pic C11.10

*  when connecting again the connectors on the scooter controller pay attention to the connectors (J7) and (J5) can be distinguished only because J5 is red coloured (Pic C11.3)

*  bend to the original position the retainer (A) below the RH side of the mounting of the footboard (Pic C11.5)

*  pay attention to that the position of the LED light and the light sensor fitted in the scooter controller correspond to the two holes (A) and (B) in the cover (Pic C8.1)

*  pay attention to that the wires of the electric loom are not pinched between the cover and the frame.

 

C.12)    Motor-controller loom (pn 3098) replacement

#       Pic C12.1 - Remove the 2 plastic caps (pn 474) on the LH side cover; unscrew and remove the 2 nuts underneath

#       Pic C12.2 - Remove the cover

#       Pic C12.2 - Unscrew the 4 screws (pn VTX48013) holding the battery support

#       Pic C12.3 - Remove the battery support without disconnecting the cables

#       Pic C12.3 - Disconnect the two parts of the round connector (C). To avoid damage to the connector do not disconnect them by pulling the relevant cables but by pulling the two parts.

#       Pic C12.4 - Pull the loom at the LH hinge between footboard and main frame

#       Pic C12.5 - Bend a little bit the retainer (A) below the LH side of the mounting of the footboard in order to allow removing of the loom.

#       Pic C12.6 - Cut the plastic clamp (A) (pn 717)

#       Pic C12.6 - Pull the loom in the direction (C) in order to remove it from the footboard mounting.

#       Pic C12.6 - Disconnect the two parts of the round connector (B) ( To avoid damage to the connector do not disconnect them by pulling the relevant cables but by pulling the two parts.

#       Pic C12.6 - Pull the loom in the direction (D) in order to remove it from the front fork

#       When reassembling:

*  Pic C12.5 - Bend to the original position the retainer (A) below the LH side of the mounting of the footboard.

*  When connecting the two parts of the round connector at the motor end and at the motor controller end, pay attention to that the arrow marked on each of the two parts corresponds to that on the other part.

*  Pay attention to not pinch the wires between the cover and the frame, especially in the point (A) of (Pic C12.1)

 

C.13)    Gears assembly (pn 3582+pn3583) replacement (Pic C13.2)

#       Pic C13.1 – Disconnect the folding automatic mechanism by pushing the lever (A) upwards and then fold manually the scooter (see owner's manual – Sec. 3 – Last par.)

#       Pic C13.2 - Unscrew nut (pn DIX06) and screw (pn VFX06050)

#       Pic C13.2 - Remove gears assembly (pn 3582+pn3583) paying attention to not lose the bushing (pn 3600) inside the gear (pn 3582)

#       When reassembling

*  add a little bit grease in the teeth and inside the said bushing

*  Connect again the folding automatic mechanism by pushing the lever (A) downwards (see owner's manual – Sec. 3 – Last par.)

 

C.14)    Geared rod (LH side) (pn 3595) (Pic C14.1) replacement

#       Remove the gears assembly (pn 3582+pn3583) (see Sec C.13)

#       Unfold completely the scooter manually

#       Pic C14.3 - Unscrew the screws (pn VNM08016) and remove the cover (pn 3177) (Pic C14.2) paying attention to not lose the two washers (A)

#       Pic C14.4 - Measure the gap (A) between the seat frame protrusion and the geared rod

#       Pic C14.3 - Unscrew the upper screw (pn 3190) paying attention to not lose the washer underneath

#       Pic C14.4 - Unscrew the lower screw (pn 3190) paying attention to not lose the shim underneath

#       Pic C14.6 - While removing the geared rod (LH side) (pn 3595) the screw (pn VNM10016) comes out from the seat front bar.

#       Pic C14.6 - Unscrew and remove the screw (pn VNM10016)

#       When reassembling:

*  Pic C14.4 - Mesh the teeth (B) and (C) so that the gap (A) is the same than that measured before disassembling

*  Add some grease on the teeth

*  Add some drops of thread lock liquid in the threads of all the screws

 

C.15)    Geared rod (RH side) (pn 3594) (Pic C15.1) replacement

#       Unfold completely the scooter

#       Pic C15.1 - Unscrew the two screws (pn VNM08016)

#       Pic C15.2 - Move sideways the cover assembly (pn 3079) paying attention to not lose the two washers (W)

#       Pic C15.2 - Measure the gap (A) between the seat frame protrusion and the geared rod

#       Pic C15.2 - Unscrew the upper screw (pn 3190) paying attention to not lose the washer underneath

#       Pic C15.2 - Unscrew the lower screw (pn 3190) paying attention to not lose the shim underneath

#       Pic C15.2 - While removing the geared rod (RH side) (pn 3594) the screw (D) comes out from the seat front bar.

#       Pic C15.2 - Unscrew and remove the the screw (D).

#       When reassembling:

*  Pic C15.2 - Mesh the teeth (B) and (C) so that the gap (A) is the same than that measured before disassembling.

*  Add some grease on the teeth

*  Add some drops of thread lock liquid in the threads of all the screws

 

C.16)    Seat sheet (pn 3021) replacement (Pic C16.1) (Versions until 31-12-2016)

#       Sec C.13 - Fold completely the scooter and disassemble the gears assembly (pn 3582+pn 3583)

#       Pic C16.3 - Unscrew the screws (pn VNM08016) and remove the cover (pn 3177) (Pic C16.2) paying attention to not lose the two washers (A)

#       Unfold completely the scooter

#       Pic C16.3 - Remove the seat cushion.

#       Pic C16.4 - Measure the gap (A) between the seat frame protrusion and the geared rod

#       Pic C16.3 - Unscrew and remove the screw (pn VNM10016)

#       Pic C16.5 - Remove the seat front bar (pn 3591) from the front edge of the seat sheet

#       Pic C16.6 - Turn backwards the seat sheet so to make it hanging to seat rear bar.

#       Pic C16.7 - Disconnect the seat frame gear (A) from the geared rod (LH side) (B) by bending sideways the bottom arm of the seat frame.

#       Pic C16.8 - Bend sideways the bottom arm of the seat frame (A) in order to disconnect it from the end of the seat rear bar (pn 3168)

#       Remove the seat sheet from the seat rear bar.

#       When reassembling pay attention to:.

*  Pic C16.4 - Mesh the teeth (B) and (C) so that the gap (A) is the same than that measured before disassembling.

*  The seat sheet is to be fitted so that two adhesive strips (A) and (B) are in the position shown in Pic C16.1

*  Add some grease on the teeth

*  Add some drops of thread lock liquid in the threads of all the screws

 

C.17)    Seat sheet (pn 3021) replacement (Versions from 01-01-2017)

#       Pic C17.1 - Remove the seat cushion .

#       Pic C17.1 - Unscrew and remove the screw (pn VNM10016)

#       Pic C17.2 - Remove the seat front bar (pn 3591) from the front edge of the seat sheet

#       Pic C17.3 - Turn backwards the seat sheet so to make it hanging to seat rear bar

#       Pic C17.4 – Unscrew the screw (pn VMA03016) at the LH from the rear seat bar. This screw is screwed on a nut on the opposite side on the bar.

#       Pic C17.5 – Move the LH end of the seat rear bar (pn 3166) rearward in order to disconnect from seat frame protrusion (A) and then remove the bar from the seat sheet.

#       Replace the sheet

#       When reassembling pay attention to:.

*  The seat sheet is to be fitted so that two adhesive strips (A) and (B) are in the position shown in Pic C17.1

 

C.18)    Cancelling the reverse speed sound (beep) warning
(For safety reasons cancel the reverse speed sound warning only when absolutely necessary)

#       Turn rearward the rocker device for setting reverse speed of the scooter.

#       Press the horn green button and immediately after also the main switch yellow button. Two short beep advise that the reverse speed warning has been cancelled.

#       To reintroduce the reverse speed warning follow the same steps as above. Three short beep advise that the reverse speed warning has been reintroduced.