Need help - Scooter broke down

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Bradster
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Need help - Scooter broke down

Well I got controller mod done and went out for a test run GPS and all.
I didnt even get it up to full speed and broke down.
Had sparks coming out of the motor.
Got off it and found out that these IDIOTS had the motor wires wrapped
so tight around the axle that the wires stretched and were sparking everywhere.
Even the protective wire coating a foot up near the controller is ripped.

I had to push it home nearly a mile! To make things worse, the wires might of tightened
around the axle cause there was resistance pushing the thing.
I couldnt push it all the way on my own, so I give the motor a little throttle while pushing.
Couldnt throttle that much or it would spark all over and very slow going.

Now what? is the controller and motor smoked?
You cant even disconnect the batteries. Under the seat is a trap door, you can see
batteries but the posts are out of reach wouldnt you know.

So does this thing have a fuse or some kinda shut off? I dont wanna get shocked, I guess
I gotta cut the harness at the motor and re-splice with some slack in there.
I can make it look professional, solder shrink wrap and wire tie it along the frame rail.

Any ideas help or thoughts on this? I dont want it to be a hazard in the garage overnight either!
Thanks!

antiscab
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Re: Need help - Scooter broke down

ah this sounds familiar.
the motor wires wrapped around tight are actually the result of the hub motor rotating relative to the chasis when instead it is meant to be fixed to it.
this happened to me aswell, and another guy a year ago.
ill try and track down the link rather than retype it.

basically for my setup i reinforced the mounting on the motor by adding two forks, one 8mm thick, the other 5mm thick, mild steel.

the motor wire shouldnt be wound at all :S

Matt

Daily Ride:
2007 Vectrix, modified with 42 x Thundersky 60Ah
Vectrix 60Ah Lithium Tyres Fuel Registration Insurance cycle analyst 2 x TC Charger & MC
conversion

antiscab
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Joined: Saturday, July 7, 2007 - 23:55
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Re: Need help - Scooter broke down

found it:
http://visforvoltage.org/forum-topic/motorcycles-and-large-scooters/673-bad-news-e-max-motor-jeopardy

ill post a picture of the forks i made in a day or two.
basically, just use the guide pieces as a template.

oh, and there are contactors just before the power stage of your controller.
so while the scooter is off, for there to be nay danger, both the contactors and the controller powerstage have to have failed.
it wont be a hazard in your garage overnight.

btw, where are you located?

Matt

Daily Ride:
2007 Vectrix, modified with 42 x Thundersky 60Ah
Vectrix 60Ah Lithium Tyres Fuel Registration Insurance cycle analyst 2 x TC Charger & MC
conversion

Bradster
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Last seen: 11 years 11 months ago
Joined: Monday, December 15, 2008 - 10:50
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Re: Need help - Scooter broke down

Matt thanks for the info, btw I live in Arizona.
I'll be able ride this new scooter most of the year if I can keep up with the repairs.

You may of also helped in another way. I found the e-max handbook section pdf files, but its
not working for me. When you click on a pdf file it brings me to a website called 1gigfree.com
Did the manual get removed or something?

chas_stevenson
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Re: Need help - Scooter broke down

Bradster,

The manuals for the E-Max have been preserved in the V is for Voltage EV DownLoad Library. We have created this page and stored the manuals on a separate server so our members may have access to them even when the originator has remove the information from the internet. If you have or find any useful information you feel may help others please send a message to the moderators using a contact link and we will be happy to post the information.

Hope this helps,
Grandpa Chas S.

PJD
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Joined: Wednesday, November 22, 2006 - 05:44
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Re: Need help - Scooter broke down

As Matt noted, the wires were wrapped around the axle because the axle spun in the fork in reaction to the hub motor's torque.

I should add that while Matt's forks or my clamping bolt are a good idea, this can usually be prevented by just periodically making sure the axle nuts are properly tightened. Use a torque wrench - 85 newton-meters, 60 foot-pounds.

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