Currie tech 500 DD Series User manual

TWIST AND GO! To start scooter turn the power switch “ON”. Twist
throttle and go.
ATTENTION
!
OWNER’S MANUAL
(DIRECT DRIVE SCOOTER SERIES)
You must read and understand this manual before using this scooter
CURRIE TECHNOLOGIES®
500 DD Series 750 DD Series
1000 DD Series Scoot-E DD Series
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2Customer Service 1-800-377-4532
Currie Technologies®
PLEASE DO NOT RETURN
THIS ITEM TO THE STORE.
For questions or assistance on assembly contact
Currie Technologies®Customer Service toll free
[phone]
Monday - Friday
8:00 am - 4:00 pm (PST)
OR
Consult the trouble shooting guide of the owner’s manual or
visit our website at www.CurrieTech.com
IMPORTANT - Activate your warranty by registering your new Currie
Technologies®product within 10 days of purchase by visiting our website at
www.CurrieTech.com.
Retain this manual along with the original sales receipt. Record the
product serial number (S/N), place of purchase and date of purchase
below.
Model Name : __________________________________________
S/N : __________________________________________________
Place of Purchase : ______________________________________
Date of Purchase : _______________________________________
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Currie Technologies®
TABLE OF CONTENTS
Section 1 . . . . . . Technical Information . . . . . . . . . . . . . . . . page 3
Section 2 . . . . . . Safety Guidelines . . . . . . . . . . . . . . . . . . . page 4-7
Section 3 . . . . . . Basic Assembly. . . . . . . . . . . . . . . . . . . . . page 8-9
Section 4 . . . . . . Repair and Maintenance . . . . . . . . . . . . . . page 10-30
Section 5 . . . . . . Frequently Asked Questions (FAQ’s) . . . . . page 31-32
Section 6 . . . . . . Limited Warranty . . . . . . . . . . . . . . . . . . . . page 33-34
Section 7 . . . . . . Pre-Ride Checklist . . . . . . . . . . . . . . . . . . page 35
Section 1 - TECHNICAL INFORMATION
500DD
Series Scooter 750DD Series Scooter Stealth 1000DD Series Scooter
Minimum Rider
Age 13 years old 13 years old 13 years old
Maximum Rider
Weight
240 lbs
(109 kg)
260 lbs
(118 kg)
260 lbs
(118 kg)
Maximum
speed*
Up to 15 mph
(24 km/h)
Up to 15 mph
(24 km/h)
Up to 15 mph
(24 km/h)
Max Range* 8 miles
(13 km)
12 miles
(19 km)
12 miles
(19 km)
Battery 24V 12Ah
SLA
24V 12Ah
SLA
36V 10Ah
SLA
Charging time** 8-10 hours 8-10 hours 6-8 hours
iZip Fusion 1000DD
Series Scooter eZip 1000DD Series Scooter Scoot-E DD Series Scooter
Minimum Rider
Age 13 years old 13 years old 13 years old
Maximum Rider
Weight
260 lbs
(118 kg)
260 lbs
(118 kg)
260 lbs
(118 kg)
Maximum
speed*
Up to 15 mph
(24 km/h)
Up to 15 mph
(24 km/h)
Up to 10 mph
(16 km/h)
Max Range* 12 miles
(19 km)
12 miles
(19 km)
18 miles
(29 km)
Battery 36V 12Ah
SLA
36V 10Ah
SLA
24V 24Ah
SLA
Charging time** 8-10 hours 6-8 hours 6-8 hours
*Maximum range and speed varies based on rider weight and terrain.
**Charge time is based on new batteries charged with a standard charger.
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4Customer Service 1-800-377-4532
Currie Technologies®
Section 2 - SAFETY GUIDELINES
LIMITATIONS OF SAFETY AND WARNING NOTICES
This owner’s manual includes important safety
guidelines and maintenance instructions. Failure to
read, understand and follow the instructions in this
manual may lead to serious injury or even death.
INSURANCE NOTICE
Your insurance policies may not provide coverage for accidents
involving the use of this electric scooter. To determine if coverage
is provided, you should contact your insurance company or agent.
This product is intended for use under adult supervision only. Even
»
under adult supervision serious injuries or even death can occur.
Always ride within your capabilities and use common sense, do
»
not ride at night. You are using this product at your own risk. Never
operate this product at a speed which is too fast for your skills.
Always drive at low speed on dusty surfaces.
This product is not intended, designed or licensed for roadway
»
use. This product is intended for use outdoors and on a private,
closed course only. Ride only on dry, smooth, solid paved surfaces
without motor vehicle traffic. Never use this product on roadways
(paved, gravel or dirt), sidewalks, driveways, parking lots near motor
vehicles, on or near steep inclines or steps, swimming pools or other
bodies of water.
This product is not regulated by transportation regulations (that is,
»
Department of Transportation (DOT) or state law).
Obey all local traffic and scooter riding laws and regulations. The
»
laws and ordinances vary greatly from municipality to municipality.
It is your responsibility to know and abide by your local restrictions.
We recommend you contact your local police or Department of
Motor Vehicles to find out about any special laws or rules governing
the use of this product where you live.
Do not ride at night.
»
WARNING
!
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Currie Technologies®
Never operate this product without proper training
or instructions.
Children under 13 years old should never operate these
scooters. Rider age does not necessarily mean that they are qualified to
operate this product. A parent should never allow this product to be used by
an individual not having the ability, coordination, maturity, skills and strength
to operate it safely and in a controlled manner.
Maximum rider weight is 240 lbs, (109kg) for the
500DD scooters and 260 lbs. (118 kg) for the 750DD, 1000DD and Scoot-E
DD series scooters. Rider weight does not necessarily mean that they are
qualified to operate this product.
Never modify this product through improper installation,
modification of existing parts or use of non-authorized accessories. Doing so
may result in denied warranty claims.
Adults must assist children in the initial adjustment procedures to unfold
scooter, adjust handlebar and steering to height, and finally to fold scooter.
Check and secure all fasteners before every ride. Before every ride, make
sure the “Easy Fold Handlebar Hinge” is in the fully upright position. Be sure
the locking pin is fully engaged and the quick release lever is in the “closed”
position.
Check and secure all fasteners before every ride.
This product is designed to be used by only one person at a time. Never
carry passengers or allow more than one person to use this product at a
time.
Always wear an approved helmet that fits and is worn properly with the
chinstrap securely buckled when using this product. Wear shoes when
using this product, never operate this product barefoot or in sandals as this
increases the risk of injury. Also wear knee pads, elbow pads, eye protection
(goggles or face shield), gloves, boots, long sleeved shirt or jacket and long
pants.
Always keep both hands on the handlebars (hand grips) and both feet on the
footboard during operation.
WARNING
!
WARNING
!
WARNING
!
WARNING
!
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6Customer Service 1-800-377-4532
Currie Technologies®
Avoid excessive speed associated with downhill riding. Always drive slowly
and pay extra attention when operating on unfamiliar terrain. Always be alert
to changing terrain conditions when operating this product. Never operate on
excessively rough, slippery or loose terrain.
Avoid sharp bumps, drainage grates, and sudden surface changes. Scooter
may suddenly stop. Always check for obstacles before operating in a new
area. Never attempt to operate over large obstacles, such as large rocks or
fallen trees.
Watch out for pedestrians
Replace worn or broken parts immediately. Do not use this product until worn
or broken parts have been replaced by a qualified mechanic.
Practice turning at low speeds before attempting to turn at faster speeds. Do
not turn at excessive speed as this could increase the risk of injury.
Do not ride with headphones. They mask traffic sounds and emergency
vehicle sirens, distract you from concentrating on what is going on around
you, and their wires can tangle in the moving parts of the scooter, causing
you to lose control.
Do not do stunts, wheelies, jumps or any other type of dangerous riding.
They can cause severe injury to you and damage your scooter.
Do not lean the scooter excessively as this may allow parts of the scooter to
contact the ground and may result in lose of control, damage to the scooter
or injury to rider.
Do not touch the motor or brakes as they can become hot from use.
WET WEATHER RIDING
This product is not meant for use in the water (damp roads, puddles, rain,
streams, etc.) or in wet weather. Never immerse this product in water as the
electrical and brake systems may be damaged. Avoid streets and surfaces
with water, sand gravel, dirt, leaves, and other debris. Wet weather impairs
traction, braking and visibility.
BATTERY CHARGER
The charger and charger port should be regularly inspected for damage
(cord, plug, enclosure, etc.). If damage is found stop using the charger until it
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STARTING
Turn the power switch to the “ON” position1.
Place one foot on the deck with both hands on the handlebars.2.
Slowly twist the throttle to operate the motor.3.
Place the other foot on the deck once you have properly balanced yourself.4.
STOPPING
To slow down or come to a stop, allow the throttle to completely return to its1.
“zero speed” position
Squeeze the brake lever(s) on the handlebar to come to a safe stop. (Note: It2.
is not necessary to skid the wheel in order to slow or stop the scooter)
Skidding the wheel can damage the wheel and is not
covered by the warranty!
STORING YOUR SCOOTER
When you are done using the scooter, turn the power switch to the1.
“OFF” position.
Always be sure to fully charge batteries (6-10 hours depending on2.
battery size) at least every 30 days.
Plug the charger into the scooter then plug the charger into the wall3.
outlet. Do not charge your battery for more than 24 hours at one
time.
5 MINUTE SLEEP MODE
Scooters are equipped with a 5 minute sleep mode. If no activity is detected
after 5 minutes the scooter will go into stasis mode to conserve the batteries.
To restart, cycle the power switch Off then On.
Never store your scooter in Sleep Mode as battery power will still be used by
the scooter. Always be sure to turn the power switch to the “OFF” position.
WARNING
!
can repaired or replaced.
The charger is not a toy and should be kept out of reach children at all times.
Always disconnect the charger from the wall outlet and the charger port on
the scooter when not using it.
Do not charge your battery for more than 24 hours at one time.
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8Customer Service 1-800-377-4532
Currie Technologies®
Section 3 - BASIC ASSEMBLY & SET-UP
IMPORTANT: Some adult assembly required. Before using your scooter
please be sure to read and follow the basic assembly, set-up and operating
instructions. Following these instructions will help insure safe riding.
TOOLS REQUIRED:
Listed below are the tools you may need to assemble and adjust your
Electro-Drive™ scooter depending on model:
STEPS FOR BASIC ASSEMBLY
Remove scooter from carton. Remove all of the packaging materials1.
from the scooter.
Install the front wheel (certain models will have the front wheel2.
already installed) being sure to properly install the safety washers.
Align the front wheel in the fork and tighten the axle nuts. Wait until
after you have installed the handlebars to connect the front brake (if
your scooter is so equipped).
Install the handlebars onto the stem, align and tighten.3.
Unfold the stem hinge. Be sure the locking pin is fully engaged and4.
close the quick release lever.
The brake(s) come pre-assembled from the factory (some scooters5.
have one brake while others have two brakes). However, you need
to check to make sure it is connected and operating properly. Test
the brake lever(s) by squeezing it. It should stop the wheel(s) easily
and NOT come in contact with the handlebar. If the brake lever(s)
needs adjusting, refer to pages 19-20 for instructions. If the brake(s)
does not work properly, DO NOT RIDE THE SCOOTER. Call
Customer Service at 1-800-377-4532 for further assistance.
Install the seat assembly, if so desired, by fully sliding the seat6.
tube into the frame and securing the pinch bolt. If the seat tube is
equipped with an indexing pin be sure to align this properly with the
frame.
Install the seat onto the seat tube if not already done and align7.
saddle angle and tilt and tighten accordingly.
Remove the battery charger from its box. Make sure the power8.
switch on the scooter is in the “OFF” position. Connect the charger
10mm box wrench•
13mm box wrench•
15mm box wrench•
17mm cone wrench•
4mm hex key wrench•
5mm hex key wrench•
6mm hex key wrench•
Phillips screwdriver•
Bicycle tire pump•
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Currie Technologies®
to the scooter first then plug the charger into the wall socket. Allow
the batteries to charge a full 6-10 hours (depending on the size of
batteries) before first use. Refer to page 17 for complete Battery
Care instructions
Before every ride, test the throttle with the pow9. er switch in
the “OFF” position. Twist the throttle, it should twist easily and
immediately spring back to the starting position when you release
it. If the throttle does not work properly, DO NOT RIDE THE
SCOOTER. Call Customer Service at 1-800-377-4532 for further
assistance.
Check tire pressure and inflate to recommended pressure as10.
necessary.
Before you ride the scooter, make sure you have
tightened all parts. Riding with a loose handlebar, front
wheel, brake, seat assembly, etc. may cause a rider to
fall, possibly damaging the scooter and causing serious
injury.
WARNING
!
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Insert the stem into the1.
steerer tube. Be sure
to insert stem past the
“Minimum Insertion Mark”.
Section 4 - REPAIR & MAINTENANCE
IMPORTANT: Some adult assembly required.
HANDLEBAR ASSEMBLY AND ADJUSTMENT
Electro-Drive™ scooters are equipped with an folding stem hinge. Take care
not to pinch your hands or fingers in the hinge when you are folding and
locking the handlebar in place. Additionally be careful not to pinch or crimp
the brake and throttle cables in the hinge whenever you fold the stem hinge.
Photo B
Open the stem quick release2.
(QR) lever (Ref Photo A)
and rotate it forward out
of the upper plate (Ref
Photo B, step 1). Slide the
QR retention pin (silver)
sideways (Ref Photo B, step
2) to disengage it from the
upper plate.
Photo A
2
1
If the
quick release lever is either
too tight (cannot be flipped to
its fully locked position) or is
too loose (can be too easily
flipped to its locked position)
refer to the “QR Lever Adjust-
ment” on page 14.
WARNING
!
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Open the stem hinge to3.
access the steerer bolt
(6mm Allen Bolt or 13mm
Hex Bolt).
4. Loosely tighten the steerer
bolt. The stem is held in
position with the expander
bolt and wedge.
Slide the QR retention pin5.
(silver) sideways (Ref Photo
A). Close the stem hinge
(Ref Photo B).
Photo A
Photo B
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12 Customer Service 1-800-377-4532
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Rotate the stem QR lever6.
forward into of the upper
plate (Ref Photo A). Close
the stem QR lever (Ref
Photo B) being sure the QR
retention pin (silver) is fully
engaged with the upper
plate.
Install the handlebars onto7.
the stem, align and tighten.
Photo B
Photo A
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Currie Technologies®
Align the handlebars to the8.
front wheel. The handlebars
must be perpendicular to the
front wheel.
9. Repeat steps 2 and 3
to once again access the
steerer bolt (6mm Allen Bolt
or 13mm Hex Bolt). Fully
tighten the steerer bolt.
The stem is held in position
with the expander bolt and
wedge.
10. Repeat steps 5 and 6
to once again secure the
folding stem. Be sure the
QR retention pin (silver) is
fully engaged with the upper
plate.
WARNING
!If you are unable to lock the handlebar folding hinge
properly, or its Quick- Release lever, or properly secure
the two main handlebar parts to the scooter, DO NOT
RIDE THE SCOOTER. Contact Currie Technologies®
Customer Service at 1-800-377-4532 for further
instructions. Failure to do so may result in serious injury
or death to the rider or severe damage to the scooter.
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14 Customer Service 1-800-377-4532
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QR LEVER ADJUSTMENT:
If the quick release lever is either
too tight (cannot be flipped to its fully
locked position) or is too loose (can
be too easily flipped to its locked
position) you will need to adjust the
QR (Quick Release) Lever.
Open the QR lever (Ref Photo A) and
adjust the 10mm nut underneath the
center pin (Ref Photo B).
If the QR lever was too tight initially
you will need to loosen the nut a 1/4
turn at a time. Test the adjustment
you have made by closing the QR
lever (Ref Photo C). The lever should
be tight in its closed position and un-
able to vibrate loose.
If the QR lever was too loose initially
you will need to tighten the nut a 1/4
turn at a time. Test the adjustment
you have made by closing the QR
lever (Ref Photo C). The lever should
be tight in its closed position and un-
able to vibrate loose.
Repeat adjustment as necessary
until QR lever is properly tightened.
If you are unable
to properly adjust the QR lever DO
NOT RIDE THE SCOOTER. Contact
Currie Technologies®Customer
Service at 1-800-377-4532 for further
instructions. Failure to do so may
result in serious injury or death to the
rider or severe damage to the scooter.
Photo A
Photo C
Photo B
WARNING
!
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BATTERY PACK, CHARGER PORT AND CHARGER
ELECTRO-DRIVE™ SMART CHARGER: The Electro-Drive™ scooter comes
with its own Electro-Drive™ Smart Charger that connects with an easy-
access charger port for recharging the batteries. This charger unit has lights
that show the battery charge status. Refer to the instructions that appear on
the charger unit and its instructions.
Use only a Currie Authorized Smart Charger to charge
the batteries. Using any other charger may damage the
batteries and void your warranty.
HOW TO CHARGE THE BATTERIES
1. IMPORTANT: Be sure the
power switch on the scooter
is in the “OFF” position. (Ref
Photo A)
Rotate open the charger port2.
cover (Ref Photo B).
Insert the Battery Charger’s3.
XLR (Male) plug into the Char-
ger Port (Ref Photo C).
Plug the Battery Charger’s AC4.
plug into a standard, grounded
110V AC outlet.
Let the batteries charge until5.
the charger lights indicate that
the batteries are fully charged,
then unplug the charger from
the scooter and the AC outlet.
Batteries like to have a full charge, so
always be sure to recharge them fully
after each ride. If you leave them in
a run-down condition, without quickly
recharging them, it will shorten their
life expectancy. The charger may get
warm to the touch, so make sure you
charge them in an open area and
do not lay anything on the charger
unit while charging. Although you
cannot over-charge the batteries
Photo A
WARNING
!
Photo C
Photo B
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16 Customer Service 1-800-377-4532
Currie Technologies®
using the Currie “Smart Charger”, we
recommend that you do not leave the
charger plugged in for more than 24
hours.
CHANGING THE BATTERY PACK
I1. MPORTANT: Be sure the
power switch on the scooter is
in the “OFF” position.
Remove the deck by unscrew-2.
ing the “D” ring deck retention
screw then lifting the deck off.
(Ref Photo A)
Remove the battery pack out of3.
the scooter’s battery tray. (Ref
Photo B)
Disconnect the battery power4.
pack connector (cut zip tie
holding the wire connector, if
necessary) (Ref Photo C)
Place the new or fully charged5.
battery pack into the battery
tray.
Reconnect the battery pack6.
connector and place all of the
cables into the tray.
Re-install the deck and secure7.
with the “D” ring deck retention
screw.
Photo A
Photo B
Photo C
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Currie Technologies®
BATTERY CARE AND MAINTENANCE
Not doing any and/or all of the following may lead to reduced performance
and/or permanent damage to the batteries. Batteries that have been
damaged by not following the below steps will need to be replaced and are
not covered under warranty.
Always be sure to fully charge batteries before first use (6-10•
hours depending on size).
Always be sure to fully charge batteries after each and every use•
(6-10 hours depending on size).
Be sure to charge batteries at least every 30 days.•
Do not store batteries below 50º Fahrenheit and never allow•
batteries to freeze (below 32º Fahrenheit).
Always be sure to turn the scooter “OFF” after each use via the•
On/Off power switch.
SLA (SEALED LEAD ACID) BATTERY CONDITIONING
SLA batteries should always be fully charged (charge time of 6-10 hours
depending on amperage of battery) before first use. This will help obtain
optimum performance.
SLA batteries have a “break-in” cycle consisting of ~ three discharge/charge
cycles before they will reach optimum performance. This involves three
complete discharges and three complete recharges (charge time of 6-10
hours depending on amperage of battery and strength of the charger). After
this initial “break-in” cycle the batteries will have increased performance and
less line voltage fluctuations under load, as indicated by the throttle LED’s.
FUSE
In the event of an overload the fuse will pop and need to be replaced. In this
instance replace only with approved part from Currie Technologies®.
Risk of fire, Do not bypass fuse.
WARNING
!
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18 Customer Service 1-800-377-4532
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THROTTLE AND BRAKE OPERATION & ADJUSTMENT
THROTTLE OPERATION
The speed of the Electro-Drive™
scooter is controlled by a grip-
twist throttle, which is located on
the handlebar.
To check the throttle operation,
turn the power switch to the
“OFF” position. Fully twist the
throttle then quickly release it.
The throttle is spring loaded and
should immediately spring back to
its original (also know as “Zero Position) position.
To accelerate, twist the right hand throttle grip towards you as you stand
on the deck plate. The more you twist the throttle, the faster the motor will
propel the scooter until you reach the scooter’s top speed.
To go slower, or coast to a slower speed, allow the throttle to spring back to
its original position. To decelerate or come to a complete stop, release the
throttle and allow it to return automatically to its original position. Then squeeze
the brake lever(s) to activate the brake(s). Remember to release the throttle
whenever you apply the brake.
The throttle and its components are fully assembled and
tested at the factory. Do not attempt to adjust them at
any time. If you feel the throttle and/or components are in
need of service DO NOT RIDE THE SCOOTER! Contact
Currie Technologies®Customer Service number at
1-800-377-4532.
If you do not fully understand how to operate your scooter
throttle properly, DO NOT RIDE YOUR SCOOTER.
Contact Currie Technologies Customer Service for
information and instructions at 1-800-377-4532.
WARNING
!
WARNING
!
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TURTLE (Slow speed)
Turn dial counter-clockwise to
reduce the overall top speed
RABBIT (top speed)
Turn dial clockwise to increase
the overall top speed up to the
maximum of 9mph
The overall top speed of the Scoot-E is controlled
via the knob located on the handlebar.
RABBIT-TURTLE SWITCH
This switch limits the top speed of the Scoot-E. The top speed can vary from
less than 2mph (dial turned all the way to the left) up to 10mph (dial turned
all the way to the right).
HOW TO USE THE THROTTLE LED’S
When the throttle is engaged (powering the motor) and the scooter is in
motion, the LED’s on the throttle indicate instantaneous line voltage as
measured at the battery terminals -- and not the available energy in the
battery pack.
The line voltage will fluctuate depending on the instantaneous load that the
motor is under. For example, when starting out from a dead stop, or going
up a steep hill, the motor will be under a high load and the “Yellow” or even
“Red” LED will illuminate. To a lesser degree, another factor that influences
the load on the motor (and therefore the LED readings) is the gearing of the
motor. Scooters with Direct Drive (DD) gearboxes are geared for slightly
higher top end speeds and therefore have a higher load when starting from
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20 Customer Service 1-800-377-4532
Currie Technologies®
a dead stop versus scooters with belt or chain drive, which have a lower top
end speed. The higher gear ration of the DD scooters will cause the Red LED
to illuminate more often compared to other scooters.
When the throttle is disengaged (i.e. no power to the motor due to the
scooter being stationary or coasting) the LED’s on the throttle will indicate
the voltage of the battery pack. The voltage of the battery pack will rise
when no load is on the motor. The best indication of how much battery life is
remaining is to check the throttle LED’s, after reaching cruising speed, on a
flat straight road as this will allow the battery voltage to stabilize and give a
much more accurate reading.
5 MINUTE SLEEP MODE
Scooters are equipped with a 5 minute sleep mode. If no activity is detected
after 5 minutes the scooter will go into stasis mode to conserve the batteries.
To restart, cycle the power switch Off then On.
Never store your scooter in Sleep Mode as battery power
will still be used by the scooter. Always be sure to turn the
power switch to the “OFF” position.
HEAT SHUT-DOWN MODE
If the controller has over-heated and power to the motor has been shut down,
turn the main power switch “OFF” for at least 30 minutes to allow the controller
to cool down before riding any more. Turn the power switch “ON” and resume
riding.
The scooter will shut down due to over-heating caused
by excessive stress on the motor (i.e. too steep a hill, too
heavy a rider, etc.).
BRAKE OPERATION
The Electro-Drive™ electric scooter is equipped with front and/or rear
brakes. It is operated by using the brake lever on the handlebars and is
designed to provide excellent stopping power for your scooter. Squeeze the
brake lever(s) firmly to bring your scooter to a safe, controlled stop.
The brake lever itself should never touch the handlebar or grip when
squeezed firmly. If it does, then immediately STOP RIDING and adjust the
brake cable.
WARNING
!
WARNING
!
Direct Drive Scooters - 2009.indd 20Direct Drive Scooters - 2009.indd 20 11/25/2008 1:41:43 PM11/25/2008 1:41:43 PM