Star EV Roadster-2+2 User manual

Owner’s Manual and Service Guide
Roadster-2+2, Roadster-4+2, Roadster-6+2
August 2014

1
Table of Contents
Specifications 2
Operation
Vehicle layout 3
Dashboard 3
Switches 4
Pedals 5
Charging 5
Cigarette lighter 5
User information 6
Driver information 6
Driving
Operation procedure 7
Safety 7
Driving on hilly terrain 7
Parking safety tips 8
Before initial use 8
Maintenance
Battery maintenance 9
Charging the battery group 11
Brake system maintenance 12
Steering system maintenance 12
Motor maintenance 12
Lubrication maintenance 12
Maintenance schedule 13
Troubleshooting 14
After-sale service 16
Monthly maintenance record 17
Electrical diagrams 18

2
Vehicle Specifications
2+2 Roadster 4+2 Roadster 6+2 Roadster
Passengers
4
6
8
Battery group
48 V, 8 x 6V, Trojan
T105
48 V, 8 x 6V, Trojan
T105
48 V, 8 x 6V, Trojan
T105
Motor
7HP, AC
7HP, AC
7HP, AC
Controller
Curtis 450A 1236
Curtis 450A 1236
Curtis 450A 1236
Top speed (mph)
19.5 (20-25 LSV)
19.5 (20-25 LSV)
19.5 (20-25 LSV)
Load capacity (lbs)
800
1080
1800
Dimensions (in)
140 x 53 x 46
156 x 53 x 50
187 x 56 x 50
Weight including
battery (lbs)
1205
1580
1300
Ground Clearance (in)
5.9
5.9
5.9
Turing Radius (ft)
14
17
19
Wheelbase (in)
67
95
125
Climbing capacity
25%
25%
25%
Front suspension
Leaf spring and shock
Leaf spring and shock
Leaf spring and shock
Steering system
Rack and pinion
Rack and pinion
Rack and pinion
Brake system
Rear drum
4-wheel hydraulic
4-wheel hydraulic
Tire size
225 / 55 / 12 DOT
225 / 55 / 12 DOT
225 / 55 / 12 DOT
Tire pressure (psi)
30
30
30
Wheel type
12 inch aluminum
12 inch aluminum
12 inch aluminum

3
Operation
Vehicle Layout
1| Dashboard
2| Steering wheel
3| Combination switches
4| CD player (optional)
5| Brake pedal
6| Forward/reverse switch
7| Accelerator pedal
8| Key switch
9| Cigarette lighter
10| Speakers (optional)
11| Charger socket
12| Turn signal lever, horn
and light switch
13|Cup holders
Dashboard
1| Speed gauge mounting point
2| Speedometer
3| Lights on indicator
4| Left turn signal indicator
5| Power display
6| Right turn signal indicator
7| Brake light
Notes:
•Low battery voltage alarm light: Red when battery voltage is low.
•Turn signal: The turn signal lever has a button on the end. Push in to sound horn; pull lever
back to turn on lights.
•High beam: The indicator will light up yellow when high beams are on.

4
Switches
Key switch
Normal off position: key can only be removed in this position
All power systems are on when in this position.
WARNING: Do not take out the key when the vehicle is running. Do not leave key in ignition
to avoid theft or accidental operation by a child.
Forward/Reverse switch
The switch has three positions. The vehicle goes forward when FWD is pressed down and backward
when REV is pressed down. When the switch is centered, vehicle is in the neutral position.
WARNING:Do not shift between forward and reverse when vehicle is running or damage to
the transmission and/or motor can occur.
Turn signal
Push lever up to illuminate right turn signal; push down to illuminate left turn signal.
Headlight switch
Pull turn signal lever into back position to turn lights on. Push back forward for lights to be in off
position.
Horn
Press down the horn button on the end of the turn signal lever to engage horn.

5
Pedals
Parking brake
The parking brake will click and lock in the down position to indicate that the parking brake is
engaged. Lightly push on the accelerator pedal to release the parking brake.
Braking
Depress the brake pedal to brake.
Accelerating
Press the pedal and control speed by force applied to the pedal.
WARNING: Before leaving the cart, put the Forward/Reverse switch in the neutral. Before
moving forward or reverse the parking brake should be released to prevent serious damage
to the brake system and related parts.
Charging, Charger Socket
Plug the larger round plug end into the vehicle charge port. Plug the power cord end into a standard
outlet (110 V) to begin the recharging cycle. See charging section (p. 11).
Cigarette lighter
Plug in any 12 V DC accessories into outlet. Ideal for use of MP3, phone chargers, mini fans and
other accessories.
Parking brake
Brake pedal
Accelerator

6
User Information
Read all vehicle specifications, and use vehicles according to manufacturer recommendations.
Do not modify the vehicles without manufacturer’s approval. Any modifications will affect the
function, safety, and warranty of vehicles.
Any replacements of spare parts by an authorized STAR EV dealer (i.e., changing batteries, tires,
seats, etc.) shouldn’t affect the safety requirements. Do not attempt to lift the suspension of this
vehicle as serious injury could occur and the vehicle will no longer be warranted by the
manufacturer.
This is a low speed electric vehicle, and should be used on approved roads and meet the road
regulations. Carefully review the laws for golf car and low speed vehicle use in the city and state
you are operating the vehicle in.
Driver Information
It is recommended that only persons with a valid motor vehicle driver’s license be allowed to
operate the vehicle.
The driver should pay close attention to road conditions, pedestrians and other vehicles on the
road.
Remind passengers to buckle seat belts and keep arms and legs inside the vehicle at all times when
it is moving.
Report accidents to your insurance company.
The driver should not modify, add or remove any parts of the vehicle. Do not add or install any
optional steering wheel unless they are designed to fit this vehicle. Please see authorized dealer in
your area for help.
The driver should operate vehicles in approved areas.

7
Driving
Operation Procedure
1| Insert the key and turn it to ON position.
2| Press the green forward switch (or reverse).
3| Release the parking brake by lightly pressing on the accelerator pedal. The speed will increase
as pedal is pressed downward.
4| When stopping the vehicle, release the accelerator pedal and depress the brake pedal slowly.
Then push down the parking pedal after stopping to engage the parking brake.
Safety
Release the parking pedal before driving to avoid any damage to the brake shoes or motor.
Do not depress the accelerator pedal too aggressively or frequently or it will shorten the life of the
drive train and components.
Do not start, stop, or turn at high speeds.
Do not pass other vehicles traveling in the same direction at intersections, blind spots, or at other
dangerous locations. Follow all traffic laws.
Avoid running over loose objects, potholes, and bumps to avoid damage to the vehicle and possible
injury to passengers.
Please observe and obey all traffic regulations, including the passenger and weight capacity
requirements, authorized speed limits, and other regulations.
Keep a clear view of the path of travel. Observe other traffic and pedestrians, and maintain a safe
distance, based on speed of travel, from a vehicle ahead.
Driving on hilly terrain
Ascend or descend grades slowly.
Do not turn around when driving on a sharp incline or decline. Be careful when driving near to the
edge of the slope.

8
Parking safety tips
Park the cart on flat and solid ground.
Depress the brake pedal. Keeping the direction switch in neutral position, turn off the ignition
switch and take out the key. Make sure that the brake pedal is locked in park. You will hear a load
click when the parking brake is engaged.
Keep the vehicle stored inside of a garage if possible. Don’t leave it outside in snow or rain, as water
can get into the electrical system which will cause damage. Check with your local dealer about the
advantages of a car cover if you cannot park the vehicle in a garage, car port, or similar covering.
Before Initial Use
Read, understand and follow the safety label on the instrument panel. Be sure you understand how
to operate the vehicle, its equipment and how to use it safely. Maintaining good performance
depends to a large extent on the proper operation of the vehicle.
New Vehicle Inspection
Before a new vehicle is put into operation, the items shown below must be performed.
1| Check status of each spare part, especially the nut on the steering wheel and braking system.
2| Check for any leakage problems with the steering system, turning system and transaxle.
3| Check the water level of each battery. Maintain proper levels (see Trojan battery guide) and do
not overfill battery cells!
4| Check if tire inflation is correct. Low pressure will lead to difficulty turning and bumpy riding.
Keep the normal air pressure for the tire to prevent premature wear. Recommended tire
pressure is 30 PSI.
5| Check for any worn items between the wiring and other locations where parts rub against each
other.

9
Maintenance
Turn off the electricity, take out the key and push down on the parking brake.
When working underneath vehicles, please use jack and triangle wood to fix the front and rear
wheels, in order to avoid accidents.
Keep the maintenance area clean and safe.
Please perform vehicle maintenance according to safety guidance. Refer to STAR EV preventative
maintenance schedule or visit an authorized dealer.
Maintain the ventilation of working sites.
Check and maintain safe working conditions. Check and maintain the braking, steering, speed
direction control system, emergency facilities, head/rear lights, controller, and safety equipment.
Check the battery cover caps to ensure they are snapped into place.
Battery Maintenance
The batteries for this vehicle have high current, high capacity, and a long lifetime. To keep the
vehicle in good performance, it is very important to maintain it in the correct procedure.
The connectors on the batteries are the output connectors. Keep the area clean and dry, with no
foreign matter or dust on it. Proper care will ensure batteries’ performance and longevity.
WARNING: Do not use tap water when filling cells. Use distilled water only!
Check the height of the electrolyte periodically. Check it once per week in summer and once every
two weeks the rest of the year. Standard height level is 10-15mm (½“) higher than the battery
plate. If is too low, please add the recommended distilled water.
Keep the wiring well-connected. After using the vehicle initially for 2-3 days, the completed
inspection for all connectors should be carried out. Inspect the vehicle once a week following. Any
loose or rusty connectors should be fixed. Loose or rusty connectors can cause high temperature,
damage, or possible sparking.

10
NOTE:Don’t over-tighten terminals!
Charge the battery immediately after discharge, or it will affect the battery life. Charge the batteries
that are in long storage or non-fully charged separately.
Keep the filling-water container clean, so no impurities will be put into the battery.
When the environment temperature is under -40° F, the density of the electrolyte after charging is
1.28 - 1.29 g/cm3. If it is more than 1.30 g/cm3, the battery can be damaged badly. Add water
immediately to keep the electrolyte value to normal. If the battery discharges by 80% (the
electrolyte is between the range 1.13 - 1.15 g/cm3), charge it immediately. At this range the vehicle
can only last 2 - 3 mi. Don’t discharge any longer, or it will damage the battery.
Charge the battery fully before storage. Charge it at least once a month for 24 hours. Discharge the
batteries and charge it once again before use.
See an authorized dealer for further help and maintenance.
Battery Replacement
Replace the batteries immediately when approaching the end of the battery’s life. The capacity of a
battery at the end of its life will decrease quickly and won’t meet the standard range (miles on full
charge). Consult with the supplier or dealer for a detailed battery replacement.
Remove battery tie-downs and cables. Lift out batteries with a commercially available lifting device.
If the batteries have been cleaned and any acid in the battery rack area has been neutralized as
recommended, no corrosion to the battery racks or surrounding area should be present. Any
corrosion found should be immediately removed with a putty knife and a wire brush. The area
should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly
dried before priming and painting with a corrosion resistant paint.
The batteries should be placed into the battery racks and the battery tie-downs tightened to 45 - 55
in. lbs. (5 - 6 Nm) torque to prevent movement but not tight enough to cause distortion of the
battery cases.
Inspect all wires and terminals. Clean any corrosion from the battery terminals or the wire
terminals with a solution of sodium bicarbonate (baking soda) and clean with a wire brush.

11
WARNING:To prevent battery explosion that could result in severe personal injury or death,
extreme care must be used with aerosol containers of battery terminal protectant. Insulate
the metal container to prevent the metal can from contacting battery terminals which could
result in an explosion.
Use care to connect the battery wires as shown. Tighten the battery post hardware to 50 - 70 in. lbs.
(6 -8 Nm) torque. Protect the battery terminals and battery wires with a commercially available
protective coating.
Battery Connections
Charging the Battery group
In order to optimize battery life, please use the recommended charger to recharge the batteries.
Keep the key switch in OFF position during charging.
Keep the charger in a cool, dry location and avoid moisture.
Charging should be monitored.
NOTE: When disconnecting the charger, be sure to unplug cord from AC power source first then
unplug cord connected to vehicle.

12
Brake System Maintenance
Adjust the gap between the brake drum and brake shoes.
Dial up the adjusting ratchet wheel of the brake drum until
the wheel cannot turn freely, then dial down the ratchet
wheel 7 - 8 teeth.
Steering System Maintenance
Check if there is any damage to the dust cover of the tie-rod. A broken dust cover will let water in
and damage the tie-rod, and the steering system will not be flexible. Replace a new one immediately
once a worn one is found. Make sure the front wheel toe-in is between 3 - 5 mm (1/8 – 3/16”). If it
exceeds this value, adjust the tie-rod screw stem.
Motor Maintenance
The drive motor is an AC motor. Keep the motor surface clean at all times. Clean the surface with a
dry cloth. Avoid any water contact inside motor.
Lubrication Maintenance
Check the brakes once a month. Fill it full if brake fluid is low in master cylinder. The front hub,
front wheel bearing, brake system, and steering system should be filled once every yearwith #3
general lithium based lubricant.
The gear oil should be changed once a year. User can choose gear oil according to the climate.
(Summer: GL-4 90, Winter: GL-80W/90)
Replace the grease for the rear axle once a year, using recommended oil type GL-5 90 and GL-5
80W/90. Fill the level to 1.2 liters (40 oz). When changing, first twist down the oil plug to discharge
the gear oil. Clean the oil plug and replace it, then inject the new gear oil.

13
Maintenance Schedule
Item weekly monthly quarterly
Check tire pressure

Check tires for abrasions

Check tightness of the bearing bolt and the tire nut

Tire rotation

Check braking and the parking function

Check brake tube for leakage

Check if brake shoes are worn

Check if steering wheel works freely

Check brake pump
•
Check tightness for the turning ball joint and rod

Check nut on the steering rack’s spindle

Check tightness of steering rack and bracket

Inspect and adjust front wheel’s toe-in

Checking tightness of front absorber and helix spring

Check height of electrolyte

Check density of electrolyte

Check if the battery’s pole is loose

Clean battery pole by water

Check light and relay performance

Clean and fix wiring connector

Check and adjust front tire’s bearing

Check or replace transaxle

Check performance of gearbox and bearing (after the first
h f )

Check motor’s bolts and nuts

Clear and lubricate front wheel bearing

Checking motor bearing

Lubricate other parts (use general oil)


14
Troubleshooting
The authorized qualification for repair, the requirement for application, safety and the
maintenance requirement should be the same.
Problem Possible reason Processing methods
Cart cannot move
Operation procedure is
wrong
Refer to user manual
Wiring connector is
corroding
Cut off the power, remove the nut,
clean the connector and replace the
nut
Battery power is low
Charge the battery
Direction switch is
damaged
Replace part
Accelerator is damaged
Replace part
Direction contactor is
damaged
Replace part
Wiring is loose
Repair or replace parts
Vehicle moves slowly and/or
stops when climbing
Vehicle is overloaded
resulting in the
shutting off the
controller when
temperature reaches
167° F
Lighten the load of the vehicle to
decrease the temperature
Releasing the accelerator pedal
does not slow down the vehicle
The spring for the
accelerator pedal is
broken and the pedal
cannot reposition
Shut off the ignition lock, step on the
parking pedal ,then contact with the
supplier

15
No indication (LEDs) on the
dashboard
Parts are loose
Lock the inserted parts
Fuse is burned out
Replace the fuse
Bumpy riding
The tire pressure is
unbalanced
Balance the air pressure
The front and rear
wheel are not aligned
Correct the assembly of the wheels
Turning is difficult
Tire pressure is too
low
Inflate tires
Shaft is short of
lubrication.
Add lubrication
The direction shaft pin
or joints are damaged
Replace parts
Turning excessively
Tie-rod is damaged
Replace part
Steering rack has not
been adjusted well or
abased
Adjust or replace
The direction shaft is
loose
Tighten direction shaft
Lack of power, slow response
Low battery power
Charge the battery
Damaged drive gear
Replace
Speed control system
is faulty
Maintain speed control system
Rear bearing is leaking oil
Axle of the tire or the
washer is damaged
Replace parts
Too much oil
Reduce oil quantity

16
Abnormal noise
Drive gear or the
bearing is damaged
Replace part
Bearing of front or
rear suspension is
damaged
Adjust or replace
Wheel screw is loose
Tighten
Motor’s bearing is
damaged
Replace part
Low braking power
Brake drum is
damaged
Replace part
Brake shoe is not clean
Keep clean
These possible causes are just for your reference and do not include all causes that result in these
listed issues.
After-Sale Service
Star EV has authorized local dealers that will provide the friendly service and technical support for
end users. Be sure to visit www.starev.com to find a dealer in your area.
Users can report faulty problems by telephone, fax and email. Keep Star EV dealers informed of the
model number, VIN number, estimated delivery time, contract number and date as well as a
detailed description or photos of the faulty parts and problems, and our team will handle it
accordingly.
Do not disassemble.

17
Monthly Maintenance record
Record VIN NO: Date
Normal Abnormal Remarks
Is tire pressure normal? Are
wing nuts tightened?
Is the batteries’ water level
normal?
Any batteries or controller
motor wirings loose?
Is the controller system
normal?
Is the fixed screw for the
steering system normal?
Are the wiring connectors
clean?
Are the body and the frame of
the vehicle normal?
Are the front axle and rear
axle normal?

18

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