Extreme 500 not working , no matter what :( !

[tune345]

Hi guys, James here.. this is going to be a long post, so stay with me as i want to describe it as much details as i can so it will be easier for you guys to help me out.

So, i bought this Extreme 500 used from a guy last month and since then my days and night have been disturbed,lol i have literally kept this scooter in front of my bed so when i wake up or sleep i see this soulless scooter in front of me 24 hours. i want to make it running again so badly that i spent almost 3 hours every day on it.. i hope some of you, can help me . The tech support of extreme scooter is horrible they reply after long time with very less details..

so to begin to explain you the current situation of the scooter is , it is running but NOT from the controller. when i connect it directly it runs full speed. but it does not run from the controller...so the guy at extreme scooter told me i have to buy a new controller type 2 which has 4 wires of throttle and 6 cable connections in total so i bought it , yesterday i received it , i was so excited i thought i would finally ride my scooter but still same problem ..

when i turn the power switch on , it does becomes powerful red and response quickly. i check the fuse its okay , i checked the batteries its okay. i checked everything its okay.

so today the guy from the extreme scooter told me i have to have a multimeter to trouble shoot my connections so i went and bought a new multimeter and did the stuff he told me to do .. he was really confusing me...

The problem is there is no light on the throttle ...even after i installed new controller which i thought was the causing the problem but then i thought this is definitely throttle problem.... but i found something very weird today..

i thought the throttle cable could have been broken from inside so i went ahead and found a point A in the throttle where i can see all the wires and point B where the connection connects to the controller.. i did test on all of the four wires. red , black, green and yellow .. a continuity test to see if the wires are broken or not... they all passed the test ... 0_0 .. so all the wires are okay in the throttle ? it has a new controller , batteries are charged and motor does run too .. then what is the problem ?

the weird thing i found in the throttle was it had 5 wires 0_0 ? ... when i looked through a the opening in the point A but at Point B it only showed 4 wires.... and this scooter supposed to have only 4 wire throttle ? ... so do i have the wrong throttle?

Please help....if you can , i will make you a delicious chocolate cookie ^__^ !

[itchynackers]

What are the voltages of each battery?

[tune345]

(12 Volt - 9 AMP X-Treme) x 4. Original Batteries.....

[dnmun]

do you know that the controller has power?

[tune345]

do you know that the controller has power?

if you mean that controller is working or not then yes it is a new controller which i received yesterday so it should work 100 % i believe, right ?

now i connected the batteries to the controller and and check the throttle port on the controller , it does say around 5 volts when i test the red and black wires and when i connect the multimeter to green and black wire... its run at full speed ... so.. i hope i answered your question and thank you for taking time to respond to this thread

[dnmun]

you connected the green wire from your controller that goes to the hall sensor in the throttle with the ground wire from your controller through your voltmeter?

[tune345]

you connected the green wire from your controller that goes to the hall sensor in the throttle with the ground wire from your controller through your voltmeter?

No... i did 2 things.

first of all let me describe you the throttle .There are four wires coming out from the throttle at point B( this is the port where i connect the four wires to the fours wires coming out from the controller). But today i found out at point A which i found out by opening the throttle where it is attached to the handle.. it has one more brown wire .. so the point A has 5 wires going but at the end Point B it only shows up 4 wires. may be it is for break the circuit to stop the circuit when i pull the brakes, but the throttle isn't attached to any break , i don't what that extra brown wire does but this scooter comes with four wire throttle only if i am not wrong.

The guy from extreme scooter gave me some steps to troubleshoot my throttle. here what he said

" X-500 Controller Version 2 Throttle Test:

First locate the connector labeled "brake" on the controller.
Unplug this connector and re try scooter, if the motor turns the brake switch is faulty.

To test your controller and throttle. Please block the rear tire of you scooter off the ground so that it will not run away. Remove the floor plate of your scooter to access the controller. Turn the power switch on. Find the connector on your controller, which should be marked “Derailleur”. This connector will have four wires going in to it. Find the red, black, and green wires. Test between the red and black wires. You should see five volts or very close to this. Now measure between the green and black wires. Without turning the throttle you should see close to one volt. Turn the throttle to full speed. You should now see around four volts. To test the output to your motor check across the motor connector with it connected to the motor and controller. Without turning the throttle you should see zero volts. As you turn the throttle toward full speed the voltage should increase from zero to forty-eight volts. I hope this helps. "


so the 2 things i did are as follows

1. i connected the red and black wires from the controller to the black and red wire of the multimeter (with it detached from the throttle cable)and it did showed around five volts actually more than 5.

2. Then i connected the green+red and black+black the port of the controller( with it detached from the throttle cable)and the motor started running at max speed.

so that is the 2 things i did but i really got confused on the instruction the guy from the extreme gave me .. when he told , "Turn the throttle to full speed. You should now see around four volts." i was like how can the throttle show voltage when it is detached from the throttle port from the controller then it rang on me that may be i have to check the multimeter through the wires when the port of throttle Point B is connected to the port of throttle from the controller .... i did not check this yet ..because it is late now so don't want to make loud noises .. but i think i stated the problem clearly here..


let me know if you guys need any extra information, i check this forum every hour if not if every minute.. i am eagerly waiting for someone who can finally help me with this...been almost a month

[dnmun]

yes,he's right, that is what you wanna see. when the throttle is connected to the controller through that plug, you wanna watch the voltage go up and down on the green wire when you turn the throttle.

you can put one tip of the voltmeter probe into the green wire where it goes into the plug or just pierce the insulation of the green wire with the tip of the probe, plug is better. the black probe goes to the black wire, ground of the controller.

[heathyoung]

OK - when you hooked up the multimeter from green (hall) to black (ground) - if you had it in continuity mode, you would have impressed a voltage on the hall connector, so the motor started working.

Problem = throttle.

You want to only have the red and black wires plugged into the throttle, twisting it should show a voltage on the green (unplugged) wire coming from the throttle. From your description, motor, controller and batteries are OK.

[tune345]

yes,he's right, that is what you wanna see. when the throttle is connected to the controller through that plug, you wanna watch the voltage go up and down on the green wire when you turn the throttle.

you can put one tip of the voltmeter probe into the green wire where it goes into the plug or just pierce the insulation of the green wire with the tip of the probe, plug is better. the black probe goes to the black wire, ground of the controller.

ok thank you for the information dnmun, i will do that that and let you know guys... but i was wondering when i did all the connections without the throttle port plugged in the controller .. wouldn't it be the same when it is connected ? ... anyways there is no light what so ever with the throttle....

[tune345]

OK - when you hooked up the multimeter from green (hall) to black (ground) - if you had it in continuity mode, you would have impressed a voltage on the hall connector, so the motor started working.

Problem = throttle.

You want to only have the red and black wires plugged into the throttle, twisting it should show a voltage on the green (unplugged) wire coming from the throttle. From your description, motor, controller and batteries are OK.

alright , perfect .. thanks for the accurate information heathyoung... that sounds like my next mission ... but there is no lights on the throttle what so ever.. if it is really the throttle that is causing a nightmare for me then would the chip in the throttle blew up if there is any ??? since you seems to know these kind of things and i am pretty noob at this...

also wanted you to know that i found 2 point point A( throttle which is attached to the handle) and Point b( where the four wires connects to the controller) i tested continuity on all of them , they all passed it.. so the wires are all good , no breaks in the wires... could it be the throttle chip ? or something else ?

[itchynackers]

(12 Volt - 9 AMP X-Treme) x 4. Original Batteries.....

No, not your capacities. What are the VOLTAGES. Measure the voltage of EACH battery with your multimeter!

[tune345]

(12 Volt - 9 AMP X-Treme) x 4. Original Batteries.....

No, not your capacities. What are the VOLTAGES. Measure the voltage of EACH battery with your multimeter!

oh ! ... i did measure all the batteries single and together.. each shows slightly higher than 12 volts, together shows 49 volts

[tune345]

Ok this is the lastest status of my situation .... the guy replied to me with few instructions to follow and i did that... so i will post his reply and my reply after i did what he told me to do.. hope you guys have more light on this and if possible help me faster than the guy from extreme scooters.. thanks

His reply
"Hello,

Here is the throttle voltage test:

Throttle Voltage Test:
Follow throttle wires until you find it’s white connector. You will be testing the “Red”, “Green”, and “Black” wires. Set your meter to test DC volts. Block rear wheel off the ground so scooter won’t take off. Turn the scooter on. Place the red meter test lead on the “Red” wire and the meter black lead on the “Black” wire. The meter should measure +5 volts. Now place the meter red lead on the “Green” wire. With out turning the throttle you should read around +.8 volts. Now turn the throttle wide open. You should now read around +4 volts. If everything else powers up on the scooter and you do not have +5 volts between the “Red” and “Black” wire the controller is bad. If you did not get the +.8 to +4 volts then the throttle is bad.


Sincerely,
Gary
"


My reply

"I did the 2 things you said Mr. Gary. They are as follows( this was done while the port of the throttle wire was connected to the port of the throttle coming from the controller. Break wire and charging wire were also unplugged while i was doing this)

1. I found out the white connector of the throttle at the end below the compartment where batteries are kept.Then i found out the 4 wires of the throttle going into the connector of the controller.. i have red,black,green and yellow as the four wires from my throttle...and i have red,black,green and blue wires from the controller.. now i placed the red lead of the multimeter into the red wire coming from the throttle ( not the controller) by piercing it with the red lead point. and then pierced black wire from the throttle wire(not from the controller) with the black lead point of the multimeter.. then i switched on the power switch ... i see 5.24 volts going through it .. meaning controller is good as you said.
2. Then i pierced the green wire coming from the throttle wire (not from the controller) with the red lead point of the multimeter and i let the black wire stay as it was previously... when i turn the power switch on ... i do not see +.8 to +4 , instead i see full power of 48 to 49 volts 0_0 ? ... it does not matter what if i throttle it up or down ... it says directly 48 to 49 volts ? does this mean , wiring on the throttle cable has been messed up 0_0 ? or the throttle chip is blown away ?"


i will be waiting for an answer asap... looks like throttle is messed up ... ok then what should i do with extra controller ... i did not check the old controller yet if it is okay or not ... but it looks like it was a problem in the throttle from the beginning ... ..any idea

[tune345]

OK - when you hooked up the multimeter from green (hall) to black (ground) - if you had it in continuity mode, you would have impressed a voltage on the hall connector, so the motor started working.

Problem = throttle.

You want to only have the red and black wires plugged into the throttle, twisting it should show a voltage on the green (unplugged) wire coming from the throttle. From your description, motor, controller and batteries are OK.

I tried your method and it showed different results then the guy from the extreme scooter. i have red,black,green and yellow wires on my throttle end where is connects to the controller and i have red,black,green and blue wires on my controller's throttle port.. so i took a pin and i took out yellow and green wires from the throttle wire( not the controller's throttle port) and i only left leave black and red wire coming from throttle and plugged it in....

i do see +5 volts when i connect my multimeter's black and red wire to the black and red wire of the throttle when it is connected to the controller but then when i connect black wire of my mutlimeter to the black wire of the throttle wire(plugged in) and red wire of my multimeter to the green wire of the throttle wire( which is uplugged) i see 0.14 volts and nothing happenes if i throttle up or down ...

this is when the green wire is not plugged it (0.14 volts as you stated and nothing happens when i throttle up or down) , when it is plugged in with all the wires .. i see a 48 volts as the guy from the extreme scooter said me to do.. and nothing happens when i throttle up or down ....



SOooooo... ??????

[heathyoung]

Green wire should be varying from between 1-4.2V as you twist the throttle. The hall sensor (in the throttle itself) is probably dead. It happens.

Time for a new one.

And yes, there is a very good chance that there was nothing wrong with your original controller.

[tune345]

Green wire should be varying from between 1-4.2V as you twist the throttle. The hall sensor (in the throttle itself) is probably dead. It happens.

Time for a new one.

And yes, there is a very good chance that there was nothing wrong with your original controller.

i thought the same , when i got different voltages but +0.8 to +4 from the green and black wires(plugged in)in the throttle..


so i did some research and found out that one can change the hall sensor but i was unable to find specific details on how to change it .. do you happen to know how to change it or any link ...

Thank you Heathyoung appreciate your kind help

[tune345]

ordered throttle today....finger crossed .. x_x .. if this does not work... i am slapping a random cat ... lol

[dnmun]

throttles can be repaired easy. the hall sensor is the honeywell SS495 ratiometric hall sensor.

the hall sensors don't usually fail, usually the magnet comes loose and gets jammed at the end of its travel so the hall sensor voltage never changes. you can pop it open and put the magnet back in place and epoxy it in place.

but you said that you got a variation in voltages from .8V to 4V on the green wire? how and when did that happen?

[tune345]

throttles can be repaired easy. the hall sensor is the honeywell SS495 ratiometric hall sensor.

the hall sensors don't usually fail, usually the magnet comes loose and gets jammed at the end of its travel so the hall sensor voltage never changes. you can pop it open and put the magnet back in place and epoxy it in place.

but you said that you got a variation in voltages from .8V to 4V on the green wire? how and when did that happen?

but i already ordered a new throttle ..... now i get this information now i feel ...its just my luck..

when everything is connected and i pierce the green and the black wire i get 48 volts ... and when i unplugged the green wire then i measure it with voltmeter i get 0.14 volts... nothing happens to the voltage when i throttle up or down in both the scenario...

i think i already have extra controller with me... now i have extra throttle too ..... ..

[tune345]

if someone one knows how to fix this throttle step by step .. then i will really really appreciate it and i will cancel the order which is about to ship

http://www.ebay.com/itm/NEW-Twist-Throt ... 0387482580

[dnmun]

i found the data sheet for the hall sensor in the throttle while looking at some other stuff, if you open up the throttle you will see it soldered into the pcb. it has to go back in exactly the same position with respect to the magnet.

[tune345]

i found the data sheet for the hall sensor in the throttle while looking at some other stuff, if you open up the throttle you will see it soldered into the pcb. it has to go back in exactly the same position with respect to the magnet.

that's look confusing but doable... so just open the throttle and fix it back ??

[dnmun]

getting the throttle apart is the trick. either you can or you can't but opening this one will give you a chance to take out the spring too.

[tune345]