Merits S331 series Bedienungsanleitung

Merits

S331/S341 series

Service Manual

Nov.1.2006 V1

Index

1. Introduction............................................................................... P1

2. Service Guide........................................................................... ..P1

2.1. How to replace or repair the Seat Assembly(S331/S341 Series) .......P3

2.1.1. To remove seat body assembly ............................................................P3

2.1.2. To replace the seat base plate ..............................................................P3

2.1.3. To replace the slide .........................................................................P4

2.1.4. To disassemble seat body ..................................................................P4

2.1.5. To replace the arm pat ......................................................................P5

2.1.6. To replace the seat post.....................................................................P6

2.2. How to replace or repair the Suspension Frame Assembly(S331/S341

Series) ...........................................................................................P7

2.2.1. To remove rear shroud assembly ..........................................................P7

2.2.2. To remove the driven wheel assembly....................................................P7

2.2.3. To remove the control panel assembly ...................................................P8

2.2.4. To remove the controller mounting plate and controller................................P8

2.2.5. To replace the disk brake...................................................................P9

2.2.6. To replace the transaxle assembly.........................................................P9

2.2.7. To remove the rear bumper and anti-tipper assembly................................. P10

2.3. How to replace or repair the Front section Assembly(S331 Series)…P11

2.3.1. To replace the tiller assembly............................................................ P11

2.3.2. To replace the caster wheel with fork assembly ....................................... P12

2.3.3. To replace the Front bumper assembly ................................................. P12

2.3.4. To replace the front wheel ............................................................... P12

2.3.5. To replace the suspension spring set .................................................... P13

2.3.6. To replace the front fork assembly .................................................... P13

2.4. How to replace or repair the Front section Assembly(S341 Series) .. P14

2.4.1. To replace the tiller assembly............................................................ P14

2.4.2. To replace the front wheel assembly.................................................... P15

2.4.3. To replace the tire of wheel assembly .................................................. P15

2.4.4. To replace the front Bumper ............................................................. P16

2.4.5. To replace the half speed sensor bracket ............................................... P16

2.4.6. To replace the steering.................................................................... P17

2.4.7. To replace front suspension arm assembly ............................................. P17

2.5. How to replace or repair the Tiller Assembly(S331/S341 Series) .... P18

2.5.1. To remove the tiller assembly ........................................................... P18

2.5.2. To remove the rear shroud of tiller .................................................... P18

2.5.3. To remove the front shroud of tiller..................................................... P19

2.5.4. To replace the regulation cylinder....................................................... P20

2.5.5. To replace the dashed board assembly ................................................ P20

2.5.6. To replace the throttle lever assembly .................................................. P21

2.5.7. To replace the electric components from dashed board assembly ................... P22

The numbers shown in this service manual is just for reference. The part numbers

should be in accordance with current exploded drawing

1. Introduction

The purpose of this manual is to provide dealers and/or distributors with the

product information and instructions that are required for servicing the

S331/S341 scooter.

2. Service Guide

The S331/S341 scooter consists of four main parts:

nSeat Assembly

nFront Frame Assembly

nSuspension Frame Assembly

nTiller Assembly

2.1. How to replace or repair the Seat Assembly

The Seat assembly includes seat body, seat base plate, slide and left / right

armrests.

2.1.1. To remove seat body assembly

Pull the end (3.02) of the swivel lever (3.03) under the seat till unlock it

and rotate the seat a little bit to the position where you can feel the seat

rotate freely then lift up the seat body assembly.

2.1.2. To replace the seat base plate

◆When should you replace the seat base plate?

◇If the seat base plate is deformation.

◇If the seat base plate out of shape due to an accident.

◆How to replace the seat base plate?

◇Please proceeding steps as follows if it has to replace.

Use ratchet & socket to loosen four screws (3.40) and spring washers

(3.41) from the bottom of the seat body assembly, then remove the seat

base plate.

2.1.3. To replace the slide

◆When should you replace the slide?

◇If the seat base plate is deformation.

◇If the seat base plate out of shape due to an accident.

◆How to replace the slide?

◇Please proceeding steps as follows if it has to replace.

Use hex. tools to loosen four screws (3.14) from the bottom of the seat

body assembly, then remove the slide (3.12).

2.1.4. To disassemble seat body

◆When should you replace the seat body?

◇If the seat body is worn out.

◇If the seat body is pierced or scratched by something.

◇If the scooter crashed cause the seat body out of shape.

◆How to replace the seat body?

◇Please proceeding steps as follows if it has to replace.

Follow the following step to disassemble seat body. a) Remove seat

body assembly (see section 2.1.1). b) Use ratchet & socket to loosen rear

two screws (3.14) fixed the slide rails. c) Pull the slide swivel lever up,

then slide the seat body forward to limit. d) Use hex. tools to loosen the

other screws (3.14) fixed the slide rails.

2.1.5. To replace the arm pad

◆When should you replace the arm pad?

◇If the arm pad is worn out.

◇If the arm pad is pierced or scratched by something.

◇If the scooter crashed cause the arm pad out of shape.

◆How to replace the arm pad?

◇Please proceeding steps as follows if it has to replace.

Revolve the knob (3.35) and pull the armrest assembly outside. If the

arm-pad (3.28) is broken, use the screw driver to loosen two screws

(3.30) and replace it.

2.1.6. To replace the seat post

◆When should you replace the seat post?

◇If the seat post is deformation.

◇If the seat post out of shape due to an accident.

◆How to replace the seat post?

◇Please proceeding steps as follows if it has to replace.

Use two open-end wrenches to loosen hexagon fixed bolt (1.63) and

screw (1.65). Adjust the seat height based (1.62) to the demanded

position (there are 5 holes on the tube for adjusting the seat height).

Then insert and tighten the bolt.

Illus. 06

2.2. Suspension Frame Assembly(S331/S341 Series)

The suspension frame assembly includes suspension frame, driven tire

assembly, transmission assembly, absorber, anti-tipper and rear bumper.

2.2.1. To remove Rear shroud assembly

◆When should you replace the rear shroud?

◇If your scooter can not avoid knocked or bumped cause the shroud

broken.

◆How to replace the rear shroud?

◇Please proceeding steps as follows if it has to replace.

1. Remove the seat body assembly first (see section 2.1.1),then pull up

rear shroud assembly (4.2) from chassis, and unplug the connector of

cable loom (indicator & rear light) (4.21) which connect with main

cable loom(5.83)

2. Untie the battery strap and unplug the connector of battery harness

from controller panel(2.56),then remove the battery

2.2.2. To remove the driven wheel assembly

◆When should you replace the driven wheel assembly?

◇If your driven wheel assembly is deformation.

◇If the driven wheel assembly out of shape due to an accident.

◇If the driven wheel assembly is worn out.

◇If the driven wheel assembly is pierced by something.

◆How to replace the driven wheel assembly?

◇Please proceeding steps as follows if it has to replace.

Illus. 07

1. Pull out the screw cover (2.79) by hand.

2. Loosen the nylon nut (2.81) by hex. tool and take it out.

3. Along the output shaft axial to take the driven wheel assembly out.

4. The other side follow the step above.(1 ~ 3)

2.2.3. To remove the controller panel assembly

1. Loosen the screw (2.57) 4 pcs. by (+) screw driver, then pull up the

controller panel(2.56).

2. Unplug 4 connectors from controller

2.2.4. To remove the controller mounting plate and controller

1. Loosen the screw (2.51) and nylon nut (2.52) by hex. tools and

wrench.

2. Take away the controller mounting plate and controller from the

frame.

3. Loosen the screw (2.54) and nylon nut (2.55) by hex. tools and

wrench ,then separate the mounting plate and controller.

Illus. 08

2.2.5. To replace the disk brake

1. Pull out the quick release pin (2.31) from brake arm (2.34), and take

away related parts (2.34~2.36)

2. Loosen the adjust spacer (2.36) till away from the end of brake wire.

3. Loosen the adjustable bolt which attached on the disk brake(2.27),

and make the groove align the same direction.

4. Put the brake wire up from disk brake(2.27) directly.

5. Take the C-clip (A) out from input shaft of transmission by pliers.

6. Loosen the screw (2.25) by hex. tools.

7. Along the output shaft axial take out the disk brake (2.27) with brake

disk (2.38).

2.2.6. To replace the transaxle assembly

◆When you should replace the transaxle assembly and the suspension

frame?

◇If the transaxle assembly has noise.

◇If the transaxle assembly can’t drive the scooter.

◇If the transaxle assembly out of shape due to an accident.

◇If the transaxle assembly is deformation.

◇If your suspension frame is deformation.

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