Service manual

XTR Electric Powerboard
Service Manual
www.tanaka-usa.com [e-mail]
Revison 002
17
Cables / Controls
On the XTR PowerBoard, the front disc brake and throttle are cable actuated. Cables should be periodically
inspected to ensure that they move smoothly, and offer full range of motion in order to maximize braking
ability and full range of throttle. Cables that have been kinked, corroded, frayed or worn significantly should be
replaced.
Brake
Figure 26
Figure 27
Figure 28
The brake lever mounted to the handlebar actuates the
front disc brake. Refer to page 6 for service and
adjustments to the mechanical front brake system. The
brake lever interfaces with the wiring harness of the unit
in one respect; the lever contains a wire routed to the
circuit board that shuts down power to the electric motor
for safety. In other words, the throttle and brake cannot
be operated simultaneously. A malfunction of the brake
safety switch will allow the unit to continue to drive the
rear wheel with the brake lever activated. This can pose a
hazardous condition and should be repaired before any
further use of the PowerBoard. A defect in the system
could indicate a problem with the lever and it’s wire, or a
problem within the circuit board. Testing is done by
bypassing the switch to verify if the problem is within the
circuit board, or within the lever and it’s wire.
To test the safety shut off switch you’ll first need to
remove the deck from the frame. Next, identify the wire
going from the brake lever to the controller board, (see
fig. 26). The wire mates to the circuit board via a small
plug-in connector. Remove the plug from the board, and
attach the test switch (part #31644), to the plug
receptacle intended for the brake wire, (Fig. 27). Be sure
the switch is in the off position before attaching to the
board. With the rear wheel elevated to allow it to turn
safely, depress the throttle lever to activate the rear
wheel. While power is driving the rear wheel, turn the
switch to the off position, (Fig. 28). Power should stop
flowing to the motor.
If the power is interrupted when conducting the test
above, then the problem is NOT with the circuit board
and it will be necessary to replace the brake lever / wire
assembly.
If the switch fails to shut off the power when tested as
described above, then the circuit board has failed and will
need to be replaced.